Effects of Specific Surface Area and Impurities of Reactive Alumina on Properties of Corundum Based Castables

Effects of specific surface area and tiny amount of impurities of reactive alumina on the workability, sinte- ring and high temperature mechanical strength of corun- dum based castables were investigated. The results show that the presence of reactive alumina with high specific surface area leads to accelerating of the hydration of calcium aluminate cement, thus shortening the working time and setting time of the castables, which can be as- cribed that the critical energy barrier for stable nuclei of hydration products of cement can be reduced by the high specific surface area of reactive alumina. The sintering of the corundum based castables can be accelerated by the reactive alumina with high specific surface area and high amount of impurities, however, the reactive alumina with too high specific surface area and impurities can al- so lead to noticeable shrinkage of castables. In addition, high temperature mechanical strength of corundum based castables can be decreased by the higher amount of trace impurities of reactive alumina due to formation of low- melting phase at high temperatures.

Influence of Particle Size Distribution of Bimodal Reactive Alumina on Properties of LCC Refractory Castables

The effect of particle size distribution of alumina has been investigated for silica-free tabular alumina low cement castables（ LCC）. Three different combinations of alumina have been included in the matrix formulation of the castables. All the three combinations are composed of a bimodal reactive alumina and a fine ground monomodal reactive alumina. The first A1 and second A2 combinations are respectively composed of bimodal and monomodal aluminas from Alteo,with a different fine /coarse particles ratio for the bimodal alumina. The two Alteo combinations have been compared with a third combination C composed of a bimodal commercially available grade and a monomodal commercially available grade. Optimization of particle size packing has been performed for the three different formulations using the Dinger and Funk model. With this optimization,the two formulations based on Alteo material（ PFR,PBR and PFR40） achieve the same level of performance in applicative tests（ flowability,cold physical properties,mechanical resistance,crystalline phases,thermal shocks and corrosion） as reference solutions on the market.

Influence of Reactive Alumina and Calcined Alumina on properties of Free Flowing Castables

Reactive alumina is a well-established group of raw materials for refractory castables to improve their rheological behavior.In this article the influence of bimodal reactive alumina and standard(<325#)calcined alumina on workability,packing density and strength of alumina based castables is examined.It will be shown that there is a significant effect on water demand and apparent density of the castable,which is depending on the percentage of reactive alumina on the one hand and on the type of reactive alumina on the other hand.The effect of the alumina on setting time and cold crushing strength has shown to be insignificant in this set of experiments.

Analysis of Corrosion Mechanisms of Low-cement or No-cement Al_(2)O_(3)-MgO Gunning Mix with Special Calcined Alumina in Rotary Slag Test

Al_(2)O_(3)-MgO and Al_(2)O_(3)-spinel low cement castables(LCC-AM and LCC-AS)have been extensively used in steel ladles as working linings.Nevertheless,the use of alumina-magnesia gunning mixes has been mainly kept for maintaining these castable linings,because of high rebound loss,poor green strength,high porosity and short life-span.Thanks to a high BET alumina(MC-G),it is now possible to develop a series of high-performance no-cement or low-cement Al_(2)O_(3)-MgO gunning mixes(NCG-AM or LCG-AM).The paper focuses on the BOF slag resistance of NCG-AM,LCG-AM,LCC-AM and LCC-AS.The corrosion mechanisms of rotary slag samples were studied by scanning electron microscopy(SEM/EDS).The results reveal different microstructures around MgO particles,depending on the four used compositions.Continuous and thicker spinel phases were formed in NCG-AM,which was proved to have the best corrosion resistance after the dynamic slag test.MC-G can provide a high diffusion flux of Al^(3+)in terms of kinetics and hence inhibits Kirkendall porosity around MgO particles.In addition,a continuous spinel phase acts like a pinning nail to reinforce the matrix and thus decreases erosion by slag.In contrast to NCG-AM,the porous spinel phase was found around unreacted MgO particles and some particles were carried away near the interface of LCC-AM and slag.The NCG-AM containing MC-G had been tested in two steel plants,and it extended the service life of the ladles up to 50%.In addition,this study suggests the potential application of NCG-AM as steel ladle linings.

Wettability of Ni-base Reactive BrazingAlloys on Alumina

The influences of the additions of Ti or / and Si on the wettability of Ni-base alloys on alumina were investigated with the sessile drop method. The interfacial chemical reaction products were analyzed by scanning etectron rnicroscope and microprobe. Their effects on the wettability and the affecting factors for them to be produced were discussed. A new Ni-base braze alloy (NiFeCr10Si15Ti) was designed for brazing alumina with the superior qualities such as low contact angle (less than 25 degrees), high work temperature (near 1073 K) and good resistance to oxidations, etc.

