Microwave and conventional treatment of low-cement high-alumina castables with different water-to-cement ratio; Part II. Dehydration

Abstract

Modern refractory castables contain between 3.5 and 5 wt.-% water that is necessary for sufficient flow during emplacement and for the formation of hydrate phases, necessary for the green strength of the material. Prior to the high temperature use of this material, it must be dried very carefully to avoid explosive spalling.This paper will demonstrate that beside conventional drying of pre-shaped materials in resistance furnaces microwave radiation is an energy saving and rapid method to remove pore water as well as hydrate bond water from the castable. In comparison to resistance furnaces, the use of microwave radiation does not affect the castable properties as there are mechanical strength (MOR, CCS), open porosity and pore size distribution. This study proved microwave radiation as valuable alternative with a series of tabular alumina based low cement castables (LLC) in which the water-to-cement-ratio (wcr = 0.64, 0.75, 0.82 and 1.13) was systematically altered by changing the cement concentration at constant mixing water concentration of 4.5%.