Abstract: A refractory article including a body having central opening extending through at least a portion of the body, the central opening having a receiving surface having a convex curvature. In an embodiment, the body can include a coupling protrusion extending from a portion of an upper surface of the body and a coupling depression on a portion of a bottom surface of the body.

Abstract: A refractory lining structure for a metallurgical vessel is characterized by at least one elongated expansion joint formed in and extending through the surface of the working lining in a substantially vertical direction. The elongated expansion joint accommodates thermal expansion of the working lining in a metallurgical vessel such as, for example, a tundish during preheating for a continuous casting operation. The elongated expansion joint decreases crack formation, delamination, and spalling of the working lining from underlying back-up linings and/or safety linings in metallurgical vessels during preheating and use, while still facilitating metal skull removal after the completion of metallurgical operations.

Abstract: A heat insulating plate (1), preferably a covering plate (5a;b), especially for thermal isolation of molten metal, especially of molten steel, in a metallurgical vessel (6), wherein the plate (3) includes a binding agent matrix (2) of at least one, set, temporary, organic binding material and aggregate grains (3) with and/or of biogenic silicic acid, preferably with and/or of rice husk ash, which grains (3) are incorporated into the binding agent matrix (2), and to a method for production of the plate (1) and its use.

Abstract: An unfired, refractory molded body (1), especially a plate, especially for thermal insulation of molten metal and/or an ingot solidifying from molten metal, that includes a binding agent matrix (2) of a set binder and aggregate grains (3) of biogenic silicic acid, preferably of rice husk ash, which are incorporated into the binding agent matrix (2), wherein the binding agent matrix (2) consists of silica gel, as well as a process for its production and its usage.

Abstract: A fluidized bed system having a containment vessel, a precast and predried monolithic refractory floor module positioned in the vessel, and a plurality of precast and predried monolithic refractory wall modules stacked within the vessel. The plurality of wall modules includes a first wall module is positioned on the floor module, wherein the floor module and the first wall module have interlocking surfaces, and wall modules adjacent to one another have interlocking surfaces. A method for assembling a fluidized bed reactor is also provided.

Abstract: A smelting ladle and a method for improving use efficiency thereof. The smelting ladle includes a housing, a working layer, and a permanent layer. The method includes: 1) rebuilding the working layer to have an outer layer and an inner layer, the inner layer being a consumable working layer which contacts with molten steel and steel slag, and the outer layer being a circulating working layer which contacts with the permanent layer or directly contacts with the housing; 2) allowing the smelting ladle to work, when the thickness of the consumable working layer is reduced to be between 0 and 20 mm, removing a residue of the consumable working layer and masoning a new consumable working layer for the smelting ladle; and 3) repeating 2) until the circulating working layer reaches a designed service life thereof, and casting a new circulating working layer for the smelting ladle.

Abstract: A castable refractory composition may include from 5% to 95% by weight of alumina, aluminosilicate, or mixtures thereof; up to 70% by weight silicon carbide; up to 10% by weight carbon; from 0.1% to 5% by weight alkaline earth metal oxide and/or hydroxide; and from 0.1% to 5% by weight of silica having a surface area of at least about 10 m2/g. The refractory composition may further include no more than 0.5% by weight of cementitious binder, and the refractory composition may not release a significant amount of hydrogen gas upon addition of water. The refractory composition may set on addition of water. An installable refractory lining may be formed using the composition and a method including at least one of casting, self-flowing, wet shotcreeting, rodding, cast-vibrating, spraying, conventional dry gunning, or high density gunning the castable refractory composition, and setting and drying the composition.

Abstract: A refractory particularly for the use in an inner lining of a blast furnace is a layered composite comprising a protective layer and a conductive layer, wherein the interlayer bonding strength between the individual layers is more than 6 MPa.

Abstract: Refractory foundry ladle liners made from castable magnesium oxide-based compositions are disclosed. The liner compositions include MgO-containing aggregate, Al2O3-containing aggregate, and an inorganic binder. The ladle liners are cast into shape, placed into ladle shells, and packed with sand. The foundry ladle assemblies, including the pre-cast MgO-based ladle liners, are reusable for multiple foundry operations.

