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n Journal of the American Ceramic Society 86(7):1146 - 1148 · December 2004 with 2,226 Reads
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2003.tb03438.x
Innocentini
Fábio A. Cardoso Mario M. Akyioshi
niversidade de Ribeirão Preto
ndolfelli
niversidade Federal de São Carlos Greenland is melting at an
Greenland was losing ice four time
new research has found. If it all m
level by seven meters. The study's
global warming is to blame. If the
relative to sea level at the turn of t
ork was to investigate the drying kinetics of high-alumina, ultra-low-cement refractory castables under continuous
hree main drying stages were identified during the castable heat-up and were related to the phase change of free water
tion of hydrated products present in the body. A clear correlation was found between the actual heating profile inside
dewatering stages under various heating schedules. Thermal analysis was used to assess the drying temperature that
t risk of steam pressure buildup and, thus, of explosive spalling.
tering
research
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rojects
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66 Citations 12 References 4 Figures
unction of the furnace Drying stages related to the actual sample Drying profiles for CAC-containing and
us heating schedules. temperature for various furnace heating… cement-free samples at a furnace heating…
se of this work was to investigate the drying kinetics (calcined aluminas A1000 SG and A3000 FL, 22 wt%, d
mina, ultra-low-cement refractory castables under m, where dp is the particle diameter) and the aggregat
heating conditions. Three main drying stages were (white fused aluminas, grades 4/10, 8/20, 10/36, 20/40, an
during the castable heat-up and were related to the 76 wt%, dp ⬍ 4.5 mm). The particle size distribution
nge of free water and to the decomposition of composition was adjusted to a theoretical curve based on A
roducts present in the body. A clear correlation was en’s packing model to obtain a potentially self-flow casta
ween the actual heating profile inside the castable a coefficient of distribution (q) of 0.21.
ewatering stages under various heating schedules. Samples were cast as 4 cm diameter ⫻ 4 cm thick c
nalysis was used to assess the drying temperature cured in the mold at 50°C (relative humidity of ⬃100%)
ents the highest risk of steam pressure buildup and, and heat-treated for 6 h at 800°C (heating rate of 1°C/min)
plosive spalling. casting, two thin K-type thermocouples (diameter of 0.2 m
inserted into some of these samples at a height of 20 mm,
at a depth of 1 mm (lateral surface) and the second at
I. Introduction (center of the body). To focus the analysis on the rem
physically absorbed water, the samples were saturated w
ORY castables are hydrated materials that require
tilled water under a vacuum for 2 h before each test.
l attention during their first heat-up. Depending on Dewatering tests were conducted in an electric furn
schedule applied, the steam that is generated may trolled by a proportional-integral-derivative (PID) syst
essurized within the ceramic structure, occasionally maximum temperature of 700°C and according to various
acking or even explosive disintegration of the prod-
schedules. The test sample was suspended in the cente
r this reason, the dry-out schedules of preshaped furnace to enable heat to reach every face of the body
are often divided into steps, aiming for safe removal neously. No forced air convection was provided in the
ree casting water at around 100°C and cement during the heat-up.
tion products at higher temperatures. However, the In the first set of experiments, the temperatures at the
uitable heating rates and dwell times is based mostly and center of the saturated specimen were monitored dur
al knowledge that takes into account the ceramic heating program. New tests were then conducted with
n, and the geometry and size of the product. In fact, samples without thermocouples to monitor the sample
able data on the duration and intensity of transfor- loss under the same heating conditions. Data on m
hat take place inside the heated structure make
temperature were computer-recorded at 5 s intervals thr
schedules preferable. This minimizes the risks of the experiments.
palling but makes the dry-out of green castables an Mass loss during drying was assessed through the no
and time-consuming operation. parameter W, which measures the cumulative fraction
ontext, this study focused on the optimization of the expelled during the heat-up per total amount of water
process of high-alumina, ultra-low-cement refractory present in the body. W varies from 0%–100% and is def
mpositions. The drying kinetics of physically absorbed
assessed during the castable heat-up at various heating
water loss pattern was directly related to the temperature
easured in the sample, allowing for the identification of
W共%兲 ⫽ 100 ⫻ 冉 Mo ⫺ M
冊
Mo ⫺ Mf
rying stages and providing guidelines to optimize where M is the instantaneous mass recorded at time ti du
astable heating schedules. heating stage, Mo the initial mass, and Mf the final mas
tested sample.
The experimental drying rate during heat-up was
II. Experimental Procedure through the derivative dW/dt by
able composition chosen for this study consisted of a dW Wi⫹1 ⫺ Wi⫺1
⫽
98 t% l i 2 t% l i l i t t
冉 冊
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98 wt%allalumina, 2See
wt%all ›calcium aluminate › cement
14, See
oa 66
Alcoa,› Pittsburgh,
(Brazil and U.S.)
