Improvements in the Manufacture and Composition of Refractory or Fire-resisting Cement or Cements.
Year: 1889

page_text: Date of Application, 6th Apr., 1889
Complete Specification Left, 19th Dec., 1889-Accepted, 1st Mar.,
1890
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture and Composition of Refractory or
Fire-resisting Cement or Cements.
We WILLIAM SMITH LEA, Potter's Manager and Consulting Potter and HENRY
MIDDLEMORE LYNAM Ironworks Manager both of Hanley in the County of Staffordshire
do hereby declare the nature of this invention to be as follows:-
The object of our Invention is the production of a fire resisting cement, and its
application as a lining for furnaces, kilns, ovens, crucibles, and all purposes in the
arts or manufactures to which such a cement is or may be applicable.
The properties of a cement produced according to our Invention are such that it
may in all or most cases be used as a fire resisting lining over common or ordinary
bricks, obviating entirely the necessity of using fire bricks; or we may use it in
conjunction with fire-bricks. We find however that in most cases a lining of our
cement of inch thickness and upwards resists more perfectly the action of intense
heat, than a very much thicker lining of the best fire brick. Owing also to the fact
that our cement lining undergoes little or no expansion or contraction from excessive
and sudden changes of temperature, it does not split nor crack, if when at a high
temperature, it is suddenly exposed to a rush of cold air; nor on the other hand if
when cold, the fire is made up and the temperature suddenly and highly raised.
is also admirably adapted for many chemical operations, being unattacked so far as
we have been able to ascertain by the most concentrated acids or acid fumes, and
other strong chemical substances. It is also more suitable as a stopping or backing
for furnaces than fire-clays generally used for that purpose. It is capable also of being
The
applied as a non-conducting covering for steam boilers, cylinders and pipes.
above are mentioned, not as enumerating but merely as illustrating generally purposes
for which our cement is applicable.
It
Our cement is composed principally or altogether of the following substances
roughly in or about of the undermentioned proportions
Disintegrated Granite
Blast furnace or basic steel slag
Steatite
Silica or Siliceous ochre
Kaolin, ground earthenware pitchers, or various kinds of
porcelaine
Phosphato of Lime-
Loam
Argil
Salt (Chloride of Sodium)
20 parts.
-
50
32
32
-
->>>
-
32
2022 642884
و,
"
"
60
"
40
"
"
"
"
"
"
Carbonate of Lime
Caustic Potash
Sulphate and Carbonate of Barium and Silicate of Soda
The Blast furnace- or basic slag, granite and steatite are first treated in the
following manner, for the purpose of thoroughly disintegrating them and reducing
them to a powder ready for being mixed with other substances as hereafter
mentioned.
The Blast-furnace- or basic slag is first calcined and washed to free it from sulphur,
and afterwards exposed in a boxed kiln or other convenient apparatus to the fumes
5 of nitric and hydrochloric (muriatic) acid at a suitable beat, the fumes being introduced
by means of an injector or other suitable apparatus. This treatment disintegrates or
throws down the slag as a rough precipitate.