Abstract: A temperature-specific compound applied to refractory substrates having molten metal-contacting surfaces creates a chemically active and viscous surface that dramatically increases the ability of the treated substrate to remove slag, dross and other inclusions from a base metal alloy as it passes through or contacts the substrate. The refractory substrates include molten metal filters used by foundries and metal casters such as reticulated ceramic foam, cellular/honeycomb, silica mesh, and others that rely on their physical or sieving ability to remove particulate impurities from the base alloy being cast. The chemically active surfaces significantly increase filtration efficiency through a treatment process tailored to the specific chemistry of the alloy being filtered, such as ferrous metals that include iron, steel and more.

Abstract: A wall lining of industrial ovens for protecting from corrosion, in particular, a heat-resistant wall made of concrete, steel, sheet metal, or the like. The lining of the wall is made of at least two layers, wherein a layer is pressurized as a blocking layer.

Abstract: Presented are an insulation brick and the method of using an insulation brick to create a thermal lining. A set of corrugations are formed into a sidewall of the brick to increase the thermal insulation. A first end of the insulation brick has a convex portion while the second end of the insulation brick has a convex portion. This allows a first insulation brick to mate with another brick in an end to end configuration.

Abstract: A carbonaceous refractory and a method of production is provided, which prevents a drop in the molten pig iron corrosion resistance, molten pig iron penetration resistance, and other properties of carbonaceous refractories required for blast furnace bottom refractories. The mechanical strength of the refractories is raised so as to suppress cracking due to thermal stress. The carbonaceous refractory comprises a carbonaceous material comprising one or more of calcined anthracite, calcined coke, natural graphite, or artificial graphite in 60 to 85 mass %, a refractory metal oxide in 5 to 15 mass %, metal silicon in 4 to 15 mass %, and carbon black in 2 to 10 mass %. An organic binder is added to refractory materials, which are kneaded, molded and fired in a nonoxidizing atmosphere.

Abstract: Exemplary embodiments of the invention provide a molten metal containment structure including a refractory molten metal containment vessel having an external surface, and a metal casing for the vessel having an internal surface at least partially surrounding the external surface of the vessel at a distance therefrom forming a spacing between the vessel and the casing. The spacing includes an unobstructed upwardly extending gap that is vented to the exterior of the structure by upper and lower openings in the casing. A layer of insulating material is preferably positioned in the spacing between the internal surface of the casing and the external surface of the vessel, with the layer of insulating material being narrower than the spacing at least at upwardly extending sides of the casing, thereby forming the unobstructed gap. The vessel may be a metal conveying trough, a housing for a metal filter, a container for a metal degasser unit, a crucible, or the like.

Abstract: A castable refractory composition may include from 5% to 95% by weight of alumina, aluminosilicate, or mixtures thereof: up to 70% by weight silicon carbide: up to 10% by weight carbon: from 0.1% to 5% by weight alkaline earth metal oxide and/or hydroxide; and from 0.1% to 5% bv weight of silica having a surface area of at least about 10 m2/g. The refractory composition may further include no more than 0.5% by weight of cementitious binder, and the refractory composition may not release a significant amount of hydrogen gas upon addition of water. The refractory composition may set on addition of water. An installable refractory lining may be formed using the composition and a method including at least one of casting, self-flowing, wet shotcreeting, rodding, cast-vibrating, spraying, conventional dry gunning, or high density gunning the castable refractory composition, and setting and drying the composition.

Abstract: A tubular melt containment member for transient containment of molten metals and alloys, especially reactive metals and alloys, includes a melt-contacting layer or region that comprises an oxygen-deficient rare earth oxide material that is less reactive as compared to the counterpart stoichiometric rare earth oxide. The oxygen-deficient (sub-stoichiometric) rare earth oxide can comprise oxygen-deficient yttria represented by Y2O3-x wherein x is from 0.01 to 0.1. Use of the oxygen-deficient rare earth oxide as the melt-contacting layer or region material reduces reaction with the melt for a given melt temperature and melt contact time.

Abstract: A method of containing molten aluminum using non-wetting materials comprising depositing MgAl2O4, or one selected from an oxide, Al2O3, nitride, AlN, BN, carbide, and SiC, onto a crucible. An apparatus for containment of molten aluminum using non-wetting materials comprising a layer of MgAl2O4, or one selected from an oxide, Al2O3, nitride, AlN, BN, carbide, and SiC, deposited onto a crucible.

