Study of the castable selection for blast furnace blowpipe

Abstract

The contradictory properties required of castable refractories makes selecting castable refractories for industrial applications challenging. This paper seeks to describe the material selection for a blast furnace blowpipe application that is subjected to sudden temperature changes and must prevent heat loss. Three commercial high alumina castables containing andalusite or mullite from different manufacturers were characterized. Thermal shock damage resistance was evaluated using thermal shock damage resistance theory and experiments. The castables’ coefficient of thermal expansion was estimated using quantitative X-ray diffraction. Crack propagation resistance was measured using the work-of-fracture technique. Thermal shock damage was experimentally evaluated by measuring the modulus of elasticity and rupture prior to and after thermal cycles. Ultimately, the microstructure of the castables was related to the thermal shock damage behavior by estimating the aggregate size and the fracture toughening mechanisms using light optical and scanning electron microscopes. Heat loss was evaluated by calculating the blowpipe shell temperature using a one-dimensional steady-state heat conduction model. The best commercial castable refractory for blowpipe showed high thermal shock damage resistance and low thermal conductivity. The results in this study agreed with thermal shock damage resistance parameters and showed a correlation between coarse microstructure with large aggregate and higher thermal shock damage resistance.