| The aim of this work was set to develop effective and practicable new methods to incorporate natural flake graphite (FG) into the Al2O 3 based castables for iron and steel making applications.; Three approaches, viz. micro-pelletized graphite (PG), crushed briquette of Al2O3-graphite (BAG) and TiO2 coated graphite (CFG), have been developed to insert flake graphite into Al2O 3 rich Al2O3-SiC based and Al2O 3-MgO based castables. These approaches were put into effect as countermeasures against the problems caused by FG in order: (1) to agglomerate the FG powders so as to decrease the specific surface area; (2) to diminish the density difference by using crushed carbon bonded compact of oxide-FG mixture; (3) to modify the surface of the flake graphite by forming hydrophilic coating; (4) to control the dispersion state of the graphite in the castable to maintain enough bonding strength; and (5) to use appropriate antioxidants to inhibit the oxidation of FG.; The whole work was divided into two stages. In stage one, Al2O 3-SiC-C castables were dealt with to compare 4 modes of inserting graphite, i.e., by PG, BAG, CFG and FG. Overall properties were measured, all in correlation with graphite amount and incorporating mode. In stage two, efforts were made to reduce water demand in the Al2O3-MgO castables system. For this purpose, the matrix portion of the castable mixes was extracted and a coaxial double cylinder viscometer was adopted to investigate rheological characteristics of the matrix slurries vs. 4 kinds of deflocculants, through which the best deflocculant and its appropriate amount were found. Efforts were then made to add up to 30% MgO into the castables, using a limited amount of powders (<0.3 mm), the rest being increased in size gradually up to the top size of 4.76 mm. Into the optimized Al2O3-MgO castables graphite was incorporated by PG and BAG, and 4 kinds of antioxidants, Si, SiC, B4C and ZrB2, were added respectively or in combination. Overall properties of the castables, were investigated in correlation with MgO amount and graphite and antioxidant packages. Optimization work on oxidation and slag resistance was pursued. Finally, microstructure analysis on the samples after oxidation and slag tests was conducted. (Abstract shortened by UMI.)... |
