Creep resistant zircon refractory material used in a glass manufacturing system
A glass manufacturing system is described herein that has a forming device (e.g., isopipe) which is made from a zircon refractory material that has an improved creep resistance property. The zircon refractory material has a composition with at least the following elements: ZrSiO 4 (98.75–99.68 wt %); ZrO 2 (0.01–0.15 wt %); TiO 2 (0.23–0.50 wt %); and Fe 2 O 3 (0.08–0.60 wt %).
1. A zircon refractory material having a composition including the following elements:
ZrSiO 4 (98.75–99.68 wt %)
ZrO 2 (0.01–0.15 wt %)
TiO 2 (0.23–0.50 wt %)
Fe 2 O 3 (0.08–0.60 wt %).
2. The zircon refractory material of claim 1 , wherein said ZrSiO 4 includes a known amount of TiO 2 and Fe 2 O 3 not counting said TiO 2 (0.23–0.50 wt %) and Fe 2 O 3 (0.08–0.60 wt %).
3. The zircon refractory material of claim 1 , wherein a binder and a dispersant were added to batch materials including ZrSiO 4 , ZrO 2 , TiO 2 and Fe 2 O 3 all of which are used to make said zircon refractory material wherein said binder and said dispersant were burned out during a sintering process to form said zircon refractory material.
4. The zircon refractory material of claim 3 , wherein said binder (2.00–4.00%) is polyethylene glycol.
5. The zircon refractory material of claim 3 , wherein said dispersant (0.06–0.25%) is polyelectrolyte.
6. The zircon refractory material of claim 3 , wherein said dispersant (0.06–0.25%) is ammonium polymethacrylate and water.
7. The zircon refractory material of claim 1 , wherein said zircon refractory material has the following composition:
ZrSiO 4 (98.75–99.65 wt %)
ZrO 2 (0.02–0.15 wt %)
TiO 2 (0.23–0.50 wt %)
Fe 2 O 3 (0.10–0.60 wt %).
8. The zircon refractory material of claim 1 , wherein said zircon refractory material has the following composition:
ZrSiO 4 (98.95–99.55 wt %)
ZrO 2 (0.03–0.15 wt %)
TiO 2 (0.30–0.45 wt %)
Fe 2 O 3 (0.12–0.45 wt %).
9. The zircon refractory material of claim 1 , wherein the zircon refractory material is used in a glass manufacturing system.
10. A method for producing a zircon refractory material, said method comprising the steps of:
mixing a plurality of batch materials including:
ZrSiO 4 (by difference)
ZrO 2 (0.01–0.15 wt %)
TiO 2 (0.23–0.50 wt %)
Fe 2 O 3 (0.08–0.60 wt %);
forming into a shape the mixed batch materials; and
firing the shaped mixed batch materials to form said zircon refractory material.
11. The method of claim 10 , wherein said step of forming includes:
spray drying the mixed batch materials; and
pressing the spray dryed batch materials to form the shaped mixed batch materials.
12. The method of claim 10 , wherein said ZrSiO 4 includes a known amount of TiO 2 and Fe 2 O 3 not counting said batched TiO 2 (0.23–0.50 wt %) and Fe 2 O 3 (0.08–0.60 wt %).
13. The method of claim 10 , wherein a binder and a dispersant were added to batch materials including ZrSiO 4 , ZrO 2 , TiO 2 and Fe 2 O 3 all of which are used to make said zircon refractory material wherein said binder and said dispersant were burned out during a sintering process to form said zircon refractory material.
14. The method of claim 13 , wherein said binder (2.00–4.00%) is polyethylene glycol.
15. The method of claim 13 , wherein said dispersant (0.06–0.25%) is polyelectrolyte.
16. The method of claim 13 , wherein said dispersant (0.06–0.25%) is ammonium polymethacrylate and water.
17. The method of claim 10 , wherein said zircon refractory material has the following composition:
ZrSiO 4 (by difference)
ZrO 2 (0.02–0.15 wt %)
TiO 2 (0.23–0.50 wt %)
Fe 2 O 3 (0.10–0.60 wt %).
18. The method of claim 10 , wherein said zircon refractory material has the following composition:
ZrSiO 4 (by difference)
Zro 2 (0.03–0.15 wt %)
TiO 2 (0.30–0.45 wt %)
Fe 2 O 3 (0.12–0.45 wt %).
19. The method of claim 10 , wherein the zircon refractory material is used in a glass manufacturing system.
20. A glass manufacturing system comprising:
at least one vessel for melting batch materials; and
a forming vessel for receiving the melted batch materials and forming a glass sheet, wherein at least a portion of said forming vessel is made from a zircon refractory material having a composition including the following elements:
ZrSiO 4 (by difference)
ZrO 2 (0.01–0.15 wt %)
TiO 2 (0.23–0.50 wt %)
Fe 2 O 3 (0.08–0.60 wt %).
21. The glass manufacturing system of claim 20 , wherein said at least one vessel includes a melting, fining, mixing or delivery vessel.
22. The glass manufacturing system of claim 20 , wherein said ZrSiO 4 includes a known amount of TiO 2 and Fe 2 O 3 not counting said batched TiO 2 (0.23–0.50 wt %) and Fe 2 O 3 (0.08–0.60 wt %).
23. The glass manufacturing system of claim 20 , wherein a binder and a dispersant were added to batch materials including ZrSiO 4 , ZrO 2 , TiO 2 and Fe 2 O 3 all of which are used to make said zircon refractory material wherein said binder and said dispersant were burned out during a sintering process to form said zircon refractory material.
24. The glass manufacturing system of claim 23 , wherein said binder is polyethylene glycol.
25. The glass manufacturing system of claim 23 , wherein said dispersant is polyelectrolyte.
26. The glass manufacturing system of claim 23 , wherein said dispersant is ammonium polymethacrylate and water.
27. The glass manufacturing system of claim 20 , wherein said zircon refractory material has the following composition:
ZrSiO 4 (by difference)
ZrO 2 (0.02–0.15 wt %)
TiO 2 (0.23–0.50 wt %)
Fe 2 O 3 (0.10–0.60 wt %).
28. The glass manufacturing system of claim 20 , wherein said zircon refractory material has the following composition:
ZrSiO 4 (by difference)
Zro 2 (0.03–0.15 wt %)
TiO 2 (0.30–0.45 wt %)
Fe 2 O 3 (0.12–0.45 wt %).