Calcium aluminate clinker as a refractory aggregate with and without barium addition and use thereof
View Patent ↗The present invention provides for a refractory aggregate composition comprising an improved calcium aluminate clinker having the formula C n A x 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 less less than about fifty weight percent C 12 A 7 . 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.
1. A refractory aggregate composition consisting essentially of:
an aggregate consisting essentially of a calcium aluminate clinker having the formula C n A x 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 fifty weight percent C 12 A 7 , and wherein greater than 98 weight percent of said calcium aluminate clinker having a particle size ranging from 325 mesh to +10 mesh.
2. The refractory aggregate of claim 1 including a hydrate phase of said C n A x .
3. The refractory aggregate of claim 1 including analogs of said C n A x .
4. The refractory aggregate of claim 1 including derivatives of said C n A x .
5. The refractory aggregate of claim 1 including wherein barium is substituted for calcium in said calcium aluminate clinker.
6. The refractory aggregate of claim 1 further comprising a barium source.
7. The refractory aggregate of claim 6 wherein said barium source addition results in the formation of analogs and derivatives of said C n A x and optionally hydrates of said C n A x .
8. The refractory aggregate of claim 7 wherein said barium source is present in one or more phases as BaO, BA 6 , and C 2 BA 4 , and combinations thereof.
9. The refractory aggregate of claim 1 wherein the alumina content of said calcium aluminate clinker is greater than or equal to sixty eight weight percent.
10. The refractory aggregate of claim 1 wherein the concentration of said C 12 A 7 is from zero to less than about 3 molar percent.
11. The refractory aggregate composition of claim 1 further comprising a calcium aluminate cement.
12. A refractory composition comprising: a refractory aggregate consisting essentially of a calcium aluminate clinker having the formula C n A x , wherein C is equal to calcium oxide, wherein A is equal to 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 calcium aluminate clinker has from zero to less than about fifty weight percent C 12 A 7 , and wherein greater than 98 weight percent of said calcium aluminate clinker having a particle size ranging from 325 mesh to +10 mesh.
13. The refractory composition of claim 12 further comprising water in a sufficient amount to achieve a castable consistency.
14. The refractory composition of claim 12 including a hydrate phase of C n A x .
15. The refractory composition of claim 12 including analogs of said C n A x .
16. The refractory composition of claim 12 including derivatives of said C n A x .
17. The refractory composition of claim 12 including wherein a barium is substituted for calcium in said calcium aluminate clinker.
18. The refractory composition of claim 12 further comprising a source of barium.
19. The refractory composition of claim 18 wherein said barium addition results in the formation of analogs and derivatives of said C n A x and hydrates of said C n A x .
20. The refractory composition of claim 19 wherein said barium is present in one or more phases as BaO, BA 6 , and C 2 BA 4 , and combinations thereof.
21. The refractory composition of claim 12 wherein said refractory aggregate further comprises a reactive alumina.
22. The refractory composition of claim 12 wherein said refractory aggregate further comprises a calcined alumina.
23. The refractory composition of claim 12 wherein said refractory aggregate further comprises tabular alumina.
24. The refractory composition of claim 12 wherein said refractory aggregate further comprises bubble alumina.
25. The refractory composition of claim 12 further comprising a surfactant.
26. The refractory composition of claim 12 further comprising a fibrous material.
27. The refractory composition of claim 12 further comprising a surfactant and a fibrous material.
28. The refractory composition of claim 26 further comprising water in an amount sufficient to achieve a castable consistency.
29. The refractory aggregate composition of claim 1 formed by sintering.
30. The refractory aggregate composition of claim 1 formed by employing a fusion process.
31. A sprayable refractory composition comprising: (a) a pumpable first component comprising (i) a refractory composition comprising a refractory aggregate consisting essentially of a calcium aluminate clinker having the formula C n A x , wherein C is equal to calcium oxide, wherein A is equal to 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 calcium aluminate clinker has from zero to less than fifty weight percent C 12 A 7 , and wherein greater than 98 weight percent of said calcium aluminate clinker having a particle size ranging from 325 mesh to +10 mesh, and a calcium aluminate cement, (ii) a dispersant, and water in an amount sufficient to achieve a pumpable consistency, and optionally (b) a second component comprising a flocculating agent, wherein said second component is added to said first component for achieving installation of said sprayable refractory composition.
32. The sprayable refractory composition of claim 31 wherein said refractory composition includes a hydrate phase of C n A x .
33. The sprayable refractory composition of claim 31 wherein said refractory composition includes analogs of said C n A x .
34. The sprayable refractory composition of claim 31 wherein said refractory composition includes derivatives of said C n A x .
35. The sprayable refractory composition of claim 31 wherein a barium is substituted for calcium in said calcium aluminate clinker.
36. The sprayable refractory composition of claim 31 wherein said refractory composition further comprises a source of barium.
37. The sprayable refractory composition of claim 36 wherein said barium source addition results in the formation of analogs and derivatives of said C n A x and hydrates of said C n A x .
38. The sprayable refractory composition of claim 37 wherein said barium is present in one or more phases as BaO, BA 6 , and C 2 BA 4 , and combinations thereof.
39. The sprayable refractory composition of claim 31 wherein said refractory aggregate further comprises a reactive alumina.
40. The sprayable refractory composition of claim 31 wherein said refractory composition further comprises a calcined alumina.
41. The sprayable refractory composition of claim 31 wherein said refractory composition further comprises tabular alumina.
42. The sprayable refractory composition of claim 31 wherein said refractory composition further comprises bubble alumina.
43. The sprayable refractory composition of claim 31 wherein said refractory composition further comprises a fibrous material.
44. The refractory composition of claim 12 further including a lightweight aggregate.
45. The sprayable refractory composition of claim 31 further comprising a lightweight aggregate.
46. The refractory composition of claim 12 further comprising a calcium aluminate cement.
47. The refractory composition of claim 12 wherein said refractory aggregate further comprises a source of barium.
48. The sprayable refractory composition of claim 31 wherein said refractory aggregate further comprises a source of barium.