Porous refractory objects and methods of forming
A batch of refractory objects may include a plurality of bodies including a ceramic material. The batch may include an average porosity of at least 25% to not greater than 75% for the volume of the batch. The batch may have at least 50 refractory objects, a minimum volume of at least 0.36 cubic meters, and an average batch Porosity Index of not greater than 7.
1 . A batch of refractory objects, comprising:
a plurality of bodies, each body of the plurality of bodies comprising a ceramic,
a first pore type of at least 23 vol % and not greater than 41 vol % for the volume of the batch, wherein an average maximum dimension of the first pore type is at least 0.1 mm and less than 2 mm; and a second pore type comprising an average maximum pore dimension not greater than 60% of the average maximum pore dimension of the first pore type,
wherein the batch comprises an average porosity of at least 25% to not greater than 75% for the volume of the batch,
wherein the batch comprises at least 50 refractory objects, a minimum volume of at least 0.36 cubic meters, and an average batch Porosity Index of not greater than 7.
2 . The batch of refractory objects of claim 1 , wherein Porosity Index is defined as [1×(number of pores of a pore size greater than 3 mm and not greater than or equal to 5 mm)+5×(number of pores having a pore size greater than 5 mm and not greater than or equal to 6.5 mm)+10×(number of pores having a pore size greater than 6.5 mm)] for each body of the plurality of bodies.
3 . The batch of refractory objects of claim 1 , wherein the first pore type comprises at least 40% and not greater than 79% of a total porosity (vol %) of the batch.
4 . The batch of refractory objects of claim 1 , comprising an average content of a third pore type of less than 5 vol %, wherein pores of the third pore type comprises an average maximum dimension of at least 3 mm and not greater 15 mm.
5 . The batch of refractory objects of claim 3 , comprising an average content of the second pore type of at least 12 vol % and not greater than 26 vol %.
6 . The batch of refractory objects of claim 2 , wherein each body of the plurality of bodies comprises an oxide, a nitride, a carbide, or any combination thereof.
7 . The batch of refractory objects of claim 1 , wherein each body of the plurality of bodies comprises zircon, wherein the batch comprises an average content of zircon of at least 60 wt. % for a weight of the batch.
8 . The batch of refractory objects of claim 1 , wherein each body of the plurality of bodies comprises a length of at least 10 cm, a width of at least 5 cm, a thickness of at least 1 cm, or a combination thereof.
9 . The batch of refractory objects of claim 1 , wherein the first pore type comprises an irregular angular shape.
10 . A method of forming a batch of refractory objects, comprising:
forming a mixture including a ceramic material, an amorphous material, or a combination thereof, wherein forming the mixture comprises reducing a pressure on the mixture to remove gases in the mixture, wherein reducing the pressure on the mixture induces a mixing or rolling action in the mixture; and
forming the mixture into a plurality of bodies of the refractory objects including a ceramic,
wherein the batch comprises a first pore type of at least 23 vol % and not greater than 41 vol % for the volume of the batch, wherein an average maximum dimension of the first pore type is at least 0.1 mm and less than 2 mm; and a second pore comprising an average maximum pore dimension not greater than 60% of the average maximum pore dimension of the first pore type,
wherein the batch comprises an average porosity of at least 25% to not greater than 75% for the volume of the batch, and
wherein the batch comprises at least 50 refractory objects, a minimum volume of at least 0.36 cubic meters, and an average batch Porosity Index of not greater than 7.
11 . The method of claim 10 , wherein the mixture comprises at least one volatile component.
12 . The method of claim 10 , wherein the mixture comprises a viscosity of at least 25,000 centipoise and not greater than 60,000 centipoise.
13 . The method of claim 10 , wherein the mixture is mixed under a vacuum at 28 in-Hg to not greater than 30 in-Hg, and the mixture is mixed for not greater than 10 minutes.
14 . A batch of refractory objects, comprising a plurality of bodies, each body of the plurality of bodies comprising a ceramic, wherein:
the plurality of bodies comprises zircon;
the batch comprises an average porosity of at least 25% to not greater than 75% for a volume of the batch,
a first pore type comprises an average maximum dimension of at least 0.1 mm and less than 2 mm and comprises an irregular angular shape, wherein the first pore type is at least 40% and not greater than 79% of a total porosity (vol %) of the batch and the first pore type is at least 23 vol % and not greater than 41 vol % for the volume of the batch; and
the batch comprises at least 50 refractory objects, a minimum volume of at least 0.36 cubic meters, and an average batch Porosity Index of not greater than 7, wherein Porosity Index is defined as [1×(number of pores of a pore size greater than 3 mm and not greater than or equal to 5 mm)+5×(number of pores having a pore size greater than 5 mm and not greater than or equal to 6.5 mm)+10×(number of pores having a pore size greater than 6.5 mm)] for each body of the plurality of bodies.
15 . The batch of refractory objects of claim 14 , comprising a second pore type, wherein the second pore type is not greater than 41% of the total porosity (vol %) of the batch.
16 . The batch of refractory objects of claim 14 , comprising a second pore type comprising an average maximum pore dimension not greater than 60% of the average maximum pore dimension of the first pore type.