Citations
PA), See all
and 4.52 wt%
supplied the matrix
12 References
water (dry
powders
4 Figures
冉 冊
dt i ti⫹1 ⫺ ti⫺1
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1146
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66 Citations 12 References 4 Figures
g profiles as a function of the furnace temperature for Fig. 3. Drying profiles for CAC-containing and cement-free samp
schedules. furnace heating rate of 10°C/min.
the similarities among the drying profiles of the and center of the body. In this case, the abrupt increase
d samples confirmed that removal of unbound water heating rate at the center signals the end of the boiling proce
t, be the main concern during the heat-up process of of the second dewatering stage, reestablishing similar h
w-cement compositions, requiring further attention to profiles for the center and surface for the remainder of the
ve pore pressurization and explosive spalling. Therefore, although heated to over 100°C, the body r
water in liquid form during most of the second drying stage
Changes during Dewatering may occur if the structure’s permeability is sufficiently l
is associated with important thermal transforma- increase the vapor pressure inside the pores, shifting the boil
e place inside the heated castable. Although part of water to higher temperatures. This effect is dangerously enh
heat is conducted into the body through the solid during the time interval in which the discrepancy in the h
profiles inside the body is maintained, when the heatin
of it is also absorbed by the liquid water retained in
st enhancing evaporation under 100°C and then increases rapidly on the surface while water is still boiling
iling above that temperature. 9 center.
s in Fig. 4 indicate that these endothermic phase Figure 4(c) shows that, for the castable heated at 10°C/mi
sses are remarkably intense during the first and critical displacement interval refers to a temperature increase
ering peaks, causing a temporary slowdown in the 160°–220°C. According to Antoine’s equation, 4 this imp
nside the castable. This effect is further accentuated theoretical steam pressure buildup from 0.6 –2.3 MPa, whic
of steam leaving the body, which decreases the be sufficiently high to cause the explosion of a green ca
heat absorption and increases the thermal gradient These values obviously refer to the maximum pressure bu
achievable in the center of the body if no release is provid
body and the surrounding atmosphere. The result is
f both dewatering stages is immediately followed by steam. In practice, the castable’s permeability and the h
n of the castable heating rate. 9 schedule determine the amount of water retained in the pore
g schedule also has a marked effect on the thermal hence, the actual intensity of the pressure buildup. Neverth
e the castable, as can be observed in Fig. 4. For the the values calculated by Antoine’s equation for the critical
ested here, the furnace heat-up at 1°C/min is suffi- tering interval represent the upper limit for steam pressuri
to produce no important internal thermal gradient, and may be reasonably compared with the mechanical t
center and surface of the sample becoming equally strength of green castables with the purpose of evaluating th
the dewatering stages. of explosive spalling.
ior changes with heating rates of 5°C/min and
pecially during the second stage when there is a
crepancy between the heating profiles at the surface IV. Conclusions
This investigation demonstrated that the dewatering proc
a continuously heated high-alumina, ultra-low-cement ca
occurs in stages and in different temperature ranges. The tw
stages involve the removal of free water, first by evaporation
100°C and by ebullition thereafter. The third stage takes pl
higher temperatures and involves the elimination of hy
phases in the castable matrix. Thermal analysis revealed th
sample’s center and surface were both remarkably sensit
endothermic processes involving the conversion of wate
steam and to the heating schedule applied. The heating p
inside the castable is therefore clearly related to the dewa
stages, providing an indirect assessment of the maximum
pressure buildup developed inside the pores, thus guidin
choice of heating schedules that minimize the risk of exp
spalling.
References
1
M. Velez, A. Erkal, and R. E. Moore, “Computer Simulation of the Dewat
Refractory Concrete Walls,” Taikabutsu Overseas, 20 [1] 5–9 (2000).
2
R. E. Moore, J. D. Smith, W. L. Headrick Jr., and T. P. Sander, “Mo
Dewatering Theory Testing and Practice: New Challenges”; presented at t
Annual Symposium on Refractories, St. Louis, MO, Mar. 1996. American C
Society, St. Louis Section, 1996.