page_text: The granite and steatite are subjected to similar treatment.
These substances are then mixed with silica or siliceous sand, kaolin or ground
earthenware and porcelaine ware, phosphate of lime, felspar, argillaceous marl, loamy
clay containing a ·large percentage of silica ochre, salt (chloride of sodium) and
carbonate of lime and carbonate and sulphate of baryta or barium.
The whole mass is then ground up with silicate of soda and chloride of sodium
dissolved in boiling water, to mix it thoroughly and to bring the cement to a proper
consistency. After being kiln dried, Roman cement is added, and the whole mixed
up with chloride of sodium and oil, preferably boiled linseed oil, and then passed
through a very fine wire screen. Caustic potash is then added and the mixture is
ready to be applied as a cement or lining.
When the cement has been applied as a plaster or lining to the furnace, kiln, or
other purpose, and the heat is got up, the carbon gas or gases liberated from the oil
prevents the cement chipping or flying-off, whilst the chlorine gas driven off liberates
the sodium, which with the potash combines with the silica and alumina forming a
glaze or glass flux; and this whilst assisting to bind the various components of the
cement together, penetrates the pores of the brickwork and binds the cement to the
brickwork, forming a dense, compact, indestructible fire-resisting mass, practically an
aluminic silicate with other silicates & quartz.
· Dated this 5th day of April 1880
J. CLARK JEFFERSON,
2, East Parade, Leeds, Agent for Applicants.
COMPLETE SPECIFICATION.
Improvements in the Manufacture and Composition of Refractory or
Fire-resisting Cement or Ĉements.
We WILLIAM SMITH LEA, Potter's Manager and Consulting Potter, and HENRY
MIDDLEMORE LYNAM Ironworks Manager both of Hanley in the County of
Staffordshire, do hereby declare the nature of this invention and in what manner the
same is to be performed, to be particularly described and ascertained in and by the
following statement:— .
The object of our Invention is the production of a fire resisting cement, and its
application as, a lining for furnaces, kilns, ovens, crucibles and all purposes in the
arts or manufactures to which such a cement is or may be applicable.
The properties of a cement produced according to our Invention are such,, that it
may in all'or most cases be used as a fire resisting lining over common or ordinary
bricks, obviating entirely the necessity of using fire bricks; or we may use it in
conjunction with fire bricks. We find however that in most cases a lining of our
cement half an inch in thickness and upwards resists more perfectly, the action of
intense heat than a very much thicker lining of the best fire brick. Owing also to
the fact that our cement lining undergoes little or no expansion or contraction
from excessivo and sudden changes of temperature, it does not split nor crack, if when
at a high temperature it is suddenly exposed to a rush of cold air; nor on the other
hand if when cold the fire is made up and the temperature suddenly and highly raised.
It is also admirably adapted for many chemical operations, being unnattacked so far
as we have been able to ascertain by the most concentrated acids or acid fumes, and
other, strong. chemical substances. It is also more suitable as a stopping or backing
for furnaces than fire clays generally used for that purpose. It is capable also of being
applied as a nonconducting covering for steam boilers cylinders and pipes. The
above are mentioned not as enumerating, but merely as illustrating generally purposes:
for, which our cement is applicable.
Our improved cement is composed of several substances, which we find may.be
mixed togther in somewhat widely varying proportions. The subjoined.. are, two
lists giving proportions which we have found to answer well in practice, and they
also illustrate the comparatively wide range which may be given to the proportions

page_text: No. II.
-
Disintegrated Granite or other rock or rocks, whose
chemical composition is chiefly silicate of Alumina
and Potash, as syenite and other granitic rocks
Blast Furnace Slag or Basic Steel Slag, glass earthen-
ware and other substances, whose chemical compo-
sition is chiefly a compound silicate of Alumina
and Potash or Soda, or other Alkali or Borax
Hydrated Silicates of Alumina and Magnesia, such
as clay, Kaolin, Steatite or other refractory clays
Silica as sand, loam, siliceous ochre-
Phosphate of Lime'
Salt
Carbonate of Lime
Caustic potash
-
50-65 per cen
5--15
"3
"
-
15
"
,,
"
5
"
"
2
22
2
"
"
1
"
"
دو
From these two tables it will be seen that our cement consists mainly o
and compound silicates of alumina, varying from 25% to 75%, and hydrated
of alumina varying from 15% to 30%. To these may be added small qua
manganese as oxide, from 2 to 2 per cent. silicate of soda, and sulphate and c
of soda. The above proportions are such as we have found to answer
practice, but it will be evident that they may be varied somewhat; as for e
if a smaller percentage of granite or granitic rock is used, a smaller perce
silicate of alumina and potash therefrom may be compensated for by an additio
percentage of caustic potash and of the materials forming the hydrated silica
the smaller percentage of quartz obtained from the granite may be compen
by the addition of sand or siliceous ochre and refractory oxides.
The granite or other granitic rock first above referred to, is subjected to a
temperature in a kiln or furnace, and whilst at this temperature, or it ma
different temperatures, it is exposed to the fumes or vapours of nitric and
chloric acids, the fumes being introduced by an injector or other convenient ap
The temperature required for this part of the operation cannot be accuratel
probably 2500 to 3000°, but we have found that with a temperature of 24
outside the kiln or oven, a suitable temperature is obtained in the interio
treatment disintegrates the granite, separating out the quartz and decompo
feldspar and mica..

