Skip to main content
Log in

Evaluation of Refractory Performance of Basic Castables Containing Magnesium-Aluminate Sol-Gel Coatings on Graphite

  • Review Papers
  • Published:
Interceram - International Ceramic Review

Abstract

A study was conducted to compare the properties of carbon-containing basic castables that incorporated graphite with and without a magnesium! aluminate sol-gel coating. A thin sol-gel coating of magnesium aluminate spinel was prepared from inexpensive precursors. The castable batch containing hydrophilic coated graphite required less water (9.5 mass-%) for mixing than the uncoated graphite (12.5 mass-%). Basic cartable containing coated graphite showed better retention of graphite mside its refractory matrix. Consequently, slag corrosion and penetration resistance were noticeably improved in the coated graphite sample. X-ray diffraction, scanning electron microscopy and investigation of physical properties were performed on the castables at different temperatures to confirm the benefits of spinel-coated graphite.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. Lee, W.E., Moore, R.E.: Evolution of in situ refractories in the 20th century. J. Amer. Ceram. Soc. 81 (1998) [6] 1385–1410

    Article  CAS  Google Scholar 

  2. Ewais, E.M.M.: Carbon based refractories.J. of the Ceram. Soc. of Japan 112 (2004) [1310] 517–532

    Article  CAS  Google Scholar 

  3. Baudin, C., Alvarez, C., Moore, R.E.: Influence of chemical reactions in magnesia-graphite refractories: 1. Effects of texture and high temperature mechanical properties.J. Amer. Ceram. Soc. 82 (1999) [12] 3529–3538

    Article  CAS  Google Scholar 

  4. Ibid: 2. Effects of aluminium and graphite contents in generic products. J. Amer. Ceram. Soc. 82 (1999) [12] 3539–3548

    Article  CAS  Google Scholar 

  5. De Aza, A.H., Valle, W.F.J., Ortega, Pena, P., DeAza, S.: Analytical characterization of a magnesia-graphite refractory. J. Amer. Ceram. Soc. 89 (2006) [5] 1704–1708

    Article  CAS  Google Scholar 

  6. Fruhwrith, O., Herzog, G.W., Hollerer, I., Rachetti, A.: Dissolution and hydration kinetics of MgO. Surface Technology 24 (1985) 301–317

    Article  Google Scholar 

  7. Salomao, R., Bittencourt, L.R.M., Pandolfelli, V.C.: A novel approach for magnesia hydration assessment in refractory castables. Ceram. Internat. 33 (2007) 803–810

    Article  CAS  Google Scholar 

  8. Yamaguchi, A.: Features and future development of the carbon containing refractory. Key Engg. Mats. (Adv. Ceramics and Composites) 247 (2003) 239–244, Trans. Tech. Publication, Switzerland

    Google Scholar 

  9. Zhang, S., Lee, W.E.: Improving the water-wettability and oxidation resistance of graphite using Al2O3/SiO2 sol-gel coatings. J. Europ. Ceram. Soc. 23 (2003) 1215–1221

    Article  CAS  Google Scholar 

  10. Mukhopadhyay, S., Dutta, S., Ansar, S.A., Das, S., Misra, S.: Spinel-coated graphite for carbon containing refractory castables. J. Amer. Ceram. Soc. 92 (2009) [8] 1895–1900

    Article  CAS  Google Scholar 

  11. Mukhopadhyay, S.: Improved sol-gel spinel (MgAl2O4) coatings on graphite for application in carbon containing high alumina castables. J. Sol-Gel Sci. Technol. 56 (2010) 66–74

    Article  CAS  Google Scholar 

  12. Mukhopadhyay, S., Ansar, S.A., Paul, D., Bhowmick, G., Sengupta, S.: Characteristics of refractory castables containing mullite and spinel coated graphites. Mater. Manuf. Process. 27 (2012) 177–184

    Article  CAS  Google Scholar 

  13. Dutta, S., Das, P., Das, A., Modak, S., Mukhopadhyay, S.: Physical characteristics of alumina-carbon refractory castables containing calcium aluminate coated graphites. Interceram-Refractories Manual 62 (2013) [4] 294–298

    CAS  Google Scholar 

  14. Mukhopadhyay, S., Das, G., Biswas, I.: Nanostructured cementitious sol-gel coating on graphite for application in monolithic refractory composites. Ceram. Internat. 38 (2012) 1717–1724

    Article  CAS  Google Scholar 

  15. Mukhopadhyay, S., Dutta, S.: Comparison of solid state and sol-gel derived calcium aluminate coated graphite and characterization of prepared refractory composite. Ceram. Internat. 38 (2012) 4997–5006