Abstract: A ramming mass for the block lining of at least some of the refractory elements of a refractory lining of a metallurgical vessel such as a blast furnace, said ramming mass being composed of a mixture of a granular phase and a binder phase, wherein the granular phase and/or binder comprises at least one component having a microporous structure or capable of forming a microporous structure by firing during the blast furnace campaign. The ramming mass is in particular intended for forming the joint between two concentric annular assemblies forming a side wall of the vessel or between a lower part of an inner annular assembly and the periphery of one or more refractory layers forming the floor of the vessel.

Abstract: A roof system for an electric arc furnace includes a skew removably attached to the electric arc furnace, a lining of refractory material affixed to the skew, and a delta composed of a refractory material. The delta has at least one aperture capable of receiving an electrode. The delta fits onto and is supported by the refractory lining that is affixed to the skew.

Abstract: A channel inductor of a channel induction furnace is disclosed. The channel inductor comprises a channel liner that defines a channel for a molten metal to flow through the channel inductor. The channel liner comprises an inlet and an outlet for the molten metal and a flange for mounting the channel liner to a refractory material lining of a pot of the channel inductor furnace. The channel liner being formed from a ceramic material that is resistant to chemical attack by the molten metal in the channel, whereby in use of the channel induction furnace direct contact between the molten metal and the channel inductor is limited to contact with the channel liner (including the flange) only and molten metal does not contact other parts of the channel inductor.

Abstract: A glass manufacturing container includes a container body and an electron donor. The container body is made of a precious metal or an alloy containing a precious metal and has an inner surface to be brought into contact with molten glass and an outer surface kept from contact with molten glass. The electron donor is electrically connected to the outer surface of the container body. The electron donor is made of an electron donating material capable of donating electrons to the container body at operating temperatures.

Abstract: A refractory particularly for the use in an inner lining of a blast furnace is a layered composite comprising a protective layer and a conductive layer, wherein the interlayer bonding strength between the individual layers is more than 6 MPa.

Abstract: A method of securing a precast refractory shape within a refractory structure, comprising the steps of forming a precast refractory shape by casting a refractory shape to have a plurality of spaced-apart cavities formed in an outer surface thereof; positioning the precast refractory within a refractory structure; and casting a refractory material around the precast refractory shape such that the refractory material covers the outer surface of the precast refractory and fills the cavities.

Abstract: A crucible includes a composite of least two materials. The two materials are selected from a group consisting of alumina, calcia, yttria, erbia, gadolinia, magnesia, hafnia, and zirconia in a composition that has better resistance to reaction with hafnium from a molten hafnium-containing alloy than a nominal crucible composition of 70 wt % magnesia and 30 wt % alumina.

Abstract: Presented are an insulation brick and the method of using an insulation brick to create a thermal lining. A set of corrugations are formed into a sidewall of the brick to increase the thermal insulation. A first end of the insulation brick has a convex portion while the second end of the insulation brick has a convex portion. This allows a first insulation brick to mate with another brick in an end to end configuration.

Abstract: Methods for making a reinforced refractory crucible for melting titanium alloys including providing a form, applying a facecoat to the form, the facecoat having at least one facecoat layer, applying a backing about the facecoat, the backing having at least one backing layer, applying at least one reinforcing element to at least a portion of the facecoat layer, the backing layer, or a combination thereof where the reinforcing element includes at least one composition selected from ceramic compositions, metallic compositions, and combinations thereof.

Abstract: A refractory bottom lining for lining the bottom of a metallurgical vessel. The refractory bottom includes a stepped portion and an impact portion. The impact portion is formed of a first refractory material. The stepped portion is formed of a second refractory material and is disposed around the impact portion. The stepped portion includes an upper surface that has a plurality of discrete surface sections. The plurality of discrete surface sections includes an uppermost surface section, at least two intermediate surface sections and a lowermost surface section. Each surface section has a different elevation such that the uppermost surface section has a highest elevation and the lowermost surface section has a lowest elevation. The uppermost surface section, the at least two intermediate surface sections and the lowermost surface section define a continuously downward stepped path from the uppermost surface section to the lowermost surface section.

