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 f...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.展开更多
During calcining the aluminum hydroxide according to the Bayer process in a rotary kiln,the process of incomplete conversion to alpha alumina by soft calcination leads to a special intermediate alumina product contain...During calcining the aluminum hydroxide according to the Bayer process in a rotary kiln,the process of incomplete conversion to alpha alumina by soft calcination leads to a special intermediate alumina product containing microcrystalline of primary crystal alpha alumina particles less than 0.4μm,and other alumina phases with finer microcrystalline of less than 0.2μm particles.This special alumina powder has similar properties to silica fume or clay,such as high surface area and reactivity,fast wetting,low water demand and high stick-ability.It can partially or completely replace silica fume and clay in dry gunning mixes.It works towards improving the high temperature resistance of the gunning material matrix as well as the corrosion resistance and service life of the gunning materials.The application results show that:the ladle cementfree alumina-magnesia dry gunning mix with this special alumina sub-micro powder,compared with traditional dry gunning materials,has lower rebound loss(<10%),better adhesion rate,higher corrosion resistance and peeling resistance;and it can replace the veneering casting repair to achieve the similar performance.A further improvement goal is to replace the initial casting linings,thus this concept will give a new revolution to the monolithic steel ladles.展开更多
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 formulat...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.展开更多
This work aims at enhancing the workability of Al2 O3-Mg O castables. Al2 O3-Mg O castables were prepared using tabular alumina particles（ 5-3,3-1,≤1 mm）,tabular alumina fines（ ≤0. 088 mm）,fused magnesia（ ≤1 m...This work aims at enhancing the workability of Al2 O3-Mg O castables. Al2 O3-Mg O castables were prepared using tabular alumina particles（ 5-3,3-1,≤1 mm）,tabular alumina fines（ ≤0. 088 mm）,fused magnesia（ ≤1 mm）,reactive alumina micropowder（ PFR40,PBR,and CL） and calcined alumina micropowder（ AC34 B5 and CT） as the main starting materials,calcium aluminate cement（ Secar71） as the binder,and polycarboxylic acid water reducer WS,FS,and AD as the dispersive agent,respectively. Effects of three dispersive agents addition（ 0. 4 mass% WS,0. 2 mass% FS and 1 mass% AD）,two kinds of reactive alumina micropowder addition（ PFR40 and PBR）,composite alumina micropowder addition（ PFR40-AC34 B5 and CL-CT,the mass ratio from 9/0 to 3/6）on the flow value,apparent porosity,bulk density,cold crushing strength and cold modulus of rupture of Al2 O3-MgO castables were investigated. The results show that：（ 1） with PBR or PFR40,the castables with0. 4 mass% WS own better performance than those with0. 2 mass% FS or 1 mass% AD;（ 2） compared with the castables with CL-CT composite powder, the castables with PFR40-AC34 B5 composite powder have slightly higher flow value; with the decreasing ratio of PFR40 and AC34 B5,or the decreasing ratio of CL andCT,the castables have declined flow value and the dried castable specimens have decreased density but the mildly changed strength; in consideration of the high price of reactive alumina,a proper compositing ratio shall be selected.展开更多
文摘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.
文摘During calcining the aluminum hydroxide according to the Bayer process in a rotary kiln,the process of incomplete conversion to alpha alumina by soft calcination leads to a special intermediate alumina product containing microcrystalline of primary crystal alpha alumina particles less than 0.4μm,and other alumina phases with finer microcrystalline of less than 0.2μm particles.This special alumina powder has similar properties to silica fume or clay,such as high surface area and reactivity,fast wetting,low water demand and high stick-ability.It can partially or completely replace silica fume and clay in dry gunning mixes.It works towards improving the high temperature resistance of the gunning material matrix as well as the corrosion resistance and service life of the gunning materials.The application results show that:the ladle cementfree alumina-magnesia dry gunning mix with this special alumina sub-micro powder,compared with traditional dry gunning materials,has lower rebound loss(<10%),better adhesion rate,higher corrosion resistance and peeling resistance;and it can replace the veneering casting repair to achieve the similar performance.A further improvement goal is to replace the initial casting linings,thus this concept will give a new revolution to the monolithic steel ladles.
文摘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.
文摘This work aims at enhancing the workability of Al2 O3-Mg O castables. Al2 O3-Mg O castables were prepared using tabular alumina particles（ 5-3,3-1,≤1 mm）,tabular alumina fines（ ≤0. 088 mm）,fused magnesia（ ≤1 mm）,reactive alumina micropowder（ PFR40,PBR,and CL） and calcined alumina micropowder（ AC34 B5 and CT） as the main starting materials,calcium aluminate cement（ Secar71） as the binder,and polycarboxylic acid water reducer WS,FS,and AD as the dispersive agent,respectively. Effects of three dispersive agents addition（ 0. 4 mass% WS,0. 2 mass% FS and 1 mass% AD）,two kinds of reactive alumina micropowder addition（ PFR40 and PBR）,composite alumina micropowder addition（ PFR40-AC34 B5 and CL-CT,the mass ratio from 9/0 to 3/6）on the flow value,apparent porosity,bulk density,cold crushing strength and cold modulus of rupture of Al2 O3-MgO castables were investigated. The results show that：（ 1） with PBR or PFR40,the castables with0. 4 mass% WS own better performance than those with0. 2 mass% FS or 1 mass% AD;（ 2） compared with the castables with CL-CT composite powder, the castables with PFR40-AC34 B5 composite powder have slightly higher flow value; with the decreasing ratio of PFR40 and AC34 B5,or the decreasing ratio of CL andCT,the castables have declined flow value and the dried castable specimens have decreased density but the mildly changed strength; in consideration of the high price of reactive alumina,a proper compositing ratio shall be selected.