    Article  CAS  Google Scholar 

  16. Dutta, S., Das, P., Das, A., Mukhopadhyay, S.: Significant improvement of refractoriness of Al2O3-C castables containing calcium aluminate nano-coatings on graphite. Ceram. Internat. 40 (2014) 4407–4414

    Article  CAS  Google Scholar 

  17. Mukhopadhyay, S.: Nanoscale calcium aluminate coated graphite for improved performance of alumina based monolithic refractory composite. Mat. Res. Bull. 48 (2013) 2583–2588

    Article  CAS  Google Scholar 

  18. Mukhopadhyay, S., Mondal, C., Chakraborty, A., Mali, D., Ghosh, S.: In depth studies on cementitious nanocoatings on graphite for its contribution in corrosion resistance of alumina based refractory composite. Ceram. Internat. 41 (2015) 11999–12010

    Article  CAS  Google Scholar 

  19. Mukhopadhyay, S., DasPoddar, P.K.: Effect of preformed and in situ spinels on microstructure and properties of a low cement refractory castable. Ceram. Internat. 30 (2004) [3] 369–380

    Article  CAS  Google Scholar 

  20. DasPoddar, D., Mukhopadhyay, S.: Spinel-bonded basic castables in relation to spinel forming agents. Interceram 51 (2002) [4] 282–288

    CAS  Google Scholar 

  21. Mukhopadhyay, S., Ghosh, S., Mahapatra, M.K., Mazumder, R., Barick, P., Gupta, S., Chakraborty, S.: Easy-to-use mullite and spinel sols as bonding agents in a high-alumina based ultralow cement castable. Ceram. Internat. 28 (2002) [7] 719–729

    Article  CAS  Google Scholar 

  22. Sako, E.Y., Braulio, M.A.L., Pandolfelli, V.C.: The corrosion and microstructure relationship for cement-bonded spinel refractory castables. Ceram. Internat. 38 (2012) 2177–2185

    Article  CAS  Google Scholar 

  23. Szczerba, J., Prorok, R., Sniezek, E., Madej, D., Maslona, K.: Influence of time and temperature on ageing and phase analysis in the MgO-SiO2-H2O system. Thermochimica Acta 567 (2013) 57–64

    Article  CAS  Google Scholar 

  24. Duran, T., Pena, P., De Aza, S., Millan, J.G., Alvarez, M., De Aza, A.H.: Interactions in Calcium Aluminate Cement (CAC)-Based Castables containing Magnesia, Part II: Hydration-Dehydration Behavior of CAC and their Mixtures with Dead-Burned and Reactive-Grade MgO. J. Amer. Ceram. Soc. 94 (2011) [3] 909–917

    Article  CAS  Google Scholar 

  25. Sako, E.Y., Braulio, M.A.L., Pandolfelli, V.C.: Microstructural evolution of magnesia-based castables containing microsilica. Ceram. Internat. 38 (2012) 6027–6033

    Article  CAS  Google Scholar 

  26. Souza, T.M., Braulio, M.A.L., Luz, A.P., Bonadia, P., Pandolfelli, V.C.: Systematic analysis of MgO hydration effects on alumina-magnesia refractory castables. Ceram. Internat. 38 (2012) 3969–3976

    Article  CAS  Google Scholar 

  27. Salomao, R., Pandolfelli, V.C.: The role of hydraulic binders on magnesia containing refractory castables: calcium aluminate cement and hydratable alumina. Ceram. Internat. 35 (2009) 3117–3124

    Article  CAS  Google Scholar 

  28. Vandchali, M.V., Sarpoolaky, H., Golestani-Fard, F., Rezaie, H.R.: Atmosphere and carbon effects on microstructure and phase analysis of in situ spinel formation in MgO-C refractories matrix. Ceram. Internat. 35 (2009) 861–868

    Article  CAS  Google Scholar 

  29. Vandchali, M.V., Sarpoolaky, H., Golestani-Fard, F., Rezaie, H.R., Aneziris, C.G.: The influence of in situ spinel formation on microstructure and phase evolution of MgO-C refractories. J. Europ. Ceram. Soc. 28 (2008) 563–569

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to S. Mukhopadhyay.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Das, P., BasuMallick, S., Maity, P. et al. Evaluation of Refractory Performance of Basic Castables Containing Magnesium-Aluminate Sol-Gel Coatings on Graphite. Interceram. - Int. Ceram. Rev. 65, 41–46 (2016). https://doi.org/10.1007/BF03401186

Download citation

  • Received:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF03401186

Keywords

Navigation