Carbon-Containing Refractory Products with a Hybrid Glaze System and Methods for Their Production

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This invention describes carbon-containing or carbon-bonded refractory materials equipped with a hybrid glazing system composed of an inner self-glazing layer and an applied outer glaze. This system provides continuous oxidation protection for the refractory's surface and enables self-repair of the outer glaze in the event of surface damage. The process also seals surface and internal pores, preventing air ingress during use, which is especially beneficial for applications involving molten metals.

Use CasesContent extracted from patent full text and abstract with AI.

• Refractory components in steel production, such as submerged entry nozzles, monoblock stoppers, and tundish tubes
• Components for pouring molten steel, metals, or slag in foundries
• Casings for porous burners or heat exchangers in high-temperature industrial settings
• Flame arresters or components in applications requiring fire and heat resistance

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly improved oxidation resistance of carbon-based refractories, extending product lifespan
• Self-healing feature of the glazing system increases reliability and minimizes maintenance
• Effective sealing of pores prevents unwanted air uptake and reduces clogging from oxides during steel casting
• Enhanced mechanical, thermal, and corrosion resistance due to the hybrid glaze and optimized composition
• Reduced risk of refractory material failure, improving safety and operational efficiency in metallurgical processes

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Patent Abstract

The invention relates to the development of carbon-containing or carbon-bonded refractory products with a hybrid glazing system made of a self-glazing and an outer glazing, said system providing a permanent oxidation protection layer on the surface and leading to a self-repair of the outer glazing in the event of damage to the surface of the glazing. The hybrid glazing system additionally leads to a sealing of the open porosity on the surface and in the interior of the carbon-containing or carbon-bonded products. In this manner, no air is suctioned during the casting process in the case of a submerged nozzle. Clogging phenomena in the form of oxides adhering in the interior of the submerged nozzle are suppressed. According to the invention, pressed or cast carbon-containing or carbon-bonded oxide-based refractory products are provided for this purpose, comprising at least 5 wt.% of a refractory oxide, said products consisting of a mixture of carbon-containing binders, additional carbon carriers with a high carbon content, and additional oxides and/or non-oxides and being provided with a surface glazing which protects against oxidation. The products are characterized in that additionally 1 to 20 wt.% of fine-powder metals or alloys based on silicon, 1 to 20 wt.% of finely ground flux, and 1 to 20 wt.% of fine silicon dioxide are contained in the pressed compounds and in that additionally an outer glazing is applied after the coking process.