A REVIEW OF REFRACTORY BOND SYSTEMS FOR MONOLITHIC

REFRACTORIES

Chris Parr, Josh Pelletier, Christoph Wöhrmeyer, Carl Zetterstrom, Magali Szepizdyn – Kerneos
SA

A plethora of bonding systems has been developed for monolithic manufacturers, either as
proprietary systems or commercial products. Each of the these systems displays a series of
intrinsic characteristics that can be exploited advantageously by the monolithic producers.

This paper will provide a state of the art review of the different bond systems by their function
and the delivered performance in a variety of model systems. A number of
composite/combination binder systems will be explored via an extensive literature review and
experimental data along with a perspective of the evolution and development of bond systems
over the last 20 years. A specific focus will be given to bond systems for monolithic castables.
Results will show the different comparative characteristics for each system and their advantages
as well as the tradeoffs that have to be made. This then gives rise to the notion that there is no
one universal bond system but rather intrinsic characteristics have to be adapted to each situation
and application in terms of placing technologies and installed performance. Conclusions will
explore future needs and development options.

EFFECT OF ADDITIVES ON THE PROPERTIES OF MAGNESIUM PHOSPHATE

CEMENT

George D. Gower, P.E. – Refractory Minerals Co., Inc.

The effects of various additives on the Magnesium Phosphate cement system are investigated.
Magnesium Phosphate cement is comprised of Mono Magnesium Phosphate and a source of
MgO (Fused or Dead Burned). This is a rapid reaction requiring additives to slow the setting of
the Cement. In addition, additives may be used to vary strength and expansion characteristics.
Utilizing a standard test mix the effect of additives on set time, flow, strength and expansion are
studied.

CEMENT HYDRATION AND STRENGTH DEVELOPMENT - HOW CAN

REPRODUCIBLE RESULTS BE ACHIEVED?

Dale Zacherl – Almatis

The consistency of high alumina cements, with regard to setting and strength development, is a
key quality feature which distinguishes different brands available in the market. The quality
testing of cement must take into account inherent variation of the cement setting behavior which
occurs, for example, in neat cement testing. When testing in castables the ambient conditions
such as temperature, humidity, and a covering of the samples can have an influence on the
strength development. The paper discusses results obtained in calorimetric testing of different
cement test grogs and of castable testing under practical laboratory conditions with different
cement content and additives in the test castables.
COMPARISON OF THE PROPERTIES OF CEMENT AND CEMENT-FREE
CASTABLE BOND SYSTEMS

Sam Bonsall – Vesuvius USA

Low and ultra-low cement castables perform well in a wide variety of applications. Several
cement-free bond systems were evaluated in comparison to cement bonds with respect to
physical properties, ability to repair (veneer over existing castable), and installation/drying
behavior. The results will be used to reach objective conclusions on the advantages and
disadvantages of each system.

HOW DO STEELMAKERS CHOOSE REFRACTORIES – THE ROLE OF BONDING

SYSTEMS

Tom Vert – ArcelorMittal Dofasco

Steelmakers are under extreme pressure with a high risk process, in an oversupplied competitive
marketplace with low margins, with very little control of their costs and refractories are one of
the only controllable components left. Selection of refractories is a balance of many factors
including safety, environment, production, costs, etc. and selection of an engineered ceramic
with detailed technical data including bonding systems can allow steelmakers a better
understanding as to the probability of success. Also, refractory suppliers, raw material suppliers
and universities need to develop tests that will simulate real life processes and not good QAQC
tests if they want to increase trials, increase product success, and increase profits! The
presentation will attempt to address these issues and a path forward for the future.

FINDINGS ON RELATIONSHIPS BETWEEN PARTICLE PACKING, ULTRAFINES

AND RHEOLOGY OF REFRACTORY CASTABLES

Bjorn Myhre – Elkem

Particle size distribution has been found to influence the flow of modern castables, in the sense
that by varying parameters in the distribution deliberate composition of vibratables or self-
flowing mixes can be readily made. There still exist a quest regarding the rheological behavior at
high shear though, which is particularly important and essential in high-shear applications like
pumping and shot-creting. In this paper theeffect of Partice Size Distribution (PSD) on flow of
castables is treated, as well as the importance of the particle shape. Particularly for the the sub-
micron fraction is demonstrated that the use of a spherical alumina instead of plate-like reactive
alumina eliminates dilatancy. Thus by using spherical alumina, the tendency to dilatant behavior
can be eliminated also in silica-free alumina castable compositions.
ACTIVATED ALUMINA BINDERS IN REFRACTORY COMPOSITIONS

Scott Barnhouse – Alteo NA

Activated Alumina (AA) can be used as a binder in zero cement and ultra-low cement refractory
systems. The history as well as the advantages and disadvantages of AA as a refractory binder
will be discussed.

