The Role of the Size Effect on the Drying of Refractory Castables—How Its Under-standing Could Narrow the Gap between Laboratory Studies and Industrial Reality

Refractories have unique capabilities such as sustaining their shape and properties at extreme conditions such as the combination of high temperatures and thermal shock,contact with molten metals and slags and in some circumstances resistance to erosion from abrasive particles.Given the large processing output of the heavy industries such as the cement and steel ones which both require high temperature processes,the refractories structures span various meters and weight of several tons.As the water removal stage of hydraulic bonded castables in industrial sites takes hours(10-60 h)due to the risk of explosive spalling,efforts to mitigate it are commonly studied.This has provided theoretical understanding of the general aspects of drying and important tools,such as the thermogravimetry analysis(TGA),for the design of refractory compositions with higher explosive spalling resistance.However,the optimization of this process is still far from the industrial reality especially because the actual linings that require the drying are orders of magnitude larger than the samples considered in the laboratory tests.Therefore,this study proposed the analysis of the sample volume effect on the water removal dynamics through TGA of high alumina castables with calcium aluminate cement.Conventionalφ5 cm×5 cm cylindrical samples were assessed in a laboratory scale equipment whereas macro TGA were carried out considering 20 cm×20 cm×20 cm and 30 cm×30 cm×30 cm cubic samples.Additionally,the effect of polymeric fibers was also considered.It was found out that the different thermal gradients within the macro TGA samples resulted in an inflection on the sample’s heating rate and that the mass loss was affected by the volume considered,especially for the composition without additives.These findings highlight the requirement of carefully taking into consideration the different dimensional sizes and thermal gradients in the samples when analyzing and interpreting the laboratory studies,and especially when trying to extrapolate such results to the industrial reality.

Alkali-earth Element Aluminates and Chromites Cement Bonded Refractory Castables

This scientific paper gives the data of theoretical and experimental research done to solre the scientific and practical problem related to the establishment of theoreti- cal basics and the dertelopment tf the technolog） ./br the production of re/iactorv eastables of high strength, high refractoriness and hostile environment resistance on the basis of aluminates and chromites of alkali-earth ele- m.ents due to the well-directed formation of the phase composition and the structure of clinker, cement stone and castables. Th, e conceptual princoples of the jbrmation of such materials are based on the primaos thermody- namically advantageous coexistence of the special-pur- pose combinatiots of phases in the subsolidus structure of the muhicomponent subsystems of the oxide system （Mg, Ca, St, Ba）O- Al2O3 -Cr2O3. The obtained data allow for the development of high-strength refracto- ry alumochromite cements and castables based on them. Specific features of the behaiior of phase formation processes and the hydration of alumochromite cements, including the structure Jormation during the castahle service hare been studied.

Internal Stress of Dense Refractory Castables During Unilateral Heating

The change of the internal stress of dense refractory castables during unilateral rapid heating was studied by the electric stress measurement. The results indicate that： （1） during rapid heating, the position near the heated surface is under compressive stress ; the closer the position to the heated surface, the larger the compressive stress; （2） the specimen bursts during the rapid heating; （3） the calculated stress of the structure at the burst moment shows that the compressive stress produced at the same depth as the cracking surface exceeds the ultimate strength of the structure.

LIRR's Project of “Study on Spalling Mechanism Mechanism of Dense Refractory Castables by Rapid Heating-up” Being Obtained the Support from National Natural Natural Science Foundation of China

LIRR＇s Priject of ＂Research on Spalling Mechanism Due to Rapid Heating-up of Dense Refractory Castables＂ declared by Wang Zhanmin,vice-president of LIRR,will gain the fund support from National Natural Science Foundation of China in 2011.

Coating Resistant Refractory Castables YB/T 4193-20091

1 Scope This standard specifies the term, definition, classification, technical requirements, test methods, quality appraisal procedures, packing, marking, transportation, storage, and quality certificate of coating resistant refractory eastables.

Alumina-magnesia Refractory Castables

This standard specifies the classification, techni-requirements, test methods, quality appraisal procedures, packing, marking, transportation, storage, and quality certificate of alumina - magnesia refractory.castables.

Self-flow Refractory Castables

YB/T 4197-2009 1 Scope This standard specifies the term and definition,classification,technical requirements,test methods,quality appraisal procedures,packing,marking,transportation,storage,and quality certificate of self-flow refractory castables.This standard is mainly applicable to high alumina,corundum,corundum spinel,and chrome corundum based self-flow refractory castables.2 Normative References

Spalling Resistance Fast-drying Refractory Castables

YB/T 4195-2009 1 Scope This standard specifies the term and definition,classification,technical requirements,test methods,quality appraisal procedures,packing,marking,transportation,storage,and quality certificate of spalling resistance fast-drying refractory castables.This standard is applicable to spalling resistance fast-drying refractory castables for steel rolling heating furnace and industrial furnace of other industries.2 Normative References

The Effect of Nano-Alumina Particles Generated in Situ in the Matrix of Ultralow and No Cement 85 wt%Al_(2)O_(3) Refractory Castables

Advanced high alumina refractory castables of ultra-low and to cement types, are well-known because of their ability on developing similar and/or superior thermal and mechanical properties. Following the recent trend of including nanoparticles in refractory castables, in this work, it is presented a novel way to obtain the benefit effects on the thermal and mechanical properties, promoted by the development in situ, of alumina’s nanoparticles in the matrix of castable (85 wt% Al2O3). The alumina nanoparticles were originated in situ after firing, due to the pyrolysis and oxidation of an aqueous resin, produced by the Pechini process. The resin played a double role, one as mixing liquid vehicle and the other as the aluminum oxide nanoparticles precursor. The results indicate a strong increase in flexural strength and elastic modulus as well as leading to a higher residual strength after thermal shock.

