An accurate correlation between high-temperature performance and cement content of the high-alumina refractory castables

Xu, Lei; Liu, Yang; Chen, Min; Wang, Nan

doi:10.1016/j.ceramint.2022.04.273

Cited by 11 publications

(7 citation statements)

References 22 publications

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“…After over 40 years of development, refractory castables with calcium aluminate cement (CAC) define an innovative solution in heat-resistant materials. Remarkable compressive strength (exceeding 150 MPa), even in extreme temperatures above 1000 °C, determines the research innovation in developing ultra-high-performance concrete (UHPC) materials with CAC binders [ 1 , 2 , 3 , 4 ]. CAC-based castables have revolutionized the metallurgical and petrochemical industries, inspiring new materials science advancements [ 5 , 6 , 7 ].…”

Section: Introductionmentioning

confidence: 99%

“…This effect results from the binder’s dehydration and cement minerals’ recrystallization. Consequently, the initial strength may decrease more than twice [ 1 , 2 , 3 , 4 ]. Still, these castables remain suitable for specific industrial applications where resistance to high temperatures is required, and mechanical properties are not critical [ 1 ].…”

Section: Introductionmentioning

confidence: 99%

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Investigating the High-Temperature Bonding Performance of Refractory Castables with Ribbed Stainless-Steel Bars

Plioplys,

Antonovič,

Boris

et al. 2024

Materials

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Refractory materials containing calcium aluminate cement (CAC) are commonly used in the metallurgical and petrochemical industries due to their exceptional mechanical resistance, even at temperatures exceeding 1000 °C, and do not require additional reinforcement. This study seeks to advance this practice by developing ultra-high-performance structures that offer building protection against fire and explosions. Such structures require bar reinforcement to withstand accidental tension stresses, and the bond performance becomes crucial. However, the compressive strength of these materials may not correlate with their bond resistance under high-temperature conditions. This study investigates the bond behavior of ribbed stainless austenitic steel bars in refractory materials typical for structural projects. The analysis considers three chamotte-based compositions, i.e., a conventional castable (CC) with 25 wt% CAC, a medium-cement castable (MCC) with 12 wt% CAC, a low-cement castable (LCC), and a low-cement bauxite-based castable (LCB); the LCC and LCB castables contain 7 wt% CAC. The first three refractory compositions were designed to achieve a cold compressive strength (CCS) of 100 MPa, while the LCB mix proportions were set to reach a CCS of 150 MPa. Mechanical and pull-out tests were conducted after treatment at 400 °C, 600 °C, 800 °C, and 1000 °C; reference specimens were not subjected to additional temperature treatment. This study used X-ray fluorescence (XRF), X-ray diffraction (XRD), and scanning electron microscopy (SEM) methods to capture the material alterations. The test results indicated that the bonding resistance, expressed in terms of the pull-out deformation energy, did not directly correlate with the compressive strength, supporting the research hypothesis.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigating the High-Temperature Bonding Performance of Refractory Castables with Ribbed Stainless-Steel Bars

Plioplys,

Antonovič,

Boris

et al. 2024

Materials

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“…They found that the compressive strength decreased faster at temperatures up to 300°C; however, at 400-1000°C, the concrete strength remained almost constant with increasing temperature. To better guide the composition design of the low-cement high-alumina refractory castables in speci c working conditions, Xu et al [7] reported an accurate correlation between their high temperature performance and cement content. The results suggested that the critical value of cement addition in this refractory is 2 wt%.…”

Section: Introductionmentioning

confidence: 99%

Effect of MgO and Al2O3 on high temperature stability performance of high-alumina cement

