Title of Invention	UNFIRED FIREBRICK CONTAINING GRAPHITE FOR CEMENTKILNS
Abstract	There is disclosed unfired firebrick for cement kilns, to be arranged in the inside lining of the low and high transition zones (4) and the sintering zone (5) of the kiln, said firebrick being characterised by the following chemical composition in weight percent: at least 62 wt% of magnesite MgO, between 12% and 20% of alumina AI2O3, between 4% and 11% of graphite, and between 7 - 9% of improving additives in a whole composition, said additives being aluminium powder, silicon metal, silicon carbide and clay; and between 3% and 4% of binding resins.

Title of Invention

UNFIRED FIREBRICK CONTAINING GRAPHITE FOR CEMENTKILNS

Abstract

There is disclosed unfired firebrick for cement kilns, to be arranged in the inside lining of the low and high transition zones (4) and the sintering zone (5) of the kiln, said firebrick being characterised by the following chemical composition in weight percent: at least 62 wt% of magnesite MgO, between 12% and 20% of alumina AI2O3, between 4% and 11% of graphite, and between 7 - 9% of improving additives in a whole composition, said additives being aluminium powder, silicon metal, silicon carbide and clay; and between 3% and 4% of binding resins.

Full Text	UNFIRED FIREBRICK CONTAINING GRAPHITE FOR CEMENT KILNS DESCRIPTION The present invention relates to unfired firebrick for cement kilns, and, in particular, said firebrick containing graphite. Thus it is a brick to be used for lining cement kilns. It is composed of magnesium and aluminium containing graphite instead of chrome or iron as in other solutions, and can be deployed locally in specific areas of the kiln where its refractory capacity is best put to use. The use of refractory materials is well known in the cement industry for lining the inside of kilns, to withstand high working temperatures, which can reach in some parts of the kiln up to 1,500 degrees Celsius, and which change rapidly within a range of 800 -1,500 degrees Celsius with resulting physical and chemical reactions However, different compositions of refractory materials present different degrees of hardness and resistance to deformation. This invention achieves a refractory material of greater hardness and resistance than the materials hitherto employed, and thus longer life. Various refractory materials are currently known and used but they all present operational and functional drawbacks, particularly as regards progressive deformation from high and rapidly changing kiln temperatures and the consequent chemical reactions. Thus, the use of materials developed hitherto presents certain limitations compared to the technical and cost advantages of the invention described herein. Thus, the use of crucible in glassmaking, limestone, silicon, chrome, aluminium oxide and silicon-aluminous glasses (F.H. Norton, Refractarios, first Spanish edition published by Blume, 1972) or the Japanese patent number JP11230679 on the role of porosity in refractory bricks, number JP11130485, as refractory panels or number JP11201649 as glass textures, and also in the arrangement of forms, in which one of the leading applications is the European patent number EP0911594 and the German number DE19729582 for pre-fabricated bricks or the patent for the invention of this applicant, Patent PCT number WO 02/059057, all these being close to the invention here presented but general and imprecise. They are all inventions derived from chemical compositions or arrangements, and either not applied specifically to the cement industry or placed in different areas within cement kilns. These deficiencies are overcome by the chemical composition of this invention: magnesium carbonate (MgCO3), alumina (AI2O3), graphite, improving additives and binding resins which increase operational functionality and performance and whose structure presents low porosity and high refractory capability. Accordingly, the present invention provides unfired firebrick for cement kilns, to be arranged in the inside lining of the low and high transition zones and the sintering zone of the kiln, said firebrick being characterised by the following chemical composition in weight percent: at least 62 wt% of magnesite MgO, between 12% and 20% of alumina AI2O3, between 4% and 11% of graphite, and between 7 - 9% of improving additives in a whole composition, said additives being aluminium powder, silicon metal, silicon carbide and clay; and between 3% and 4% of binding resins. In summary, the result obtained from this combination of elements leads to a technical advantage with a product of greater hardness and greater resistance to heat and physical and chemical reactions, from which various significant economic advantages derive, given that with the new invention, the number of outages of kilns falls, as do the amounts spent on maintenance and replacement of materials consumed in each working period, and advantages in the productive process for the busiest kilns - rotative kilns - obtaining greater resistance and hardness. In order to obtain a better understanding of the aforesaid general characteristics, and with respect to application, herewith are attached a number of drawings of the invention as described below. Figure 1: Profile view of a rotative kiln for the cement industry using satellite coolers in a unit made up of an heat exchanger (1), and area for calcination (2), safety zone (3), transition zones - high and low - (4), sintering zone (5), exit zone (6), coolers (7) kiln head (8), and flame throwers (9). Figure 2: Profile view of a rotative cement kiln with a grid cooler deployed in a unit combining a heat exchanger (1), a burner zone (2), a safety zone (3), transition zones - high and low - (4), sintering zone (5), exit zone (6), cooler (7), oven head (8) and flame thrower (9). And showing the deployment in the kiln of the areas where this refractory brick is used: the transition zones - high and low - (4) and the sintering zone (5). ABSTRACT UNFIRED FIREBRICK CONTAINING GRAPHITE FOR CEMENT KILNS There is disclosed unfired firebrick for cement kilns, to be arranged in the inside lining of the low and high transition zones (4) and the sintering zone (5) of the kiln, said firebrick being characterised by the following chemical composition in weight percent: at least 62 wt% of magnesite MgO, between 12% and 20% of alumina AI2O3, between 4% and 11% of graphite, and between 7 - 9% of improving additives in a whole composition, said additives being aluminium powder, silicon metal, silicon carbide and clay; and between 3% and 4% of binding resins. FIG. 1 There is disclosed unfired firebrick for cement kilns, to be arranged in the inside lining of the low and high transition zones (4) and the sintering zone (5) of the kiln, said firebrick being characterised by the following chemical composition in weight percent: at least 62 wt% of magnesite MgO, between 12% and 20% of alumina AI2O3, between 4% and 11% of graphite, and between 7 - 9% of improving additives in a whole composition, said additives being aluminium powder, silicon metal, silicon carbide and clay; and between 3% and 4% of binding resins.

