Process and mixture for forming a coherent refractory mass on a surface

Abstract

A mixture as described herein and a process for forming a coherent refractory mass on a surface of a refractory comprised of at least one silicon compound, the process including providing a mixture comprised of combustible particles including silicon particles, refractory particles of one or a plurality of substances which constitute a major portion by weight of the mixture, and particles of another substance or precursor thereof which are nonmetallic and which cause the incorporation of silica, formed by the combustion of silicon, into a crystalline lattice within the coherent refractory mass; and projecting the mixture against the surface of a refractory, simultaneously with oxygen, so that the combustible particles react in an exothermic manner with the projected oxygen and release sufficient heat to form the refractory mass under the action of heat of combustion.

What is claimed is:  
     
         1 . A process for forming a coherent refractory mass on a surface of a refractory comprised of at least one silicon compound, the process comprising: 
 providing a mixture comprised of combustible particles including silicon particles, refractory particles of one or a plurality of substances which constitute a major portion by weight of the mixture, and particles of another substance or precursor thereof which are nonmetallic and which cause the incorporation of silica, formed by the combustion of silicon, into a crystalline lattice within the coherent refractory mass; and    projecting the mixture against the surface of a refractory, simultaneously with oxygen, so that the combustible particles react in an exothermic manner with the projected oxygen and release sufficient heat to form the refractory mass under the action of heat of combustion.    
     
     
         2 . The process according to  claim 1 , wherein the particles of another substance are selected from the group consisting of magnesia and wollastonite.  
     
     
         3 . The process according to  claim 2 , wherein at least a portion of the silica formed by the combustion of silicon is incorporated into a crystalline lattice which is a forsterite-type lattice.  
     
     
         4 . The process according to  claim 1 , wherein the combustible particles further comprise aluminum particles.  
     
     
         5 . The process according to claims  2  and  4 , wherein at least a portion of the silica formed by the combustion of silicon is incorporated into a crystalline lattice which has a lattice type selected from the group consisting of a forsterite-type lattice, a spinel-type lattice and a cordierite-type lattice.  
     
     
         6 . The process according to  claim 1 , wherein the refractory particles constituting a major portion by weight of the mixture are silicon carbide particles.  
     
     
         7 . The process according to  claim 1 , wherein the refractory particles constituting a major portion by weight of the mixture are silica particles.  
     
     
         8 . A mixture of particles intended for a process for forming a coherent refractory mass on a surface of a refractory comprised of at least one silicon compound by projecting the mixture and oxygen against said surface, the mixture comprising: 
 combustible particles including silicon particles capable of reacting exothermically with oxygen to release sufficient heat to form the coherent refractory mass under the action of the heat of combustion;    refractory particles of one or a plurality of substances which constitute a major portion by weight of the mixture; and    particles of another substance or precursor thereof which are nonmetallic and which cause incorporation of silica, formed by the combustion of silicon, into a crystalline lattice within the coherent refractory mass.    
     
     
         9 . The mixture according to  claim 8 , wherein the particles of another substance are selected from the group consisting of magnesia and wollastonite.  
     
     
         10 . The mixture according to  claim 8 , wherein the combustible particles further comprise aluminum particles.  
     
     
         11 . The mixture according to  claim 8 , wherein the refractory particles constituting a major portion by weight of the mixture are silicon carbide particles.  
     
     
         12 . The mixture according to one of claims  8 , wherein the refractory particles, constituting a major portion by weight of the mixture, are silica particles.