Table of Contents. Chapter 1 Designing refractory castables. Chapter 2 Fundamentals on particle dispersion. Foreword

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1 Table of Contents F.I.R.E. Foreword Preface xiii xv xvii Chapter 1 Designing refractory castables 1. Introduction 1 2. Refractory castables features 3 3. Book content overview Fundamentals on particle dispersion Particle size distribution and packing design Binder additives and their setting mechanisms Installation techniques, highlighting the shotcrete method Curing and drying behavior and their optimization Magnesia hydration and its effect on the performance of MgO-containing compositions Spinel-containing alumina-based castables Carbon-containing castables Designing the microstructure for specific applications Final remarks References 17 Chapter 2 Fundamentals on particle dispersion 1. Introduction Driving force for agglomeration Dispersion mechanisms Electrostatic mechanism Steric mechanism Electrosteric mechanism 36 vii

2 4. Dispersants Dissociation and density of charged sites Adsorption ability Polyelectrolyte chain length and secondary effects Matrix dispersion and cast able rheology Stability maps Rheological aspects Workability and setting behavior Coagulation mechanisms applied for refractory cast able consolidation Direct coagulation casting (DCC) Final remarks References Further reading 90 Chapter 3 Particle size distribution and packing design 1. Introduction Particle size distribution (PSD) effect on packing Particle packing models Main factors affecting particle packing Particle size distribution role in castable processing and properties Mixing ceramic particles Rheological behavior Mechanical strength improvement based on packing optimization and raw materials selection Packing effect on permeability Polymeric fiber addition and its effect on PSD Creep behavior Final remarks References Further reading 155 viii

3 Chapter 4 Refractory castable binders 1. Introduction Hydraulic binders Calcium aluminate cements (CACs) Hydratable alumina (HA) Experimental techniques used to assess the binder hydration behavior and setting Effect of castable s matrix and additives on binder hydration Evolution of CAC and HA-bonded castables properties during the curing stage Chemical binders (phosphates) Bonding mechanisms Colloidal binders Colloidal silica (CS) Colloidal alumina (CA) Final remarks References 245 Chapter 5 Installation techniques: focusing on shotcreting 1. Introduction Evolution of installation techniques: why and when to select shotcrete? Shotcreting castables Dry and wet mixes Material requirements and operational aspects Final remarks References 309 ix

4 Chapter 6 Drying behavior and design of refractory castables 1. Introduction Drying behavior of refractory castables General concepts and typical drying steps Drying schedules and scale-up effect Castables design Roles of polymeric fibers to enhance permeability Geometrical aspects Effects on castable s rheology Fiber types Polymeric and metallic fibers: mechanical reinforcement Roles of aluminum powder Final remarks References Further reading 418 Chapter 7 Magnesia-containing refractory castables 1. Introduction Magnesia hydration mechanisms Magnesia hydration effects on refractory castables Selecting the most suitable magnesia source MgO hydration effect on castable processing Interactions between magnesia and different castables raw materials Alternatives to inhibit magnesia hydration In situ magnesia hydration as a binding agent Final remarks References 487 x

5 Chapter 8 Spinel-containing alumina-based refractory castables Contents 1. Introduction Formulation design using pre-formed spinel General features Post-mortem evaluation of a pre-formed spinel composition Mastering the microstructure to optimize the pre-formed spinel castable properties Formulation design with in situ spinel formation Mechanism of in situ spinel formation Mastering the microstructure to optimize the spinelforming castable properties Final remarks References Further reading 591 Chapter 9 Carbon-containing refractory castables: design, properties and applications 1. Introduction Raw materials for carbon-containing castables Carbon sources Other components Basic features for carbon-containing castable design Water wettability and dispersion of graphite Carbon oxidation Applications Final remarks References Further reading 664 xi

6 Chapter 10 Designing the microstructure for specific applications 1. Introduction Nano-scaled materials Nano-carbon Nano-oxides Bio-inspired refractories Transient liquid phase-containing refractory systems Boron-based sintering additives Final remarks References Further reading 719 Index 721 Authors Profiles 733 xii