Abstract: A crucible includes a composite of least two materials. The two materials are selected from a group consisting of alumina, calcia, yttria, erbia, gadolinia, magnesia, hafnia, and zirconia in a composition that has better resistance to reaction with hafnium from a molten hafnium-containing alloy than a nominal crucible composition of 70 wt % magnesia and 30 wt % alumina.

Abstract: A frame/brick and/or a stave/brick construction, having a frame having a plurality of ribs and a plurality of channels, wherein a front face of the frame defines a first opening into each of the channels, and a plurality of bricks wherein each brick is insertable into one of the plurality of channels via its first opening to a position, upon rotation of the brick, partially disposed in the one channel such that one or more portions of the brick at least partially engage one or more surfaces of the one channel and/or of a first rib of the plurality of ribs whereby the brick is locked against removal from the one channel through its first opening via linear movement without first being rotated.

Abstract: The invention relates to a water-containing slip for producing a BN-containing coating on a substrate, which comprises, based on the solids content of the slip, a) 45-90% by weight of BN, b) 3-25% by weight of boehmite nanoparticles, c) 0.5-5% by weight of at least one borate, d) 2-30% by weight of at least one water-insoluble boron compound which is different from the components a) and c), e) 2-30% by weight of an organic compound, where the solids content of the slip is 15-60% by weight.

Abstract: A refractory lining system comprises an inner refractory layer; and an outer layer located outside of the inner refractory layer, the outer layer comprising: a plurality of layer segments; and at least one control joint located between the plurality of layer segments, the at least one control joint configured to allow expansion and contraction in the outer layer. A segment of an outer layer of a refractory lining comprises an edge shaped corresponding to a control joint configured to allow expansion and contraction in the outer layer.

Abstract: To provide a long-life refractory capable of maintaining durability under severe conditions. The castable refractory comprises a mixture containing at least one of 2 to 10 mass % of silicon carbide and 3 to 10 mass % of chamotte, as an auxiliary raw material, and a binder material, with the remaining balance being one or more main raw materials selected from corundum, mullite, bauxite, chamotte, talc and silica, and is used in an environment exposed to an alkali component-containing hot gas atmosphere. In an alkali component-containing gas atmosphere at a high temperature (750° C. or more), silicon carbide and/or chamotte are vitrified to a thickness of 1 mm or less in the surface layer of the refractory to prevent the alkali component-containing gas from intruding inside of the refractory.

Abstract: Cooling panels (31) are attached to the shell (11) of a metallurgical vessel to form an internal lining of the shell. Each panel (31) comprises a coolant flow tube (36) bent to form inner and outer panel sections (37, 38) of zig-zag formation. Panel mounting pins (43) connected to the outer panel section (38) by connector straps project laterally outwardly from the panel through openings (45) in the shell and tubular shell protrusions (46) surrounding the openings (45). The ends of pins (43) are connected to the outer ends of protrusions (46) by welding metal discs (47) thus forming connections exteriorly of the shell in a way which seals the openings (45). Coolant inlet and outlet connectors (42) for the panel project outwardly through openings (48) in the shell and surrounding tubular protrusions (49) and connections are made by welding discs (51) between the connectors (42) and protrusions (49).

Abstract: The present invention relates to an induction furnace for melting of metals that do not connect inductively in solid state. The induction furnace has a lining comprising a mixture of graphite and silicon carbide and has an electric conductivity higher than the electrical conductivity of the metal to be melted when metal is in solid state, but lower than the electrical conductivity of the metal to be melted when the metal is in molten state. The invention further relates to a lining for induction furnace and to a method for producing such lining.

Abstract: Exemplary embodiments of the invention provide a molten metal containment structure including a refractory molten metal containment vessel having an external surface, and a metal casing for the vessel having an internal surface at least partially surrounding the external surface of the vessel at a distance therefrom forming a spacing between the vessel and the casing. The spacing includes an unobstructed upwardly extending gap that is vented to the exterior of the structure by upper and lower openings in the casing. A layer of insulating material is preferably positioned in the spacing between the internal surface of the casing and the external surface of the vessel, with the layer of insulating material being narrower than the spacing at least at upwardly extending sides of the casing, thereby forming the unobstructed gap. The vessel may be a metal conveying trough, a housing for a metal filter, a container for a metal degasser unit, a crucible, or the like.

