Development of alumina based bonding matrix system and its use in castable refractories

The use of the self-flowing castable refractories as kiln material in processes likes iron-steel, cement and ceramic production is on the rise. Studies on the binding matrix in these monolithic ceramics have also been the focus of research because of the important effect of the matrix on the thermal shock and corrosion resistance of these materials. Reactive alumina with different particle size distribution, specific surface area and crystal size are the important constitutes of the matrix system.The reactive alumina developed using alumina and aluminum hydroxides from Seydişehir were characterized using BET, PSA, XRD and SEM techniques. Their physical and mechanical properties were compared with imported reactive alumina. Under consideration of the economical side, positive results were obtained. The developed matrix material was used in self-flowing refractories. The physical properties of the materials including porosity, their compression and bending strengths, and rheological properties were found to be within desired limits. Thermal shock resistance and corrosion resistance against Iskenderun slag were investigated and the results were evaluated in terms of the microstructure. Furthermore, calcium hexa aluminate was produced and their influences onthe properties of material were investigated.