Wang

Guo

2023

Preprint

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High-alumina cement has an important position in refractory materials with its good performance at high temperatures, but its own disadvantages such as strength inversion and unstable transformation of hydration products have always limited its development. To clarify the working mechanism of high-alumina cement and improve its high temperature resistance, MgO and Al2O3 were added to the high-alumina cement paste. The optimal design method was used to determine the influence of each factor on the high temperature stability of the cement paste. The raw material ratios were optimized and the strength change patterns of the specimens under the optimal ratio were verified. From a microstructure perspective, the high temperature evolution of the hardened paste of high-alumina cement was explored using X-ray diffraction, scanning electron microscopy, thermogravimetry, and differential scanning calorimetry. The results show that the introduction of refractory powders, especially Al2O3, can significantly improve the volumetric stability of the cement paste at high temperatures. When the water-cement ratio is 0.20, the admixture of MgO is 5% or 10%, and Al2O3 is 20%, the high temperature volume stability of the cement paste is the best. However, its corresponding mechanical strength is weakened to some extent with an increase in calcinating temperature. Moreover, the structure-property evolution process of cementite under high temperature calcinating conditions was verified by microstructural characterization, especially the improvement effect of the refractory powder on the high temperature resistance of the cement paste. The results of this study can serve as a guide for the development of high-alumina cement and its cementing materials, as well as for the improvement of their properties.

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“…Additionally, the hydratable alumina can also improve the hot properties of alumina-magnesia castable. 8,24,[34][35][36] Nevertheless, the hydration of magnesia will lead to the cracking of castable and affects several processing steps, such as curing and drying. Considering this aspect, the addition of microsilica would be a common way to inhibit the MgO hydration for the formation of MgO-SiO 2 -H 2 O phase.…”

Section: Introductionmentioning

confidence: 99%

“…Thus, the volumetric stability of alumina–magnesia castable was improved for the expansion of in situ spinel formation with the addition of magnesia. Additionally, the hydratable alumina can also improve the hot properties of alumina–magnesia castable 8,24,34–36 . Nevertheless, the hydration of magnesia will lead to the cracking of castable and affects several processing steps, such as curing and drying.…”

Section: Introductionmentioning

confidence: 99%

A post‐mortem analysis of the used gel‐bonded Al₂O₃–MgAl₂O₄ castables in an industrial steelmaking ladle

Liu³

et al. 2022

Int J Applied Ceramic Tech

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In this work, a cement-free alumina-spinel (Al 2 O 3 -MgAl 2 O 4 ) castables with a new aluminum-magnesium gel binder were developed to line the Ruhrstahl Heraeus refining ladle, chemical attacks, and degradation mechanisms of the used alumina-spinel castables after industrial trials were investigated. The results indicated that a reaction product layer of (Mg, Fe)Al 2 O 4 was observed between the slag layer and penetration layer (PL), which was mainly derived from the reaction between MgAl 2 O 4 spinel in the refractory matrix and FeO t from slag or an oxidation of steel, and thereby prevented the further penetration of FeO t . Meanwhile, the in situ spinel could also entrap slight CaO, SiO 2 , and FeO t from the infiltrated slag to form composite spinel in the PL. Moreover, chemical corrosion/penetration and structural spalling dominated the degradation process of the refractory lining in this case. Cracks formed between the deteriorated layer and original layer because of mechanical and thermal stress, which caused spalling from the refractory's hot face.

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An accurate correlation between high-temperature performance and cement content of the high-alumina refractory castables

Cited by 11 publications

References 22 publications

Investigating the High-Temperature Bonding Performance of Refractory Castables with Ribbed Stainless-Steel Bars

Investigating the High-Temperature Bonding Performance of Refractory Castables with Ribbed Stainless-Steel Bars

Effect of MgO and Al2O3 on high temperature stability performance of high-alumina cement

A post‐mortem analysis of the used gel‐bonded Al₂O₃–MgAl₂O₄ castables in an industrial steelmaking ladle

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An accurate correlation between high-temperature performance and cement content of the high-alumina refractory castables

Cited by 11 publications

References 22 publications

Investigating the High-Temperature Bonding Performance of Refractory Castables with Ribbed Stainless-Steel Bars

Investigating the High-Temperature Bonding Performance of Refractory Castables with Ribbed Stainless-Steel Bars

Effect of MgO and Al2O3 on high temperature stability performance of high-alumina cement

A post‐mortem analysis of the used gel‐bonded Al2O3–MgAl2O4 castables in an industrial steelmaking ladle

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A post‐mortem analysis of the used gel‐bonded Al₂O₃–MgAl₂O₄ castables in an industrial steelmaking ladle