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Journal of Ceramic Science and Technology 3/2025

Vol. 16, No. 3 · September 2025

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Effects of Changing the Specific Surface Area in the Ceramic Matrix of CAC-Containing Refractory Castables on the Dispersion and Mixing Process

F. Holleyn, T. Waldstädt, J. Kasper, L.T. Ibarra Plata, C. Dannert, O. Krause

Pages 173-186 · DOI: 10.4416/JCST2024-00023

Beside the coarse and medium grain size distribution, the matrix components play a central role in the performance of refractory castables. On the basis of practical experience, it is evident that the particle size distribution (PSD) and the resulting specific surface area of the ceramic matrix exert a significant influence on the processing, setting and sintering properties of refractory castables, which in turn influence each other. However, there is a lack of detailed highly systematic studies regarding the extent to which the properties of refractory castables are influenced by changes in …

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Structure, Microstructure and Properties of Lightweight Aluminosilicate Refractory Aggregates and Castables

D. Madej, A. Bąk, D. Bielewicz, A. Aksamit, A. Hecman, W. Mikulski

Pages 117-124 · DOI: 10.4416/JCST2024-00015

Lightweight aggregates and castables are of great significance for energy saving and the reduction of emissions. In this work, lightweight aluminosilicate aggregates were produced using high-quality kaolin and porogenous material by means of high-temperature processing and investigated in terms of XRD mineralogy, bulk density, open porosity, and microstructure. In addition, the influence of the lightweight aggregates on the bulk density, cold crushing strength, microstructure, thermal properties and thermal shock resistance of refractory castables was investigated in detail. For this reason, l …

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The Influence of Titania, Carbon Black and Graphite on the Spinel Formation in a Magnesia Alumina Castable

J. Angelkort, L. Himmel, Y. Lakotta-Weinhold, A. Reichert, M. Mix

Pages 135-140 · DOI: 10.4416/JCST2024-00017

In this work, we studied the effect of small additions of titania and three carbon sources on the spinelization of magnesia alumina castables. Compared to additive-free reference samples, titania-containing magnesia alumina castables were found to exhibit improved sinterability and higher cold crushing strength after firing. In parallel, significantly higher amounts of spinel formed during heat treatment when titania had been added to the castable.For the carbon-containing samples, the grain size of the carbon source proved to be an important parameter controlling the influence on spinelizatio …

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Investigating the Use of Sugar Alcohol as an Alternative Non-Toxic Binder to Conventional Coal Tar/Coal Tar Pitch for Use in Taphole Clay

I. Cameron, A. Garbers-Craig

Pages 141-152 · DOI: 10.4416/JCST2024-00019

Currently, the main purpose for obtaining alternative binders for use in taphole clay is to reduce the exposure to harmful polycyclic aromatic hydrocarbons (PAH) associated with conventional coal tar (CTht) binders. Some advances have been made such as using lower-PAH alternative binders or phenolic resole resins (resin-bonded) in taphole clays. The use of non-toxic binders has become exceedingly difficult due to the versatility of CTht in taphole clay. This study investigated a combination binder system that consisted of a sugar alcohol (research-grade glycerine) and phenolic resole resin as …

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Novel Binder Systems for No-Cement Castables: A Comprehensive Evaluation of Mechanical Strength and Hot Properties

H. Peng

Pages 153-160 · DOI: 10.4416/JCST2024-00021

Cement-free binders have recently attracted significant attention due to their rapid drying and superior high-temperature performance, including enhanced thermo-mechanical properties, refractoriness under load, and corrosion resistance, compared to low-cement castables (LCCs). Despite these advantages, conventional no-cement castables (NCCs) exhibit limited mechanical strength at intermediate temperatures (600 to ∼ 1 000 °C). This study aims to develop innovative binder systems for NCCs, specifically targeting intermediate temperature applications, while also being suitable for high temperatur …

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Thermomechanical and Thermochemical Behaviour of Silica- and Spinel-Sol-Bonded High-Alumina Refractory Castables

E. Brochen, C. Dannert, M. Thiesen, T. Ibarra, O. Krause, S. Abdelouhab, C. Lang

Pages 107-116 · DOI: 10.4416/JCST2024-00014

While calcium aluminate cements have become established as a \"workhorse\" for refractory castables (reliable and cost-effective), they nonetheless have certain drawbacks (high risk of explosive spalling during drying, limited resistance to acidic slags and ashes) and, after years of optimization, only limited potential remains for further improvements. By contrast, colloidal suspensions (sols) are increasingly used as bonding solutions in the industry (silica sols) and, despite their current limitations (providing low green strength and limited refractoriness), they have much to offer. Especi …

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Corrosion of Cement-Bonded Refractory Castables due to Hydrogen-Containing Atmosphere

T. Tillmann, T. Leber, T. Tonnesen

Pages 161-172 · DOI: 10.4416/JCST2024-00022

This study examined the influence of a hydrogen-containing atmosphere on cement-bonded refractory castables. Two series of tests were conducted using different materials, a fireclay and a high-alumina castable with SiC. Each test series consisted of three samples exposed in a tube furnace at temperatures of 1 100 °C and 1 500 °C for 24 and 72 hours. The temperature of 1 100 °C represents the upper temperature limit of a direct reduction plant, while 1 500 °C should provoke corrosion. An optical examination revealed a change in colour, due to the formation of oxygen vacancies. At 1 100 °C, ther …

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Corrosion Study and Thermodynamic Calculations for MgO-C Refractories Containing CMA Additive

M. Ludwig, M. Sułkowski, M. Klewski, E. Wojtaszek-Jajków, D. Madej

Pages 125-134 · DOI: 10.4416/JCST0024_00016

MgO-C refractories are extensively utilized in the steel industry, particularly in steel ladles, basic oxygen furnaces, and electric arc furnaces. These materials are subjected to intense mechanical and thermal stresses, as well as aggressive interactions with corrosive agents. The most severe wear typically occurs upon contact with slag or molten metal; therefore, the use of high-purity raw materials is essential to ensure durability under such conditions. To enhance the thermomechanical performance of MgO-C refractories, antioxidants are commonly incorporated, leading to the formation of hig …

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