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

H. Peng

Journal of Ceramic Science and Technology, Vol. 16, No. 3 (2025), pp. 153-160

DOI: 10.4416/JCST2024-00021

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Abstract

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 temperatures (> 1 300 °C). The research evaluated the flowability, setting behavior, and mechanical strength of NCCs incorporating novel cement-free binders, in comparison to conventional NCCs and LCCs. Additionally, hot properties such as hot modulus of rupture (HMOR), hot abrasion resistance (HAR), and refractoriness under load (RUL) were assessed. The results demonstrated that the novel binder system provided superior mechanical strength and improved hot properties at intermediate temperatures, surpassing conventional NCCs, while maintaining comparable performance at elevated temperatures. Notably, RUL results indicated that the novel binder facilitated sintering and/or mullite formation at a lower temperature (∼ 800 °C) compared to the reference NCC (∼ 1 300 °C), with reduced shrinkage after maximum expansion. Scanning electron microscopy (SEM) analysis confirmed that the novel binder influenced both the temperature and morphology of mullite formation, contributing to the observed improvements.

Keywords

No-cement refractory castables, microsilica-gel binder, intermediate-temperature applications, mullite formation.

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