Study of the Corrosion of High Alumina Refractories by Al_2O_3-CaO Slag as a Reactive Impregnation Mechanism

The corrosion of refractories results from reactive transport,namely,transport of agents and chemical reactions of these agents with impregnated medium. On one hand,the transport involves either diffusion or impregnation depending on the state of the corrosive agents and the microstructure of the host media. On the other hand,chemical reactions may be very numerous and complex.This study focused on the reactive impregnation of Al2O3- CaO slag into porous high alumina refractory. The transport properties of the refractory material were identified by means of a dedicated capillary rising test. Chemical reactions between the solid high alumina skeleton and Al2O3- CaO slag involve successive dissolution / precipitation mechanisms forming aluminates of lime. Contrary to the thermodynamic properties of the binary system,the kinetics of these solid / liquid reactions is not well known.Corrosion tests associated with the quenching method,XRD analyses were performed for a better understanding of the kinetics. The results of this study open up a coupling approach for predicting the corrosion wear of refractory.

Review of Matrix Aluminas for Refractory Formulations

Historically,ground calcined aluminas were the first high-alumina matrix products that were used in refractory formulations, in both shaped and unshaped products. At that time the flow properties of castables were enhanced by the use of silica fume. This was followed later by the development of fully ground reactive aluminas which contributed to the design of the matrix below 63 μm. In addition to aggregate fines,a range of bi-modal and multi-modal reactive aluminas were also developed. These not only gave improved physical properties but also better castable workability. This paper reviews matrix alumina developments over time,from basic ground calcines to complex multi-modal matrix products and their globally standardised manufacture.

Characteristics of alumina particles in dispersion-strengthened copper alloys

Two types of alumina dispersion-strengthened copper（ADSC） alloys were fabricated by a novel in-situ reactive synthesis（IRS） and a traditional internal oxidation（IO） process. The features of alumina dispersoids in these ADSC alloys were investigated by X-ray diffraction, scanning electron microscopy, and high-resolution transmission electron microscopy. It is found that nano-sized γ-Al2O3 particles of approximately 10 nm in diameter are homogeneously distributed in the IRS-ADSC composites. Meanwhile, larger-sized, mixed crystal structure alumina with rod-shaped morphology is embedded in the IO-ADSC alloy. The IRS-ADSC composites can obtain better mechanical and physical properties than the IO-ADSC composites; the tensile strength of the IRS-ADSC alloy can reach 570 MPa at room temperature, its electrical conductivity is 85% IACS, and the Rockwell hardness can reach 86 HRB.

Relation Between Sintering Reactivity of Matrix and Thermal Shock Resistance of Ultra-low Cement Bonded Corundum-spinel Castables for Fired Purging Plugs

Purging plugs installed in the bottom of steel ladles are widely used for the secondary refining of high quality steel grades.The dynamic service conditions and temperature gradients caused by the cold inert gas blown through the plug during stirring create a strong thermal shock impact on the materials.This can affect its service life and restrict the safety and efficiency of steel making if the plug fails during use.In this work,the influence of the particle size distribution (PSD) and amount of reactive alumina on the sintering behavior of ultra-low cement bonded corundum-spinel based castables was investigated on lab scale.The relationship between sintering reactivity of matrix and thermal shock resistance of castables was evaluated in detail.Results show that the sintering of castables can be intensified by using finer reactive alumina.However,excessive sintering of the castable through finer reactive alumina is negative for thermal shock resistance.The microstructure characterization reveals that castables with more intense sintering show denser matrix structure,which is less effective in hampering crack propagation and therefore results in decline of their thermal shock resistance.

Self-glazing SiC-andalusite Refractories for High Temperature Gasification Applications

The combination of SiC and andalusite with calcium aluminate binder for castables in high corrosive gasifying environments is a promising alternative refractory system for many different slag systems. After sintering,a glassy protective layer has been identified. Beside the interactions of the refractories with intermediate slag also the thermomechanical properties,the thermal shock performance and the microstructure have been evaluated as a function of different binder systems.

Colloidal Silica Sol Bonded Castables for High Temperature Applications

A colloidal silica sol bonded product range is introduced by an example targeting high temperature applications in steel making. Placement and setting characteristics are shown. The thermal mechanical properties and resulting advantages are presented as well as the performance enhancement in corrosion resistance. Properties are compared to a common ULCC product. Results of the industrial trial phase are discussed.