INORGANIC MATERIALS AND CERAMIC MATRIX COMPOSITES |
|
|
|
|
|
Research Status and Development Trend of Lightweight Refractories |
YIN Hongfeng, DANG Juanling, XIN Yalou, GAO Kui, TANG Yun, YUAN Hudie
|
College of Materials and Mineral Resources, Xi’an University of Architecture and Technology, Xi’an 710055 |
|
|
Abstract Refractory, as a high-temperature furnace lining, exerts a crucial role for energy saving in industry. The ceramic industry already have gained a better energy-saving and rapid firing by means of building lightweight kiln and kiln car with light insulating material. However, the furnaces, in which working lining contacts or even reacts with the molten metal, slag, raw materials or intermediate products, require a higher density so as to ensure better corrosion resistance and longer service life, and in consequence, often have large heat capacity, high energy consumption and low thermal efficiency. Working lining refractory used in high-temperature furnaces usually consists of aggregate and matrix (except casting refractories), and aggregate has a high density while the matrix is relatively loose and more vulnerable to slag attack. With the change of thermal physical properties, the metamorphic layer will be spalled, whether the aggregate is damaged or not. Thus properly lightweight aggregates should not significantly reduce the strength or anti-media erosion resistance of refractory. Lightweight refractories refer to a class of refractories with density between light and heavy refractories. In this kind of refractories, aggregates with higher porosity (especially closed porosity) substitute for dense aggregates. Under the premise of retaining high-temperature performance, the use of lightweight refractories with lower heat capacity and thermal conductivity can achieve the purpose of thermal insulation and energy saving. Therefore, lightweight aggregates have a dominant impact on the preparation process, microstructure and performance of lightweight refractory. In this paper, material systems, related properties and the preparation methods of lightweight refractory aggregate are summarized, including partial sintering method, sintering agent loss by pore-forming agent, in situ decomposition pore-forming technique, foaming method, nanoparticle-assisted sintering method, discharge plasma sintering method and so on. And then it reviews the application of lightweight aggregates, the related performance and the effectiveness in refractory castable, unburned carbon-containing refractories and fired shaped products. However, research has revealed the difficulty to obtain satisfactorily low apparent porosity and water absorption while pursuing reduction of aggregate’s thermal conductivity and bulk density in the preparation of lightweight aggregates, which has become an obstacle to the popularization of lightweight refractory. We also delineate a combinatorial method of carbo-thermal reduction, transporting oxidation, combined with reactive sintering method, which dispenses with the preparation of lightweight aggregates and is capable of producing corundum-spinel lightweight refractory with density gradient. Finally, the paper sketches out the future prospect for the research of lightweight refractory, from the perspectives of the fabrication of lightweight aggregate, as well as processing techniques, performance evaluation, standards and specifications of lightweight refractories.
