2025 ECerS - FIRE Summer School - Hong Peng

Monolithic Refractories: From Formulation to Future Breakthroughs

Dr. Hong Peng

Elkem, Norway

Monolithic refractories are crucial in high-temperature industrial applications, offering significant advantages over traditional brick refractories due to their seamless structure and superior performance. This presentation explores the journey of monolithic refractories from their formulation to the future breakthroughs driving their evolution.

The formulation of monolithic refractories involves a meticulous selection of raw materials, including aggregates, binders, and additives, to achieve desired properties such as thermal stability, mechanical strength, and resistance to chemical attack. The choice of binders—whether hydraulic, chemical, or organic—plays a pivotal role in determining the setting and hardening characteristics of the refractory. Additionally, the incorporation of additives like dispersants, deflocculants, retarders, accelerators, and drying agents enhances the workability and performance of the final product. Advanced methodologies, such as EMMA software, have been introduced for formulation design to optimize the particle size distribution of the mixes.

The manufacturing processes of monolithic refractories encompass various techniques such as self-flowing, vibro-casting, gunning, ramming, and shotcreting. Each method is tailored to specific application requirements, ensuring optimal installation and performance. The dry-out profile is crucial for refractory castables as it ensures the proper removal of moisture, preventing spalling and explosions.

Advancements in monolithic refractory technology have led to the development of innovative binders, enhancing their durability and efficiency. The transition from cement-bonded binders to cement-free binders has garnered significant attention due to faster dry-out times, improved hot properties, and a reduced CO2 footprint when cement is replaced by low-CO2 products such as microsilica. Additionally, ongoing research aims to develop more sustainable materials with lower environmental impact. These improvements benefit industries like steel, cement, and petrochemicals by increasing operational efficiency and reducing maintenance costs.

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