Engineering aggregates—The next frontier for high-performance refractories

Examples from recent decades recount great progress in engineering of refractories. Reducing calcium aluminate cement by adopting silica fume and ultrafine alumina powders in refractory castables greatly improved their high-temperature properties and helped shift a large fraction of refractories from prefired bricks to in-situ installed castables.1 Replacing conventional carbon sources with nanoscale carbon brought about low-carbon refractories, leading to reduced carbon pick up in steel refining processes.2 Mullite formed in-situ instead of admixed in the refractory matrix achieved much higher strength and thermal shock resistance for refractory products.3 Use of nanosized silica improved flowability of castables.4

Further, a variety of new additives incorporated into shaped and unshaped refractories helped optimize phase distribution, structural bonding, damage resistance, etc. For example, organic-based dispersant helps improve the dispersion of ultrafine silica and alumina powders in castables;5 boride- and carbide-based antioxidants help protect carbon from oxidation in carbon-bonded refractories;6 barium-containing additives in aluminosilicate refractories improve corrosion resistance against aluminum melts;7 and small amounts of alumina in nitride-bonded SiC refractories can improve strength by changing grain morphology.8

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