|
Published: 09 August 2018
|
|
|
|
1 李楠,顾华志,赵慧忠.耐火材料学[M].北京:冶金工业出版社,2010. 2 Du B, Gu H Z, Li Z K, et al. Effect of different Al2O3 on microstructure and properties of lightweight microporous corundum aggregates[J].Journal of Wuhan University of Science and Technology,2012,35(5):377(in Chinese). 杜博,顾华志,李正坤,等.不同氧化铝对轻量微孔刚玉骨料结构与性能的影响[J].武汉科技大学学报,2012,35(5):377. 3 Deng Z Y, Yang J F, Beppu Y, et al. Effect of agglomeration on mechanical properties of porous zirconia fabricated by partial sintering[J].Journal of the American Ceramic Society,2002,85(5):1961. 4 Nanjangud S C, Brezny R, Green D. Strength and Young’s modulus behavior of a partially sintered porous alumina[J].Journal of the American Ceramic Society,1995,78(1):266. 5 Liu R P, Wang C A. Effects of mono-dispersed PMMA micro-balls as pore-forming agent on the properties of porous YSZ ceramics[J].Journal of the European Ceramic Society,2013,33:1859. 6 Dele-Afolabi T T, Azmah Hanim M A, Norkhairunnisa M, et al. Investigating the effect of porosity level and pore former type on the mechanical and corrosion resistance properties of agro-waste shaped porous alumina ceramics[J].Ceramics International,2017,43:8743. 7 Mohanta K, Kumar A, Parkash O, et al. Low cost porous alumina with tailored microstructure and thermal conductivity prepared using rice husk and sucrose[J].Journal of the American Ceramic Society,2014,97(6):1708. 8 Sandoval M L, Talou M H, Martinez A G T, et al. Mechanical testing of cordierite porous ceramics using high temperature diametral compression[J].Journal of Materials Science,2010,45(18):5109. 9 Pabst W, Gregorová E, Sedlárová I, et al. Preparation and characterization of porous alumina-zirconia composite ceramics[J].Journal of the European Ceramic Society,2011,31:2721. 10 Isobe Toshihiro, Kameshima Yoshikazu, Nakajima Akira, et al. Preparation and properties of porous alumina ceramics with uni-directionally oriented pores by extrusion method using a plastic substance as a pore former[J].Journal of the European Ceramic Society,2007,27:61. 11 Isobe Toshihiro, Tomita Takahiro, Kameshima Yoshikazu, et al. Preparation and properties of porous alumina ceramics with oriented cylindrical pores produced by an extrusion method[J].Journal of the European Ceramic Society,2006,26:957. 12 Isobe Toshihiro, Kameshima Yoshikazu, Nakajima Akira, et al. Extrusion method using nylon 66 fibers for the preparation of porous alumina ceramics with oriented pores[J].Journal of the European Ceramic Society,2006,26:2213. 13 Deng Z Y, Fukasawa T, Ando M. Microstructure and mechanical properties of porous alumina ceramics fabricated by the decomposition of aluminum hydroxide[J].Journal of the American Ceramic Society,2001,84(11):2638. 14 Suzuki Yoshikazu, Kondo Naoki, Ohji Tatsuki. Reactive synthesis of a porous calcium zirconate/spinel composite with idiomorphic spinel grains[J].Journal of the American Ceramic Society,2003,86(7):1128. 15 Salomão R, Ferreira V L, Oliveira I R D, et al. Mechanism of pore generation in calcium hexaluminate (CA6) ceramics formed in situ from calcined alumina and calcium carbonate aggregates[J].Journal of the European Ceramic Society,2016,36:4225. 16 Chen Huan, Zhao Lei, He Xuan, et al. The fabrication of porous corundum spheres with core-shell structure for corundum-spinel castables[J].Materials and Design,2015,85:574. 17 Ahmad Rizwan, Ha Jang-Hoon, Song In-Hyuck. Enhancement of the compressive strength of highly porous Al2O3 foam through crack healing and improvement of the surface condition by dip-coating[J].Ceramics International,2014,40:3679. 18 Honeyman-Colvin P, Lange F F. Infiltration of porous alumina bodies with solution precursors: Strengthening via compositional grading, grain size control, and transformation toughening[J].Journal of the American Ceramic Society,1996,79(7):1810. 19 Fu Lvping, Huang Ao, Gu Huazhi, et al. Effect of nano-alumina sol on the sintering properties and microstructure of microporous corundum[J].Materials and Design,2016,89:21. 