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Development of spinel and calcium hexa-aluminate bonded high alumina refractories

Objective



This proposal concerns the development of an improved relatively inexpensive. environmentally friendly spinel CA6 bonded high alumina refractory which increases the life span of ladle lining and allows more cleanness of the steel in secondary treatments. The Programme is expected to be achieved within 48 months.
The spinel high alumina materials have shown good potential by dramatically increasing the life span and the stability of ladle lining compared to the basic and high alumina materials traditionally used as refractories. Other possible applications are in Portland cement rotary kilns, waste incinerator furnaces or in glass furnace heat exchangers.
By investigating routes using inexpensive raw materials and cost saving processes the project aims to increase the use of spinel content refractories. The project will explore an innovative way of obtaining a reliable refractory not only in a shaped fomm but also in an unshaped form ( castable monolithic lining).
By studying the ternary diagram Al2O3 MgO CaO the basic research will focus on specific chemical range compositions. Behaviour of selected matrixes within the high alumina zone of the diagram against molten steel and slag attacks and the respective mechanisms of corrosion and penetration at operating temperatures (1650 C ) will be studied.
To obtain the refractory matrixes different processing routes will be focused on, using selected raw materials. The preparation of these raw materials will also be studied. The innovative Doloma plus Alumina route will be particularly investigated in order to obtain an economically advantageous refractory cement.
The matrixes will be selected and characterised by studying the physical chemical properties. the thermo mechanical behaviour and the microstructure features.
The refractory product will be obtained by adding mixtures of alumina to the previously screened matrixes. Then the qualification of the raw materials, the procedures and the manufacturing technology for pressed shaped bricks and for castable refractory products will be stated. The final characteristics and specific refractoriness properties will be measured. Resistance to corrosion and penetration against molten steel and slag attacks will receive special attention.
To complete the project, pre industrial scale trials will be carried out in steel factories by lining ladles at different stages of the secondary steel process in order to verify all the parameters previously established at laboratory scale. Assessments will be made concerning lining procedures, repair compounds application, pre heating and firing conditions. In addition, the behaviours of the fired and the unfired shaped linings and the concrete monolithic lining will be compared. Special attention will be paid to resistance against penetration, corrosion, wear rate, thermo mechanical properties and spalling effects under operating conditions.
A suitable technology of specific monolithic ladle lining including procedures of installation and pre heating schedule will be
established with the cooperation of refractorist and user.
Finally, a technical economic balance sheet will be established comparing data to current refractory ladle lining.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Pasek-Espana SA
Address
1,Dr Carreno 1
33400 Asturias
Spain

Participants (6)

ALCOA - Industrial Chemicals Europe
Germany
Address
37,Palme Straße 37
60439 Frankfurt-am-main
CONSEJO SUPERIOR DE INVESTIGACIONES CIENTIFICAS
Spain
Address
S/n,la Corredoria S/n
33011 Oviedo
CONSEJO SUPERIOR DE INVESTIGACIONES CIENTIFICAS
Spain
Address
Antigua Carretera De Valencia Km 24.300
28500 Arganda Del Rey
Corporacion Siderurgica Integral Productos Cargos SA
Spain
Address

33280 Gijon
EKO Stahl GmbH
Germany
Address

15872 Eisenhüttenstadt
INSTITUT NATIONAL DES SCIENCES APPLIQUEES DE LYON
France
Address
Avenue Albert Einstein 20, Bètiment Blaise Pascal
69621 Villeurbanne