Steam Oxidation Resistance of Silicon Carbide Castables at Elevated Temperatures

Silicon carbide castables of different SiC contents(86%and 71%,by mass)were prepared using white fused corundum,silicon carbide particles and fines,activated alumina powder,silica fume and pure calcium aluminate cement as main starting materials,heat treating at 1000℃ for 3 h,and oxidizing in steam atmosphere at 1000℃ for different durations(100,200,300,400 and 500 h).The mass and volume before and after oxidation,the bulk density,the apparent porosity and the cold compressive strength were tested.The phase composition and the microstructure before and after oxidation were analyzed by XRD and SEM.The results indicate that:(1)within 300 h of oxidation duration,silicon carbide shows an increasing oxidation rate;however,the oxidation rate is low during 300-500 h of oxidation duration;2)the oxidation rate of the specimen with 71%SiC is slightly higher than the one with 86%SiC;3)with the increasing oxidation degree of silicon carbide,the apparent porosity of the specimens tends to increase,followed by the declining bulk density and cold compressive strength.

Study on Mechanism of Explosive Spalling of ULC Castables During Rapid Drying

Inner vapor pressure and temperature of vulnerable explosive spalling positions in refractory castables during rapid drying were measured by embedding pressure transmitting pipes and thermocouples during casting. The measured vapor pressure, temperature, and tensile strength of the castables were analyzed and discussed. A hollow sphere shell model was used to analyze the stress induced by the vapor pressure based on the structure of refractory castables. The mechanism of refractory castables explosive spalling caused by vapor-induced pore split was proposed. By comparing the vapor-induced stress and the tensile strength of the castables, the explosive spalling mechanism was validated quantitatively.

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.

Research on application of different particle sizes of cordierite on castable refractory

Effect of different particle sizes of cordierite on properties of castable refractory by different heat treatment temperatures were investigated respectively with mullite and bauxite as raw materials, calcium aluminate cement as binders. After 24 h curing in mould and another 24 h curing at 110 ℃ after demoulding, the specimens were heat treated at 1 000 ℃, 1 300℃ and 1 500℃ for 3 h, respectively. The bulk density （ BD）, permanent linear change （ PLC）, modulus of rupture（MOR） and clod crushing strength（CCS）, thermal expansion coefficient and thermal shock resistance were examined. The results show that there is no obvious effect on adjusting permanent linear change and bulk density of castables by adding different particle sizes of cordierite at low temperature and intermediate temperature. Modulus of rupture of castable increase with the decreasing of the particle sizes of cordierite after heat treated by 1 000 ℃ and 1 300℃. In this experiment, thermal shock resistance of the castable with cordierite whose particle size is 0 - 1 mm is the best.

Development and Application of Castables for Ladle Nozzle of Electric Arc Furnace

The castables for ladle nozzle were developed using brown corundum as the main raw material and the right amounts of complex additives . The influence of several additives on the properties such as strength and permanent linear change of the samples was studied . The results showed that applying complex additives improved the strength and the volume stability of the castables greatly. The campaign of the castables for ladle nozzle has increased from about 40 heats to 70 heats.

Analysis of Efflorescence of Castables in Walking Beam Reheating Furnace

When the castable refractory linings are installed without drying out sufficiently and exposed to high humidity for a long time,white fibrous or powdery substance appears on the surface,which is called“efflorescence”.The main reason is the cement of castable refractory linings contacts with C02 and moisture in the atmosphere to form calcium carbonate(CaC03).In general,efflorescence takes place more readily in lightweight castable refractories.In the walking beam reheating furnace construction project,there are many white powdery substances in the walking beams,because the construction procedure causes poor ventilation in the surrounding area,and the internal moisture of castable refractory linings cannot be evaporated effectively.In future,the project programming should consider the environmental humidity and surrounding ventilation.

Surface Crack Network Detection on MgO-based Refractory Castable by Digital Image Correlation

A preliminary application of the digital image correlation（ DIC） is presented aiming to detect and analyze crack networks which are induced by stresses arising during curing and drying（ CD） of Mg O containing refractory castable slabs. Surface images of castable samples placed in a specially designed climatic chamber were recorded over the CD stages with a digital camera and processed by the DIC technique to measure the displacement fields. Post-processing DIC results were carried out to estimate the length,orientation and opening of cracks in the networks. The methodology is highlighted and the first experimental results are shown pointing out its future potential to better understand the effect of the physical aspects（ particle size,chemical analysis,temperature,etc.） and the structural ones（ slab shape and size） on processing and performance of advanced refractory castables.