Full Text

UNFIRED FIREBRICK CONTAINING GRAPHITE FOR CEMENT KILNS
DESCRIPTION
The present invention relates to unfired firebrick for cement kilns, and, in
particular, said firebrick containing graphite.
Thus it is a brick to be used for lining cement kilns. It is composed of
magnesium and aluminium containing graphite instead of chrome or iron as in
other solutions, and can be deployed locally in specific areas of the kiln where
its refractory capacity is best put to use.
The use of refractory materials is well known in the cement industry for
lining the inside of kilns, to withstand high working temperatures, which can
reach in some parts of the kiln up to 1,500 degrees Celsius, and which change
rapidly within a range of 800 -1,500 degrees Celsius with resulting physical and
chemical reactions However, different compositions of refractory materials
present different degrees of hardness and resistance to deformation. This
invention achieves a refractory material of greater hardness and resistance
than the materials hitherto employed, and thus longer life.

Various refractory materials are currently known and used but they all
present operational and functional drawbacks, particularly as regards
progressive deformation from high and rapidly changing kiln temperatures and
the consequent chemical reactions. Thus, the use of materials developed
hitherto presents certain limitations compared to the technical and cost
advantages of the invention described herein. Thus, the use of crucible in
glassmaking, limestone, silicon, chrome, aluminium oxide and silicon-aluminous
glasses (F.H. Norton, Refractarios, first Spanish edition published by Blume,
1972) or the Japanese patent number JP11230679 on the role of porosity in
refractory bricks, number JP11130485, as refractory panels or number
JP11201649 as glass textures, and also in the arrangement of forms, in which
one of the leading applications is the European patent number EP0911594 and
the German number DE19729582 for pre-fabricated bricks or the patent for the
invention of this applicant, Patent PCT number WO 02/059057, all these being
close to the invention here presented but general and imprecise. They are all
inventions derived from chemical compositions or arrangements, and either not
applied specifically to the cement industry or placed in different areas within
cement kilns.
These deficiencies are overcome by the chemical composition of this
invention: magnesium carbonate (MgCO3), alumina (AI2O3), graphite,
improving additives and binding resins which increase operational functionality
and performance and whose structure presents low porosity and high refractory
capability.

