Jamb spray mixes including fused silica and methods of utilizing the mixes
A jamb spray mix comprising: 0.1% to 10% phosphate by weight based on total weight of dry ingredients in the mix, 5% to 15% plasticizer by weight based on total weight of dry ingredients in the mix, the balance of dry ingredients including fused silica particles and impurities, and at least 20% water by weight based on total weight of the mix. In certain non-limiting embodiments, a coating of the jamb spray mix is applied to a refractory brick surface region in a coke oven using an air pressurized applicator and associated nozzle.
1. A jamb spray mix comprising:
0.1% to 10% phosphate by weight based on total weight of dry ingredients in the mix;
5% to 15% plasticizer based on total weight of dry ingredients in the mix;
the balance of dry ingredients including fused silica particles and impurities; and
at least 20% water by weight based on total weight of the mix.
2. The jamb spray mix of claim 1 , wherein the mix comprises 60% to 95% fused silica particles by weight based on total weight of dry ingredients in the mix.
3. The jamb spray mix of claim 1 , wherein the mix comprises 70% to 90% fused silica particles by weight based on total weight of dry ingredients in the mix.
4. The jamb spray mix of claim 1 , wherein the mix comprises 80% to 90% fused silica particles by weight based on total weight of dry ingredients in the mix.
5. The jamb spray mix of claim 1 , wherein the fused silica particles comprise at least two fused silica particle fractions with different particle size distributions.
6. The jamb spray mix of claim 5 , wherein the fused silica particle fractions include at least two fused silica particle fractions selected from a first fused silica particle fraction sized −30 mesh to +50 mesh, a second fused silica particle fraction sized −50 mesh to +100 mesh, and a third fused silica particle fraction sized −120 mesh.
7. The jamb spray mix of claim 1 , wherein the fused silica particles include a first fused silica particle fraction sized −30 mesh to +50 mesh, a second fused silica particle fraction sized −50 mesh to +100 mesh, and a third fused silica particle fraction sized −120 mesh.
8. The jamb spray mix of claim 1 , wherein the mix includes, by weight based on total weight of dry ingredients in the mix, at least one fused silica particle fraction selected from:
15% to 30% of fused silica particles sized −30 mesh to +50 mesh;
25% to 45% of fused silica particles sized −50 mesh to +100 mesh; and
18% to 35% of fused silica particles sized −120 mesh.
9. The jamb spray mix of claim 1 , wherein the mix includes, by weight based on total weight of dry ingredients in the mix, at least one fused silica particle fraction selected from:
18% to 28% of fused silica particles sized −30 mesh to +50 mesh;
28% to 40% of fused silica particles sized −50 mesh to +100 mesh; and
21% to 31% of fused silica particles sized −120 mesh.
10. The jamb spray mix of claim 1 , wherein the mix includes, by weight based on total weight of dry ingredients in the mix, at least one fused silica particle fraction selected from:
20% to 25% of fused silica particles sized −30 mesh to +50 mesh;
32% to 38% of fused silica particles sized −50 mesh to +100 mesh; and
24% to 28% of fused silica particles sized −120 mesh.
11. The jamb spray mix of claim 1 , wherein the phosphate comprises sodium phosphate.
12. The jamb spray mix of claim 1 , wherein the mix comprises 2% to 5% of phosphate, by weight based on total weight of dry ingredients in the mix.
13. The jamb spray mix of claim 1 , wherein the plasticizer comprises a refractory clay selected from a ball clay and bentonite.
14. The jamb spray mix of claim 1 , wherein the dry ingredients in the mix further comprise boric acid.
15. The jamb spray mix of claim 1 , wherein the mix further comprises 0.1% to 10% of powdered boric acid by weight based on total weight of dry ingredients in the mix.
16. The jamb spray mix of claim 1 , wherein the water content is at least 30% by weight based on total weight of the mix.
17. A method of treating a refractory brick surface region in a coke oven, the method comprising:
mixing with water a composition comprising 0.1% to 10% phosphate by weight based on total dry weight of the composition, 5% to 15% plasticizer by weight based on total dry weight of the composition, and the balance of dry ingredients including fused silica particles and impurities, thereby forming a jamb spray mix comprising at least 20% by weight water based on total weight of the mix; and
applying a coating of the jamb spray mix to the refractory brick surface region using an air pressurized applicator and associated nozzle.
18. The method of claim 17 , wherein water is not added to the jamb spray mix at the nozzle.
19. The method of claim 17 , wherein a thickness of the coating is 0.5 mm to 50 mm.
20. The method of claim 17 , wherein the mix comprises 60% to 95% fused silica particles by weight based on total dry weight of the composition.
21. The method of claim 17 , wherein the mix comprises 70% to 90% fused silica particles by weight based on total dry weight of the composition.
22. The method of claim 17 , wherein the mix comprises 80% to 90% fused silica particles by weight based on total dry weight of the composition.
23. The method of claim 17 , wherein the fused silica particles comprise at least two fused silica particle fractions with different particle size distributions.
24. The method of claim 23 , wherein the fused silica particle fractions include at least fused silica particle fractions selected from a first fused silica particle fraction sized −30 mesh to +50 mesh, a second fused silica particle fraction sized −50 mesh to +100 mesh, and a third fused silica particle fraction sized −120 mesh.
25. The method of claim 17 , wherein the fused silica particles include a first fused silica particle fraction sized −30 mesh to +50 mesh, a second fused silica particle fraction sized −50 mesh to +100 mesh, and a third fused silica particle fraction sized −120 mesh.
26. The method of claim 17 , wherein the mix includes, by weight based on total dry weight of the composition, at least one fused silica particle fraction selected from:
15% to 30% of fused silica particles sized −30 mesh to +50 mesh;
25% to 45% of fused silica particles sized −50 mesh to +100 mesh; and
18% to 35% of fused silica particles sized −120 mesh.
27. The method of claim 17 , wherein the mix includes, by weight based on total dry weight of the composition, at least one fused silica particle fraction selected from:
18% to 28% of fused silica particles sized −30 mesh to +50 mesh;
28% to 40% of fused silica particles sized −50 mesh to +100 mesh; and
21% to 31% of fused silica particles sized −120 mesh.
28. The method of claim 17 , wherein the mix includes, by weight based on total dry weight of the composition, at least one fused silica particle fraction selected from:
20% to 25% of fused silica particles sized −30 mesh to +50 mesh;
32% to 38% of fused silica particles sized −50 mesh to +100 mesh; and
24% to 28% of fused silica particles sized −120 mesh.
29. The method of claim 17 , wherein the phosphate comprises sodium phosphate.
30. The method of claim 17 , wherein the mix comprises 2% to 5% of phosphate, by weight based on total dry weight of the composition.
31. The method of claim 17 , wherein the plasticizer comprises a refractory clay selected from a ball clay and bentonite.
32. The method of claim 17 , wherein the dry ingredients in the mix further comprise boric acid.
33. The method of claim 17 , wherein the mix further comprises 0.1% to 10% of powdered boric acid by weight based on total dry weight of the composition.
34. The method of claim 17 , wherein the water content is at least 20% by weight based on total dry weight of the composition.