A 50 YEAR HISTORY OF CONTRACT REFRACTORY DRYOUT / HEATUP

SERVICES

Irish Cobane – Hotwork

Contract refractory dryout / heatup services have played an important role in practically all
refractory consuming industries and particularly the quality assurance of monolithic refractory
linings. Since the invention of the high velocity excess air burner in the UK in the early 1960's
and the subsequent use of that equipment to impart controlled uniform heating of refractory lined
furnaces and vessels, the technology has been accepted as "best practice" for initial dryout /
heatup of refractory linings regardless of whether it is to uniformly heat pre-fired refractory
brick linings or moisture removal from monolithic linings. In conjunction with the development
of high density, low moisture monolithic refractory products and particularly with the advent of
Calcium Aluminate and other chemical binder systems, the ability to perform closely controlled
uniform heating using a professional refractory dryout contractor has had a significant impact on
the life cycle of both brick and monolithic refractory linings and the ever increasing use of the
latter in today's refractory consuming industries.

This paper discusses the invention of the high velocity burner, the role it played in the founding
of Hotwork UK (1962) and subsequently Hotwork-USA (1965) as the companies who brought
refractory dryout services to the world. Also discussed are the various monolithic refractory
binder systems encountered over the years, dryout curves and the challenges encountered in
bringing refractory linings into service in a manner conducive to providing maximum service life
in the applications for which they were designed.

REFRACTORY CASTABLE BINDER ENGINEERING

Victor C. Pandolfelli – Federal University of S. Carlos – Brazil

Considering that the major volume consumption of refractory castables is for the steel making
industry, calcium aluminate cement (CAC) is usually the most common binder. Nevertheless,
CAC is not the best option for densification at temperatures in the 800°C-1200°C range, for
applications where high thermal shock and erosion resistances are essential properties, such as
for petrochemical and aluminum industries. Taking these aspects into account, novel castable
formulation concepts were designed aiming to attain sintering at lower temperatures without the
drawbacks of permanent liquid phase containing systems. The successful use of colloidal binders
and transient phases will be presented as an alternative to attain such requirements, based on the
high refractoriness, high erosion and thermal shock resistances, and hot mechanical strength
achieved. The outstanding performance, points out the great potential of these routes to increase
the working life and reduce the maintenance stops of the production units. Besides bonding with
nano particles and transient phases, some experimental innovative techniques will also be
highlighted such as brucite morphology engineering for the development of Al2O3-MgO cement-
free refractory castable. The use of hydrating agents that could change the Mg(OH)2 crystals
shape in the resultant microstructure, minimizing the drawback related to the in-situ reaction
expansion and providing suitable green mechanical properties, will be presented and discussed.

THE USE OF PHOSPHATES AS BINDERS AND ADDITIVES FOR REFRACTORIES

Erwin Schmidt – Chemische Fabrik Budenheim KG

The paper presents a brief roundup of various types of phosphates,

their properties and applications as binders for shaped and unshaped refractories,
as well as their application as additives for castables and hardeners for silicates.

BONDING SYSTEM IN MgO-CaO-Fe2O3 REFRACTORY FOR EAF FURNACE

BOTTOMS

Henry He and Steve Mangin – Magnesita Refractories

Binders with low melting points are often added into the refractory mixes in order to create
sintering at lower temperature. These binders can compromise not only the refractoriness but
also the erosion resistance. One of the unique bonding systems is the bonding system for electric
arc furnace bottom material made of MgO-CaO-Fe2O3. In this bonding system, the dicalcium
ferrite (C2F) forms a transient liquid phase to initiate the liquid sintering and densification at a
temperature as low as 1300C. However, the liquid phase then disappears gradually with the
migration of iron oxide in the liquid into MgO and the formation of magneiowustite, leaving
behind ceramic bonded structure with high refractoriness.

There are two ways to achieve this bonding system. One is to add iron oxide into the blended
magnesia and doloma, which results in high refractoriness and high erosion resistance to the
EAF slag. The other is to use MgO-CaO-Fe2O3 grains, which results in quick sintering and high
shrinkage.

CORRELATION BETWEEN MEASURED THERMOPHYSICAL DATA AND

MINERALOGICAL CONSTITUTION OF REFRACTORIES

Peter Quirmbach and Hartmut Koerber – Deutsches Institut fuer Feuerfest und Keramik (DIFK)

Thermophysical data concerning different kind of strength, creep and erosion and corrosion
resistance obviously correlates with microstructural design. Apart from the right choice of grain
parameter the constitution of matrix phase fundamentally influences the binding forces and their
impact to product behavior. The correlation determining effect will be discussed in terms of
structure-property relations by means of representative examples.
GUNMIX – A NEW MOISTENING SYSTEM TO IMPROVE BONDING IN DRY
GUNNING

Christian Wolf – Velco GmbH

For many years the dry gunning procedure is used for the cold and hot repair of refractory
linings. By means of the new VELCO development, the GUNMIX®-system, the moistening of
the gunning mix will be improved considerably, resulting in better physical properties of the
gunning mix and less dust and rebound. For small gunning amounts GUNMIX® is a cost-saving
alternative to labour intensive procedures such as Wet-Shotcreting. Applications for hot and cold
installation in steel- , aluminium-, cement industry and waste incineration will be shown.