SHAMOTTE REFRACTORY MATERIALS ON THE BASIS OF TECHNOGENIC RAW MATERIALS FOR LINING OF THERMAL UNITS OF FOUNDRY PRODUCTION

The article presents the research results of possibility of use of waste refractory materials, slag of electric furnace steelmaking, waste of overburden rocks as technogenic raw materials for the manufacture of refractory materials that meet the requirements of GOST  390-96 «Shamotte and semi-sour refractory products of general purpose and mass production». As a binder aqueous ceramic astringent suspension (ACAS) was used, obtained by mechanical activation of microsilica dust in an alkaline medium with pH  =  11  –  12. As additives that increase the resistance of refractory materials, selfflaking steelmaking slags were used, characterized by high content (70  %) of calcium silicates (γ-2СаО·SiO2 ). As a plasticizing additive, refractory clay of overburden with a plasticity index of 21  –  29 and refractoriness of 1450  °С was used. The production technology of ceramic concrete with a «floating» framework has been the basis for receiving refractories on the basis of technogenic raw materials. The resulting materials were subjected to two stage drying at temperatures of 60  –  70  °C and 120  –  130  °C, the firing was absent. The effect of the slag content in the charge and the granulometric composition of the refractory aggregate on the quality indices of the products were studied. It was established that an increase in the proportion of slag in the charge promotes an increase in the heat resistance of refractories by 55  –  72  %. At the same time it was established that high concentrations of slag (over 20  wt.  %) leads to a decrease in strength of refractory materials by 20  –  30  %. Granulometric composition of the aggregate affects the strength characteristics of the material, however, when the content of slag is 10  wt.  % this effect disappears. The optimal composition of the charge compositions and methods of formation were found, providing the high-quality refractory materials based on technogenic raw materials. By a method of moist pressing, fire-resistant chamotte products of marks SHВ were produced (with refractoriness not less than 1650  °С). By the method of vibrocompaction using clay overburden as the plasticizer, the resulting refractories were received, corresponding to the Marche SWISS (fire resistance not lower than 1630  °С). Refractories based on technogenic raw materials can be recommended for use as alternative materials for lining of various types of heating units and elements of their constructions of foundry and metallurgical production, with a maximum application temperature of 1250  °C.

refractory materials, silica-alumina materials, technogenic raw materials, metallurgical slag, waste, parameters, high temperature units

1. Entin V.I. Status and prospects of refractory enterprises in Russia. Novye ogneupory. 2005, no. 7, pp. 73-77. (In Russ.).

2. Aksel’rod L.M. etc. Sluzhba ogneuporov: sprav. izd. [Service of refractories]. Kashcheev I.D., Grishenkov E.E. eds. Moscow: Intermet Inzhiniring, 2002, 656 p. (In Russ.).

3. Kashcheev I.D., Strelov K.K., Mamykin P.S. Khimicheskaya tekhnologiya ogneuporov [Chemical technology of refractories]. Moscow: Intermet Inzhiniring, 2007, 752 p. (In Russ.).

4. Khoroshavin L.B. Dialektika ogneuporov [Dialectic of refractories]. Ekaterinburg: Izd-vo Ekaterinburgskaya Assotsiatsiya Malogo Biznesa, 1999, 359 p. (In Russ.).

5. Khoroshavin L.B. How to pay more attention to the secondary refractories. Novye ogneupory. 2006, no. 7, pp. 39-42. (In Russ.).

6. Khoroshavin L.B., Ovchinnikov I.I., Nevolin S.G., Yumagulov  M.Kh. Raising the efficiency of utilization of secondary refractories. Refractories and Industrial Ceramics. 2001, vol. 42, no. 1-2, pp.  80–82.

7. Shvydkii V.S., Ladygichev M.G., Shvydkii D.V. Teoreticheskie osnovy ochistki gazov: uchebnik dlya vuzov [Theoretical foundations of gas purification: Textbook for universities]. Moscow: Mashinostroenie-1, 2001, 502 p. (In Russ.).

