REFRACTORY COMPOSITION

Abstract

A refractory brick, comprised of a refractory material having about 55% to about 96% by weight magnesia particles or magnesia particles containing spinel precipitates, about 3% to about 20% by weight fine zirconia particles having a particle size less than 35 Tyler mesh (less than 425 μm), and about 1% to about 25% of a material selected from the group consisting of coarse zirconia, coarse spinel, coarse alumina-zirconia, and combinations thereof.

Description

Claims

1. A refractory brick, comprised of a refractory material having: about 70% to about 96% by weight magnesia particles;about 3% to about 20% by weight fine zirconia particles having a particle size less than 35 Tyler mesh (less than 425 μm); andabout 1% to about 8% coarse zirconia or about 1% to about 12% coarse spinel.

2. A refractory brick as defined in claim 1, wherein said refractory material has about 1% to about 8% by weight coarse spinel.

3. A refractory brick as defined in claim 1, wherein said refractory material has about 1% to about 4a% by weight coarse zirconia.

4. A refractory brick as defined in claim 1, wherein said refractory material is comprised of: about 7% by weight magnesia particles between 3 Tyler mesh and 6 Tyler mesh;about 30% to about 36% by weight magnesia particles between 6 Tyler mesh and 14 Tyler mesh;about 19% to about 23% by weight magnesia particles between 14 Tyler mesh and 48 Tyler mesh; andabout 20% to about 27% by weight magnesia particles less than 48 Tyler mesh.

5. A refractory brick as defined in claim 4, wherein fine zirconia particles comprise about 7% to about 14% by weight of said refractory material.

6. A refractory brick as defined in claim 5, further comprising coarse spinet having particles sized less than 6 Tyler mesh (3.35 millimeters).

7. A refractory brick as defined in claim 5, further comprising coarse spinel having particles sized between 6 Tyler mesh (3.35 millimeters) and 28 Tyler mesh (600 μm), said spinel comprising about 3% to about 8% by weight of said refractory material.

8. A refractory brick as defined in claim 5, further comprising coarse zirconia, said coarse zirconia comprising about 2% to about 4% by weight of said refractory material.

9. A refractory material, comprised of: about 70% to about 96% by weight magnesia particles;about 4% to about 20% by weight fine zirconia particles having a particle size less than 35 Tyler mesh (less than 425 μm); andabout 3% to about 8% by weight of coarse spinel having particles sized less than 6 Tyler mesh (3.35 millimeters).

10. A refractory material, comprised of: about 70% to about 96% by weight magnesia particles;about 3% to about 20% by weight fine zirconia particles having a particle size less than 35 Tyler mesh (less than 425 μm); andabout 2% to about 8% by weight of coarse zirconia.

11. A refractory material as defined in claims 9 or 10, comprised of: about 7% by weight magnesia particles between 3 Tyler mesh and 6 Tyler mesh;about 30% to about 36% by weight magnesia particles between 6 Tyler mesh and 14 Tyler mesh;about 19% to about 23% by weight magnesia particles between 14 Tyler mesh and 48 Tyler mesh; andabout 20% to about 27% by weight magnesia particles less than 48 Tyler mesh.

12. A refractory material as defined in claim 11, wherein fine zirconia particles comprise about 7% to about 14% by weight of said refractory material.

13. A refractory brick, comprised of a refractory material having: about 55% to about 96% by weight magnesia particles or magnesia particles containing spinel precipitates;about 3% to about 20% by weight fine zirconia particles having a particle size less than 35 Tyler mesh (less than 425 μm); andabout 1% to about 25% of a material selected from the group consisting of coarse zirconia, coarse spinel, coarse alumina-zirconia, and combinations thereof.

14. A refractory brick as defined in claim 13, wherein said coarse spinel or spinel precipitates has the formula A2+O.B23+O3, wherein A comprises Mg, Fe, Mn, Zn or combinations thereof and B comprises Al, Fe, Mn or combinations thereof.

15. A rotary kiln comprised of: a tubular metallic shell; anda lining of refractory brick disposed along the inner surface of said shell, said refractory brick comprised of: magnesia particles or magnesia particles containing spinel precipitates; andabout 3% to about 20% by weight fine zirconia particles having a particle size less than 35 Tyler mesh (less than 425 μm).

16. A rotary kiln as defined in claim 15, wherein said refractory brick further comprises about 1% to about 25% of a material selected from the group consisting of coarse zirconia, coarse spinel, coarse alumina-zirconia, and combinations thereof.

17. A rotary kiln as defined in claim 16, wherein said coarse spinel has the formula A2−O.B23+O3, wherein A comprises Mg, Fe, Mn, Zn or combinations thereof and B comprises Al, Fe, Mn or combinations thereof.