Accordingly, the present invention provides unfired firebrick for cement
kilns, to be arranged in the inside lining of the low and high transition zones
and the sintering zone of the kiln, said firebrick being characterised by the
following chemical composition in weight percent: at least 62 wt% of magnesite
MgO, between 12% and 20% of alumina AI2O3, between 4% and 11% of
graphite, and between 7 - 9% of improving additives in a whole composition,
said additives being aluminium powder, silicon metal, silicon carbide and clay;
and between 3% and 4% of binding resins.
In summary, the result obtained from this combination of elements leads
to a technical advantage with a product of greater hardness and greater
resistance to heat and physical and chemical reactions, from which various
significant economic advantages derive, given that with the new invention, the
number of outages of kilns falls, as do the amounts spent on maintenance and
replacement of materials consumed in each working period, and advantages in
the productive process for the busiest kilns - rotative kilns - obtaining greater
resistance and hardness.

In order to obtain a better understanding of the aforesaid general
characteristics, and with respect to application, herewith are attached a number
of drawings of the invention as described below.
Figure 1: Profile view of a rotative kiln for the cement industry using
satellite coolers in a unit made up of an heat exchanger (1), and area for
calcination (2), safety zone (3), transition zones - high and low - (4),
sintering zone (5), exit zone (6), coolers (7) kiln head (8), and flame
throwers (9).
Figure 2: Profile view of a rotative cement kiln with a grid cooler deployed
in a unit combining a heat exchanger (1), a burner zone (2), a safety zone
(3), transition zones - high and low - (4), sintering zone (5), exit zone (6),
cooler (7), oven head (8) and flame thrower (9).
And showing the deployment in the kiln of the areas where this refractory
brick is used: the transition zones - high and low - (4) and the sintering zone
(5).

ABSTRACT
UNFIRED FIREBRICK CONTAINING GRAPHITE FOR CEMENT KILNS
There is disclosed unfired firebrick for cement kilns, to be arranged in the
inside lining of the low and high transition zones (4) and the sintering zone (5)
of the kiln, said firebrick being characterised by the following chemical
composition in weight percent: at least 62 wt% of magnesite MgO, between
12% and 20% of alumina AI2O3, between 4% and 11% of graphite, and
between 7 - 9% of improving additives in a whole composition, said additives
being aluminium powder, silicon metal, silicon carbide and clay; and between
3% and 4% of binding resins.
FIG. 1

There is disclosed unfired firebrick for cement kilns, to be arranged in the
inside lining of the low and high transition zones (4) and the sintering zone (5)
of the kiln, said firebrick being characterised by the following chemical
composition in weight percent: at least 62 wt% of magnesite MgO, between
12% and 20% of alumina AI2O3, between 4% and 11% of graphite, and
between 7 - 9% of improving additives in a whole composition, said additives
being aluminium powder, silicon metal, silicon carbide and clay; and between
3% and 4% of binding resins.

Documents:

763-KOLNP-2005-CORRESPONDENCE.pdf

763-KOLNP-2005-FORM 27.pdf

763-kolnp-2005-granted-abstract.pdf

763-kolnp-2005-granted-claims.pdf

763-kolnp-2005-granted-correspondence.pdf

763-kolnp-2005-granted-description (complete).pdf

763-kolnp-2005-granted-drawings.pdf

763-kolnp-2005-granted-examination report.pdf

763-kolnp-2005-granted-form 1.pdf

763-kolnp-2005-granted-form 18.pdf

763-kolnp-2005-granted-form 3.pdf

763-kolnp-2005-granted-form 5.pdf

763-kolnp-2005-granted-gpa.pdf

763-kolnp-2005-granted-reply to examination report.pdf

763-kolnp-2005-granted-specification.pdf

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Patent Number

226787

Indian Patent Application Number

763/KOLNP/2005

PG Journal Number

52/2008

Publication Date

26-Dec-2008

Grant Date

24-Dec-2008

Date of Filing

29-Apr-2005

Name of Patentee

FAJARDO SOLA PEDRO

Applicant Address

C/ MARQUES DEL TURIA, 1, E-46930 QUART DE POBLET (VALENCIA)

Inventors:

#	Inventor's Name	Inventor's Address
1	FAJARDO SOLA PEDRO	C/ MARQUES DEL TURIA, 1, E-46930 QUART DE POBLET (VALENCIA)

PCT International Classification Number

C04B 35/04

PCT International Application Number

PCT/ES2002/000468

PCT International Filing date

2002-10-03

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	PCT/ES2002/000468	2002-10-03	IB