Application Research of Dense Sintered Alumina in Iron Runner Castables

Three different kinds of corundum aggregates-tabular sintered alumina, dense sintered alumina, and fused dense corundum-were introduced into the silica fume .free or silica fume containing Al2O3 -SiC - C iron runner castables to investigate their influences on the flow ability, linear change on heating, bulk density, apparent porosity, cold strength, hot modulus of rupture, therm, al shock resistance, slag resistance, oxidation resistance as well as wear resistance of Al2O3 - SiC - C iron runner castables. The results show that （ 1 ） compared with the specimens with fused dense corundum, the specimens with dense sintered alumina have equivalent installation property, slag resistance and oxidation resistance, equivalent or even higher cold modulus of rupture, cold crushing strength and hot modulus of rupture, exhibiting better thermal shock resistance and cold wear resistance ; （2） adopting bimodal alumina micropowder LISAL22RABL as well as water reducers ZX2 and ZD2 can well reduce the water requirement of silica fume free castables, solving the problem of deteriorated flow ability resulted from the lack of silica fume; since the lack of silica fume avoids the formation of low melting point liquid, the hot modulus of rupture and the thermal shock resistance of the silica fume free castables are both better than those of the silica fume containing castables ; （3） the density of the castable specimens with dense sintered alumina is 4% -6% lower than that of the castable specimens with Jhsed dense corundum so the refractories consumption of one iron runner reduces by 5% by using the tastable with dense sintered alumina, which obviously reduces the cost of refractories.

Application Performance of Microporous Sintered Alumina in Alumina Magnesia Castables for Ladles

In this study,a kind of microporous sintered alumina was analyzed and applied.The microporous sintered alumina has a lot of nano and sub-micron closed pores in the crystals,the average pore size of 140 nm,and the thermal conductivity of 4.864 at 800℃,38%lower than that of common sintered alumina.The microporous sintered alumina was used as the aggregates in alumina magnesia castables for ladles to replace the common sintered alumina.The properties of the microporous alumina castable were measured,and the temperature field of the ladle outer wall was simulated and calculated.The results show that the refractoriness under load(T0.6)and the hot modulus of rupture(1400℃,0.5 h)of the microporous castable are the same as the common castable;the thermal conductivity at 800℃decreases by 15%;the retention ratio of modulus of rupture increases by about 5%after five thermal shock cycles(1100℃,water quenching);and the temperature of the ladle outer wall is reduced by 5-41℃.

Preparation and Application of Bauxite-based Sintered Mullite Homogenized Grog in Ladle Castable

Preparation of bauxite-based sintered mullite homogenized grog was introduced and its application in ladle castable was studied.Two kinds of bauxite-based sintered mullite homogenized grogs were used,named as GA and GB,respectively.The results show that bauxitebased sintered homogenized grog with uniform components,stable microstructure and mullite as main crystal phase can be prepared using joint process of three-step homogenization,automatic component batching,wet cogrinding,high-temperature calcinations.It also indicates that carbon steel ladle castables with GA or composite aggregate of GA and GB as main materials have the same excellent general performance indicators,great erosion resistance,anti-strip performance and longer service life in field applications,and compared with castables with single aggregate of GA,the castables with aggregate of GA and GB as main materials had higher cost performance because of lower bulk density of GB.

Particle Size Distribution,Powder Agglomerates and Their Effects on Sinterability of Ultrafine Alumina Powders

An intensive study of the particle size distribution of four commercial ultrafine alumina powders to obtain information about the powder agglomeration and relate them to the compactibility and the sinterability has been made.

Effect of Titania Additive on Structural and Mechanical Properties of Alumina–Fluorapatite Composites

Mechanical properties of alumina-fluorapatite composites with different titania additive amounts （0, 0.5, 1, 1.4, 2, 3, 4 and 5 wt%） have been investigated between 1200 and 1600℃. The optimum values of densification and mechanical properties of composites have been reached with 1.4 wt% of titania after the sintering process at 1500℃ for 1 h. Thus, the rupture strength of alumina-26.52 wt% Fap-1.4 wt% TiO2 reaches 75 MPa. At higher temperature and beyond 1.4 wt% TiO2 ,the densification and mechanical properties were hindered by the formation of both intergranular porosity and secondary phase. X-ray diffraction （XRD） analysis of alumina-Fap-TiO2 composites shows the formation of aluminium titanate （Al2O3-TiO2：Al2TiO5 ）. The 27Al magic angle scanning nuclear magnetic resonance analysis of Al2O3-Fap-TiO2 composites reveals the presence of octahedral and pentahedral aluminium and novel environment relative to tetrahedral aluminium sites.

Primary slag formation behavior during reduction process of SFCA-I and SFCA

Because the formation behavior of primary slag which decomposed from complex calcium ferrite(SFCA-I and SFCA)is not quite clear,the migration behavior of CaO and Al_(2)O_(3) derived from high basicity or high alumina sinter is always worth studying.The reducibility of three representative sinter samples and the formation behavior of primary slag during reduction process were investigated via X-ray diffraction,scanning electron microscopy,and energy-dispersive spectroscopy characterization.The results show that the reducibility of high basicity sinter is superior to that of high alumina sinter.Minerals with poor reducibility like hercynite and brownmillerite and with large-grained particles like free alumina and silica form in sinters with basicity of 2.4 and Al_(2)O_(3) content of 4 wt.%,respectively.The appearance of these minerals can well explain the reduction stagnation phenomenon occurring in these sinter samples.The migration behavior of CaO and Al_(2)O_(3) during slag formation process is different.CaO can easily combine with SiO2 to form silicate phase or firstly form calcium-rich ferro-aluminate solid solution and then transform to silicate phase,while Al_(2)O_(3) firstly combines with CaO and FeO to form solid solution and then,gradually combines with SiO2 to form calcium aluminum silicate phase.