Patent ID: 8505336

Claim:
A method of preparing a refractory, comprising: providing a first set of components comprising alumina and zirconia, wherein the first set of components comprises 35 wt % to 55 wt % alumina particles and 25 wt % to 45 wt % zircon particles, and wherein the zirconia comprises a first portion having a larger particle size, the first portion comprising zircon sand and a second portion having a smaller particle size, the second portion comprising zircon flour; and providing a colloidal silica binder at 5 wt % to 20 wt % of the dry weight of the first set of components, mixing the first set of components with the colloidal silica binder to form a refractory composition comprising 55 wt % to 65 wt % alumina, 20 wt % to 25 wt % zirconia, and 15 wt % to 25 wt % silica; and forming a monolithic refractory composition on a surface of a furnace.