3
M. D. M. Innocentini, C. Ribeiro, J. Yamamoto, A. E. M. Paiva, L.
Bittencourt, R. P. Rettore, and V. C. Pandolfelli, “Drying Behavior of Re
https://www.researchgate.net/publication/229622153_Drying_Stages_During_the_Heating_of_High-Alumina_Ultra-Low-Cement_Refractory_Cast… 4/9
11/5/2019 (PDF) Drying Stages During the Heating of High-Alumina, Ultra-Low-Cement Refractory Castables
See all › See all › See all › Castables,”
4 Am. Ceram. Soc. Bull., 80 [11] 47–56 (2001).
D. A. Bell, “First Heat-up of Ladle citation
Linings”; pp. Share
292–94 in UNITE Download full-text PDF
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66 Citations 12 References 4 Figures Proceedings. American Ceramic Society, Westerville, OH, 1997.
5
P. Kalifa, F. D. Menneteau, and D. Quenard, “Spalling and Pore Pressure
at High Temperatures,” Cem. Concr. Res., 30, 1915–1927 (2000).
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G. W. Scherer, “Theory of Drying,” J. Am. Ceram. Soc., 73 [1] 3–14 (19
7
W. C. J. Wei and C. L. Hsieh, “Drying Kinetics of Ultrafine Alumina Ca
Drying Control Chemical (DCC),” J. Ceram. Soc. Jpn., 107 [4] 313–17 (19
8
K. Oda, H. Itoh, T. Matsumoto, and Y. Ono, “Drying Characteristic o
Dense Castable,” Taikabutsu Overseas., 13 [2] 21–28 (1992).
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M. D. M. Innocentini, C. Ribeiro, L. R. M. Bittencourt, and V. C. Pan
“Fluid Dynamics and Thermal Aspects of the Dewatering of High-Alumina
tory Castables: Removal of Physically Absorbed Water,” J. Am. Ceram. Soc.,
ation found between the actual heating profiles inside the 2696 –98 (2001).
e dewatering stages for various furnace heating schedules 10
N. Schmitt, J. F. Hernandez, V. Lamour, Y. Berthaud, P. Meunier, and J.
e of 1°C/min, (b) heating rate of 5°C/min, and (c) heating “Coupling Between Kinetics of Dehydration, Physical and Mechanical Beha
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References (12)
and explosion resistance of cured samples was carried out in a device that simultaneously measured the
les and the samples' temperature [22] , when applying heating rates of 2, 5 and 20 °C/min up to 600 °C. On the other
s were conducted at room temperature [23] using samples obtained after drying at 110 °C/for 24 h and calcining at 200,
...
(heating rate = 5 °C/min) and explosion re- sistance (heating rate = 20 °C/min) of the cured castables were ana- lyzed in
d for thermogravimetric analyses of re- fractory materials [21] . Cylindrical samples (d = 50 mm x height = 50 mm) were
le inserted approxi- mately in the middle of these specimens (in order to allow the detection of the sample's temperature
nts) and cured at 30 °C for 24 h. ...
drying rate profiles of the castables (Fig. 4b), it was detected a first peak related to water evaporation and gel phases
0 °C), followed by a second one that corresponds to both vapor release and hydrate decomposition (∼280 °C) [27] . As
eak evaporation intensity for the TAB sample was higher than the corresponded one for TSZ castable, meaning that a
r was retained in the microstructure of the former, which could lead to higher potential of pressurization during ebullition
o avoid such restrictions and to reduce the chances of explosive spalling [59][60] [61] [62][63] researchers contin- ued to
tent and finally cement free castables were developed [11,[64][65][66]. A number of cement-free bonding systems have
ave changed the castable properties significantly, and these include different colloidal systems like silica, alumina,
ratable alumina (HA); micro-silica; etc. ...
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ctory
SeeCastables
all › — An
SeeOverview
all › See all ›
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66 Citations 12 References 4 Figures
dry weight, P i (g) is the suspended weight and P u (g) is the saturated weight of the evaluated specimens.
asurements were carried out up to 600 °C using cylindrical specimens (40 mm × 40 mm, one specimen per composition)
in an apparatus developed to evaluate refractory materials [36] . A heating rate of 5 °C min −1 was used during these
e mass change and the deri- vative of the mass change was calculated as indicated in Eqs. ...
castables with enhanced explosion resistance due to in situ formation of phases with lamellar structure
ture of stainless steel fibers application is about 1100 °C under oxidation and normal conditions (Lau, Anson 2006).
pylene, polyamide and others) are required for dense and deflocculated castables to facilitate the removal of water
tial heating (Innocentini et al. 2002;Leung, Balendran 2002;Peret et al. 2003) because castables are prone to explosive
ating (Innocentini et al. 2003a (Innocentini et al. , 2003bOlivier, Fabien 2014). These fibers shrink at a temperature
olve at ~150 °C, when the temperature is further increased. ...
g
rzy Witek · Romualdas Mačiulaitis · Rimvydas Stonys
RAM TEC
Li · Pingan Chen · Boquan Zhu
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