Refratários avançados sinterizados com líquidos transientes

Abstract

Sintering additives (AS) have great potential to be applied in refractory castables as they reduce the densification temperature of these products. Additionally, these components may induce the generation of a transient liquid phase in the microstructure at high temperatures, which can react with the other materials of the composition to give rise novel solid refractory phases. Considering these aspects, the present work evaluated the role of five different AS (boron oxide, boric acid, sodium borosilicate, magnesium borate and boron carbide) when added to alumina-based castable compositions containing hydratable alumina as binder. Based on the thermomechanical characterization, XRD analysis and the in situ elastic modulus measurement, boron carbide (B4C) have been selected as a promising AS because this material sped up the sintering process at lower temperatures and induced the aluminum borates formation due to the reaction between the liquid phase and the fine alumina contained in the castable matrix. Afterwards, the effects of B4C was evaluated in ultra-low calcium oxide castables bonded with: colloidal alumina (AC), hydratable alumina (AB) and/ or SioxX®-Zero (SZ). SZ-bonded materials (4 wt.%) had good performance at temperatures around 1100°C due to the mullite generation. On the another hand, castables containing AC as binder (4 wt.% of solids) and 0.5 wt.% of B4C are promising options to be used in working conditions between 600-815°C, whereas the same mixture without B4C could only be densified above 1100°C. Similar effect was observed when 1.0 wt.% B4C was added to SZ-containing castables as the aluminum borates generation allows these compositions to be used in working conditions around 815°C. Therefore, an appropriate AS selection for high-alumina castables with ultra-low CAC content has the potential to favour the earlier sintering of the refractory and improve its thermomechanical properties, which can fulfill the requirements of the petrochemical industry.