Effect Of In-situ Synthesis Of Organic Grid Structure On Properties Of Non-burning Magnesium-calcium-based Refractories

Magnesia-calcium-based refractories are consider one of the most commonly used alkaline refractories in industries such steel,lime,cement,etc.It has unique properties such as high refractoriness,high corrosion resistance in an alkaline environment,good abrasion resistance and hot mechanical strength.Typically,these ceramic refractories contain 20–50wt%of the CaO phase.Although existence of CaO leads to the absorption of some impurities?such as S,P,etc.?in the steel melt and allows for the production of a clean melt.However,Cao can spontaneously react with the water in the environment to form the expansive phase Ca?OH?₂,which leads to the cracking and pulverization of magnesia calcium refractories.Thus reducing the service life of magnesia-calcium-based refractories.The non-burning magnesium-calcium-based refractories only has a drying stage without sintering,resulting a low initial strength.The friction and collision during transportation can cause damage to the brick.Thus improvement needed in the performance of early strength,hydration resistance and high temperature sintering of a non-burning magnesium-calcium-based refractories.In the present work the room and high temperature performance along with microstructure of the ferrocene catalysis anhydrous phenolic resin and the in-situ synthesis of organic grid structure at the heat treatment of 200-1650?temperature range were detailed investigated.More interestingly detailed studied of the various characteristics improvement with various parameters were made.?1?The performance of the prepared sample shows a regular variation with the increasing contents of ferrocene drying with 200?.The variation appeared in bulk density,cold crushing strength,hydration resistance,load softening temperature and compressive creep.The slag resistance of sample was increased first and then decreased with increasing of ferrocene content.While the apparent porosity was decreased first and then increased with the increase of ferrocene content.The morphology of the organic grid structure generated is directly related to the ferrocene content?0%,0.5%,1%and 1.5%?.The in-situ synthetic organic grid structure was appeared the most uniform and complete when the ferrocene content was 1%.Interestingly the performance of the sample having 1%ferrocene seemed outstanding in both the normal and high temperature performance test.Furthermore the appeared bulk density was 2.88 g/cm³,porosity was 6.32%,cold crushing strength was 121.59 MPa,the hydration resistance time up to 450 h,the load softening deformation rate at 1650?was 1.23%and the compressive creep at 1500?is 50 h.The recorded deformation rate was 0.22%.The results of the slag resistance tests were appear the best.?2?The observed experiment results illustrate that,by adding 1%of ferrocene the normal temperature performance shows a trend of increasing first and then decreasing in a heat treatment of 600-1200?temperature range.It was concluded from various structure and elemental analysis?XRD,SEM and EDS?that for each sample the in-situ synthesized organic grid structure was gradually carbonized to form regular crystalline carbon.?3?It was found that the normal and high temperature performance of the non-burning magnesium-calcium-based refractories shows better results in reducing atmosphere compared to oxidizing atmosphere.Furthermore the introduction of ferrocene can efficiently improve the sintering performance of non-burning magnesium-calcium-based refractories compared to non-burning magnesium-calcium-based refractories with 1%ferrocene sintered at 1650?under various atmospheres.The analysis of the SEM and XRD measurement proved that the introduction of ferrocene in the sample sintered at 1650?under various atmosphere.The final product was appeared in the formation of CaFe₂O₅ with some C residues.