Abstract: The present invention provides for a refractory aggregate composition comprising an improved calcium aluminate clinker having the formula CnAx wherein C is calcium oxide and A is aluminum oxide, wherein n is an integer from about 1 to about 12, wherein x is an integer from about 1 to about 24, and wherein said clinker has from zero to less than about fifty weight percent C12A7. Analogs, derivatives and hydrates of the improved calcium aluminate clinker are provided. A refractory composition and a sprayable refractory composition are disclosed comprising the improved calcium aluminate clinker. A method for improving the insulating character and/or penetration resistance of a liner in contact with molten aluminum in an aluminum manufacturing process or during aluminum transport is provided.

Abstract: A refining apparatus for scrap silicon using an electron beam which is suitable for recycling of scrap silicon which is formed during the manufacture of silicon products such as silicon wafers includes a vacuum chamber, a crucible installed within the vacuum chamber, a hearth which is installed next to the crucible within the vacuum chamber and which receives granular scrap silicon and which melts granular silicon by irradiation with an electron beam and which supplies molten silicon to the crucible, and a raw material supply apparatus which is installed within the vacuum chamber and which stores a prescribed amount of granular scrap silicon and supplies the stored granular scrap silicon via a chute.

Abstract: The present invention relates to an industrial furnace for smelting metals, in particular nonferrous metals, and the respective nozzle element.

Abstract: A mold dimensioned to be positioned within a refractory-lined tundish. The mold has an upper wall and a side wall extending downwardly from the upper wall, the side wall having a shape generally conforming to the shape of the internal cavity of the tundish and having a lower end formed to rest on the refractory lining on the bottom wall of the refractory-lined tundish. The upper wall and side wall define an interior chamber. The side wall of the mold and the refractory lining on the sloping wall of the tundish form a gap therebetween. The gap extends around the mold, the mold being dimensioned such that the gap between the side wall of the mold and the refractory lining on the side wall of the tundish is wider at an upper portion of the internal cavity than at a lower portion of the cavity. A heating means extends through the upper wall of the mold for heating the interior chamber of the mold.

Abstract: Disclosed is a continuous casting nozzle having a refractory portion formed to contain a dolomite clinker and arranged to define a surface region adapted to be in contact with molten steel, which is capable of protecting a working surface of the nozzle from alumina build-up due to alumina in molten steel, while improving corrosion resistance, even during long-term continuous casting of molten steel. The refractory portion is prepared by adding a binder to a mixed material and subjecting the obtained mixture to kneading, forming and heat treatment. The mixed material comprises a dolomite clinker which has an average particle size of 0.8 mm or less and a CaO content of 50 mass % or less. The mixed material has a ratio W1/W2 of 0.33 or more, wherein W1 is a content by mass of CaO, and W2 is a content by mass of MgO. The mixed material comprises a dolomite clinker and a magnesia clinker. Alternatively, the mixed material comprises a dolomite clinker and a magnesia clinker.

Abstract: The present invention relates to a process for making a wear lining for casting ladles and pouring boxes used in foundries, in which process the wear lining is formed by introducing into a casting ladle or pouring box a pourable mass consisting of a granular or particulate refractory material that has a low heat conductivity and contains at least 4 wt-% of sodium silicate or potassium silicate and which binds together to form a solid mass in situ by means of a silica-containing gel precipitated from the silicate by the addition of a suitable ester or mixture of esters, optionally combined with the introduction of carbon dioxide. The invention also relates to a process for increasing the service life of the wear lining made in this way by adapting its MgO content according to whether it—the lining—comes into contact mainly with molten metal or molten slag.

Abstract: A refractory container for evaporating metals, having improved useful life and corrosion resistance properties, the evaporation surface of the container having a plurality of grooves formed at the bottom surface. The grooves have either a depth of at least 1.2 mm, a width of at least 1.75 mm, or an interval spacing of at least 2.2 mm between adjacent grooves (or centers of adjacent grooves), and combinations thereof.