8. Chentsova L.I. Ochistka i pererabotka promyshlennykh vybrosov i otkhodov: ucheb. posobie dlya vuzov [Purification and processing of industrial emissions and waste: Manual for universities]. Krasnoyarsk: SibGTU, 2012, 250 p. (In Russ.).

9. Cherepanov K.A., Gladkikh I.V., Cherepanova V.K. Kompleksnaya pererabotka i utilizatsiya tverdykh dispersnykh otkhodov v metallurgii: ucheb. posobie dlya vuzov [Integrated processing and disposal of dispersed solid waste in metallurgy: Manual for universities]. Novokuznetsk: SibGIU, 2001, 214 p. (In Russ.).

10. Pivinskii Yu.E. Neformovannye ogneupory [Unshaped refractories]. Moscow: Teplotekhnik, 2003, 448 p. (In Russ.).

11. Pivinskii Yu.E. Dyakin P.V. Preparation and properties of corundum HCBS and ceramic concretes. Part 1. Mixed HCBS in the system electrocorundum - Very fine quartz glass. Refractories and Industrial Ceramics. 2010, vol. 51, no. 1, pp. 25–31.

12. Pivinskii Yu.E., Dyakin P.V. Preparation and properties of corundum HCBS and ceramic concretes. Part 2. Composition and properties of compacted ceramic concretes. Refractories and Industrial Ceramics. 2010, vol. 51, no. 1, pp. 32–38.

13. Pivinskii Yu.E., Suzdal’tsev E.I. Kvartsevaya keramika i ogneupory. V 2 t. T. I. Teoreticheskie osnovy i tekhnologicheskie protsessy [Quartz ceramics and refractories. In 2 vols. Vol. I. Theoretical foundations and technological processes]. Pivinskii Yu.E. ed. Moscow: Teploenergetik, 2008, 672 p. (In Russ.).

14. Pivinskii, Yu.E., Suzdal’tsev E.I. Kvartsevaya keramika i ogneupory. V 2 t. T. II. Materialy, ikh svoistva i oblasti primeneniya [Quartz ceramics and refractories. In 2 vols. Vol. II. Materials, their properties and applications]. Pivinskii Yu.E. ed. Moscow: Teploenergetik, 2008, 464 p. (In Russ.).

15. Pivinskii Yu.E. HCBS ceramic concretes in the XXI century - problems and prospects for applying technology in the field of silicate materials science. Part 1. Refractories and Industrial Ceramics. 2011, vol. 52, no. 2, pp. 107–115.

16. Gladkikh I.V., Kuimov D.S. The use of technogenic raw materials for the refractory blocks. Izvestiya VUZov. Chernaya metallurgiya = Izvestiya. Ferrous Metallurgy. 2006, no. 2, pp. 63–66. (In Russ.).

17. Gladkikh I.V., Volynkina E.P. Utilization of ash microspheres of the West Siberian HCBS in the production of non-combustible composite materials. Ekologiya i promyshlennost’ Rossii. 2009, February, pp. 32–34. (In Russ.).

18. Fedoseenko V.A., Gontaruk E.I., Zatakovoi Yu.A., Evtushenko  E.I., Rubanov Yu.K. Improvement in technology for initial processing of metallurgical slag. Stal’. 2001, no. 12, pp. 77–80. (In Russ.).

19. Pivinskii Yu.E., Rozhkov E.V. Ceramic castables - final stage in the evolution of low-cement refractory castables. Part 3. Refractories and Industrial Ceramics. 2003, vol. 44, no. 3, pp. 134–140.

20. Pivinskii Yu.E. Keramicheskie i ogneupornye materialy: izbr. tr. T. 2 [Ceramic and refractory materials. Vol. 2]. St. Petersburg: Stroiizdat SPb, 2003, 668 p. (In Russ.).

21. Pivinskii Yu.E. Reologiya dispersnykh sistem, VKVS i keramobetony. Elementy nanotekhnologii v silikatnom materialovedenii: izbr. tr. T. 3 [Rheology of disperse systems, HCBS and ceramic concretes. Elements of nanotechnology in silicate materials science. Vol. 3]. St. Petersburg: Politekhnika, 2012, 682 p. (In Russ.).