Waste to Wealth Strategy: Preparation and Properties of Lightweight Al2O3-SiO2-Rich Castables Using Aluminum Dross Waste

Aluminum dross is a well-known industrial waste generated in the aluminium industry, and its recycling and reuse is still a worldwide issue. Herein, aluminum dross waste (ADW) was recycled to progressively replace the aggregate fraction of clay at 70, 75, 80, 85, and 90 wt% for the fabrication of Al2O3-SiO2-rich porous castable refractories. Their physical properties and mechanical behavior were assessed by the measurement of linear shrinkage rate, bulk density, apparent porosity, cold crushing strength, and thermal conductivity. The microstructure and phase evolutions were analyzed via scanning electron microscopy (SEM) and X-ray diffraction (XRD). The incorporation of 85 wt% of ADW allowed the development of a waste-containing conventional refractory castable with improved properties as compared to those of the other samples. The sustainable refractory castable exhibited decent thermal conductivity and physical and mechanical characteristics, and is suitable for application as reheating furnace lining. It is a “green” practice to partially replace the traditional raw materials with industrial waste in the manufacture of conventional refractory castables and provides environmental and economic benefits.

Production of fine-ground aluminas NK-Alumina 11 and NK-Alumina 14 for low-cement refractory castables

The characteristics of fine-ground aluminas NK-Alumina 11 and NK-Alumina 14, developed in JSC «PKF «NK», for low-cement refractory castables are presented. It is shown that the quality indicators of the developed aluminas are not inferior to foreign analogues.

Effects of Disodium Hydrogen Phosphate Addition and Heat Treatment on the Formation of Magnesium Silicate Hydrate Gel

The formation of magnesium silicate hydrate gel is crucial in preventing magnesia aggregates from over hydrated during the construction of refractory castables since the presence of magnesium hydroxide diminish the mechanical properties of the material. This work aimed to investigate the accelerating effects of sodium hydrogen phosphate and heat treatment on the formation of magnesium silicate hydrate gel. Time-dependent pH of magnesia - silica fume slurries with and without sodium hydrogen phosphate addition and heat treatment was measured to verify the dissolution of MgO and magnesium silicate hydrate formation. The effects of sodium hydrogen phosphate were differentiable only at small added amounts, whereas heat treatment at 50 degrees Celsius performed noticeable acceleration. This observation could be applicable in molding to maintain the stability of basic refractory castables.