Industrial waste-derived alumina-zirconia-silica low cement castable

Abstract

High-strength low cement castables have been produced for the first time from the demolished waste of glass furnaces (AZS). Rheology studies indicate the high prominence of longchain ionizable sodium tripolyphosphate STPP (0,2 wt. %) as a dispersant for electrostatic stabilization and rheological characteristics improvement of the entire alumina-zirconiasilica refractory castable. In this work, four castable mixes of various Andreasen packing modulus (n 0,22, 0,23, 0,24, and 0,25) have been formulated using the Andreasen equation. The castable of Andreasen packing modulus n = 0,25 demonstrates an outstanding compressive strength (1118,15 kg/cm2 ) and a moderate bulk density (2,65 g/cm3 ) when fired at 1375 o C. It has showed the highest dimensional stability and its permanent linear change hasn’t exceeded 0,6 % at 1300 o C. This castable displays high thermal shock resistance (30 cycles) and high abrasion resistance (abrasion loss ~ 2,05 % after 280 abrasion test cycles) when fired at 1300 o C. Its superb abrasion resistance recommends its usage in high wear rate sections of cement kiln and its great thermal shock resistance makes it an excellent choice in the case of kiln instability. The outcomes indicated that the tailored castable of n = 0,25 is highly recommended for lining the inlet of rotary cement kiln at temperatures 1000‒1300 o C. In this context, this work opens the door wide for the use of glass kiln demolished waste for the installation of high-strength lowcement refractory castable for lining the inlet cement kiln. Ill. 11. Ref. 50. Tab. 3.