20 Fu Lvping, Gu Huazhi, Huang Ao, et al. Effect of MgO micropowder on sintering properties and microstructures of microporous corundum aggregates[J].Ceramics International,2015,41:5857. 21 Fu Lvping, Huang Ao, Gu Huazhi, et al. Fabrication and characte-rization of lightweight microporous alumina with guaranteed slag resistance[J].Ceramics International,2016,42:8724. 22 Perko Sebastjan, Dakskoblerand Ales, Kosmac Tomaz. High-performance porous nanostructured ceramics[J].Journal of the American Ceramic Society,2010,93(9):2499. 23 Dakskobler Aleš, Kocjan Andraz, Kosmac Tomaz. Porous alumina ceramics prepared by the hydrolysis-assisted solidification method[J].Journal of the American Ceramic Society,2011,94(5):1374. 24 Fujita H, Lev C G, Zok F W, et al. Controlling mechanical properties of porous mullite/alumina mixtures via precursor-derived alumina[J].Journal of the American Ceramic Society,2005,88(2):367. 25 Kocjanand Andrãz, Shen Zhijian. Colloidal processing and partial sintering of high-performance porous zirconia nanoceramics with hierarchical heterogeneities[J].Journal of the European Ceramic Society,2013,33:3165. 26 Oh Sung-Tag, Tajima Ken-Ichi, Ando Motohide, et al. Strengthening of porous alumina by pulse electric current sintering and nanocomposite processing[J].Journal of the American Ceramic Society,2000,83(5):1314. 27 Chakravarty D, Ramesh H, Rao T N. High strength porous alumina by spark plasma sintering[J].Journal of the European Ceramic Society,2009,29(8):1361. 28 Matsumoto H, Ohta S, Ohba J. Influence of pore structure and chemical composition on slag resistance of alumina aggregates[J].Refractories,2009,61(12):640. 29 Yan Wen, Li Nan, Han Bingqiang. Influence of microsilica content on the slag resistance of castables containing porous corundum-spinel aggregates[J].International Journal of Applied Ceramic Technology,2008,5(6):633. 30 Liang Yonghe, Huang Ao, Zhu Xinwei. Dynamic slag/refractory interaction of lightweight Al2O3-MgO castable for refining ladle[J].Ceramics International,2105,41:8149. 31 Fu Lvping, Gu Huazhi, Huang Ao, et al. Possible improvements of alumina-magnesia castable by lightweight microporous aggregates[J].Ceramics International,2015,41:1263. 32 Zou Yang, Huang Ao, Gu Huazhi, et al. Effects of particle distribution of matrix on microstructure and slag resistance of lightweight Al2O3-MgO castables[J].Ceramics International,2016,42:1964. 33 Zou Yang, Gu Huazhi, Huang Ao, et al. An approach for matrix densification based on particle packing and its effect on lightweight Al2O3-MgO castables[J].Ceramics International,2016,42:18560. 34 Liu Guangping, Jin Xuejun, Qiu Wendong, et al. The impact of bonite aggregate on the properties of lightweight cement-bonded bonite-alumina-spinel refractory castables[J].Ceramics International,2016,42:4941. 35 Tomiya Hisashi, Takisawa Tomoaki, Tada Hidenori. Low thermal conductivity Al2O3-MgO-C bricks for steel ladle[J].Refractories,2010,62(1):34. 36 Peng C H, Li N, Han B Q. Study on slag corrosion resistance of microporous magnesia-spinel carbon refractories[J].Bulletin of the Chinese Ceramic Society,2009,28(2):307(in Chinese). 彭从华,李楠,韩兵强.微孔镁尖晶石碳耐火材料的抗渣性能研究[J].硅酸盐通报,2009,28(2):307. 37 Imai K, Takada T. Development of low thermal conductive basic brick for transition zone of cement rotary kiln[J].Refractories,2009,61(5):231. 38 Ren Bo, Li Yawei, Sang Shaobai, et al. Lightweight design of bau-xite-SiC composite refractories as the lining of rotary cement kiln using alternative fuels[J].Ceramics International,2017,43:11048. 39 Lin Xiaoli, Yan Wen, Ma Sanbao, et al. Corrosion and adherence properties of cement clinker on porous periclase spinel refractory aggregates with varying spinel content[J].Ceramics International,2017,43:4984. 40 尹洪峰,辛亚楼,党娟灵,等.刚玉-尖晶石轻量耐火材料的制备与性能[C]∥《耐火材料》创刊50周年和《China’s Refractories》创刊25周年典暨行业技术发展研讨会.洛阳,2016:105. |
|
|
|