page_text: The steatite and the blast furnace- or basic steel slag are treated in a similar
manner, with the exception, that is advisable first to calcine and grind the slag and
then to wash it in order to remove the sulphur.
The disintegrated and decomposed material is next reduced by grinding to a powder,
and after or during the grinding operation it is mixed with the sand or siliceous ochre,
loam, phosphate and carbonate of lime, caustic potash or borax, and manganese,
approximately in the proportions above stated. This mixture is then again ground
up to a finer powder, with the addition of silicate of soda and salt, (chloride of sodium).
The addition may be made in a dry state as crystals or powder or in solutions or by
dissolving in boiling water; also potassic silicate and chloride may be used instead of
sodic silicate and chloride, when their respective costs will alow this, or suitable
quantities of highly siliceous (i.e. difficultly fusible) glass may be employed.
For the purpose of storage it is preferable to kiln dry the mixture before the addi-
tion of the salt, sodic silicate, caustic potash, phosphate and carbonate of lime, borax
and manganese, and only to add these immediately before use.
The above mixture with the addition of salt and sodic silicate is ground up with
clean water until it is of the consistency of plaster. It is then ready for use and is
applied by plastering it over the bricks or walls of the furnace, kiln or other place,
(afterwards referred to as kiln or furnace), to which it is to be applied by means of
à trowel or other suitable tool. It is best applied at first by a thin coating only,
afterwards thicker coatings; the kiln or furnace being fired after each successive
coating is applied. For general purposes the thickness of the coating is conveniently
from inch to inch in thickness; but this may be varied according to the purpose
for which the kiln or furnace is afterwards to be used, and the more or less refractory
character of the bricks or backing to which it is applied. In some cases, as for
.instance in covering the roof of a kiln or furnace, it may suffice to lay on the cement
(for this purpose mixed to a thinner consistency), by means of a brush as in
whitewashing.
The addition of oil, preferably boiled linseed oil about 5 gallons per ton of cement
to the cement, though not necessary, greatly facilitates the reactions which take place
when the lining is fired, and assists in increasing or maintaining the large quantity
of uncombined silicate of alumina (i.e. as simple silicate of alumina and not a
. compound silicate of alumina and of some alkali or alkalies, or base or bases.
The object of my Invention as above described is to produce a highly refractory
cement, composed for the most part of a simple (i.e. uncombined) silicate of alumina;
which will stand great and rapid changes of temperature without the risk of splitting
or flying or of losing its coherence. The subjection of the granite, slag, etc. as
above described to acid fumes, serves not only to disintegrate the granite, but is so
regulated as to neutralize the alkaline or basic action of the other constituents, or
rather the affinity of the silicic acid for the alkalies and earthy bases. The regu-
lation of the temperature at this stage is of importance, since the action of silicic
acid becomes rapidly stronger with the increase of temperature, whilst its action at
low temperatures is comparatively feebler than that of hydrochloric and nitric acid.
It is the object of this part of the process especially, to prevent the premature fusion
of the materials, which would form a glassy or vitreous compound; by avoiding too
high a temperature at this stage, the mass is kept so to say in a devitrified condition,
thereby favouring the formation during the subsequent firing of the cement, of a
larger proportion of uncombined or simple silicate of alumina, rather than that of
compound silicates of alumina and earthy or alkaline bases.
We are aware that some of the substances we employ have before been used in
the manufacture of cement; but we are not aware that all the essential constituents
of our cement have been previously used together, in or about within the proportions
herein specified, nor subjected to the same treatment.
Our cement further is not only applicable as a lining on or over places exposed to
a high temperature, but in admixture with highly aluminous clays, graphite and other
materials generally used therefor, it may be employed with advantage in the manu-
facture of bricks, gas and other retorts, muffle kilns, and crucibles..

page_text: Having now particularly described and ascertained the nature of our said Inven-
tion and in what manner the same is to be performed we declare that what we
claim is
1°. The production of a fire resisting cement or compound for use as a lining on
or over kilns, furnaces, or other places exposed to high temperatures; or for use as
an admixture in the manufacture of retorts, crucibles and other vessels exposed to
high temperatures, by the herein described treatment of heating at the proper
temperature, subjecting to the action of hydrochloric acid and nitric acid fumes, and
grinding and mixing, (with subsequent firing, when spread as a lining,) the herein-
before mentioned substances in or about in the given proportions, all substantially
as herein specified.
20. The herein before method of manufacturing refractory cements, which consists
of the following steps viz. :-Disintegrating the materials whose chemical composition
is chiefly that of a compound silicate of alumina and of alkali or earthy bases mixed
with free silica, as granite, blast furnace slag and basic steel slag or their equivalents
by subjecting the same to the simultaneous action of heat and of the vapours of nitric
and hydrochloric acids, reducing the disintegrated materials and mixing therewith
materials whose composition is chiefly hydrated silicate of alumina, as clay or steatite,
and siliceous materials as sand and loam, together with phosphate and carbonate of
lime, caustic potash, borax, and manganese, and again reducing the compound and
mixing therewith chloride of sodium and an alkali silicate or silicates, as potassic
silicate, all substantially as herein set forth.
3°. As a step in the above process, the mode of disintegrating highly aluminous
silicates, hydrated or otherwise, which consists in subjecting the same to the
simultaneous action of heat and of the vapours of nitric and hydrochloric acids.
Dated this 18th day of December 1980.
J. CLARK JEFFERSON, A.R.S.M., Wh. Sc.,
2, East Parade, Leeds, Agent for Applicants.