Abstract: An insulating refractory lining for insulating the inner surface of a vessel defined by a metal shell. The refractory lining is comprised of a first refractory layer overlaying an inner surface of a metal shell. The first refractory layer is comprised of a cast refractory material and has a first side facing the metal shell and a second side facing away from the metal shell. A plurality of discrete, spaced-apart cavities are formed in the first side of the first refractory layer. The cavities define air pockets between the metal shell and the first refractory layer.

Abstract: A method of handling liquid non-ferrous metals after smelting. The liquid metal is in contact with a solid refractory material, and in the absence of electrical currents passing through the liquid-metal-contacting surfaces. The solid material is Ti3SiC2. The liquid non-ferrous material can be aluminum or an aluminum alloy, magnesium or a magnesium alloy, or other non-ferrous materials as to which the Ti3SiC2 material is stable.

Abstract: Cooling panels (31) are attached to the shell (11) of a metallurgical vessel to form an internal lining of the shell. Each panel (31) comprises a coolant flow tube (36) bent to form inner and outer panel sections (37, 38) of zig-zag formation. Panel mounting pins (43) connected to the outer panel section (38) by connector straps project laterally outwardly from the panel through openings (45) in the shell and tubular shell protrusions (46) surrounding the openings (45). The ends of pins (43) are connected to the outer ends of protrusions (46) by welding metal discs (47) thus forming connections exteriorly of the shell in a way which seals the openings (45). Coolant inlet and outlet connectors (42) for the panel project outwardly through openings (48) in the shell and surrounding tubular protrusions (49) and connections are made by welding discs (51) between the connectors (42) and protrusions (49).

Abstract: A casting ladle has a body (2) with a base (3) and walls (4, 6, 8) made of a laminated composite ceramic material that includes multiple layers of a woven fiber reinforcing fabric embedded in a ceramic matrix. A rigid support element (20) for attaching the ladle to a handling device is embedded within the composite ceramic material. In a preferred form, the reinforcing fabric is made of woven glass and the matrix material includes calcium silicate and silica.

Abstract: A crucible comprising Al2O3 and at least one selected from rare earth oxides inclusive of Y2O3 as main components and characterized by firing at 500–1,800° C., the distribution of the rare earth oxide at a higher proportion in a fine particle portion having a particle size of up to 0.5 mm than in a coarse particle portion having a particle size in excess of 0.5 mm, and the substantial absence of the reaction product of the rare earth oxide with Al2O3 is suitable for the melting of a rare earth alloy.

Abstract: Disclosed is a free flowing dry back-up material which comprises: from 67 to 96% by weight of fly-ash; from 2 to 15% by weight of a heat sensitive binder such as boric acid; from 2 to 7% by weight of a non-wetting agent such as calcium fluoride; from 0 to 10% by weight of a heat expandable material, viz. a material expandable as a function of the temperature such as vermiculite or graphite; and from 0 to 1% by weight of a dust suppressant such as kerosene. This material which is useful in particular in the aluminum industry has the advantages of being water free and free flowing, such avoiding the use of vibrator to position it into a shell. It also has a low density and a low thermal conductivity. Moreover, it is organic free as compared to the existing materials which use an organic binder to ensure a low temperature set; and it sets at a temperature lower than 400° F.

Abstract: A lining for a ladle used to handle molten metal. The lining is comprised of a first course of like, refractory bricks arranged horizontally in the ladle, the first course having an upper surface. A second course of like refractory bricks is arranged to spiral within the ladle. The second course is disposed on the first course, and the second course has an upper surface. A starter comprised of at least one refractory component is dimensioned to form a contoured ramp surface. The starter is disposed between the first course and the second course of like refractory bricks. The ramp surface at one end of the starter set is aligned with the upper surface of the first course and the ramp surface at another end is aligned with the upper surface of the second course.

Abstract: A trough is described for carrying molten metal, comprising an outer shell defined by a bottom wall and two side walls, an insulating layer filling the outer shell and a conductive U-shaped refractory trough body for carrying molten metal, the trough body being embedded in the insulating layer. At least one heating element is positioned in the insulating layer, adjacent to but spaced apart from the trough body, to provide an air gap between the heating element and the trough body.