Low-cement refractory castables are increasingly becoming the preferred choice in the field of monolithic refractories. Not only have developed countries like the United States, France, Japan, and the UK made significant progress in this area, but emerging economies such as China, India, and Brazil have also seen remarkable development over the past decade due to advancements in metallurgical technologies. However, Russia has lagged behind in adopting these materials. In recent years, Russian manufacturers have started exploring low-cement refractory castables alongside ceramic and vibratory castables. These high-performance materials have been successfully applied in various metallurgical equipment across the Commonwealth of Independent States (CIS), with foreign suppliers playing a key role in initial research, testing, and production.
Several major companies in the region, including Oskol Electrometallurgical AG, Breznikov Magnesium Plant, Mitsich Machine Works, Magnitogorsk Steel Company, San Lipei Tsk Steel Corporation, and North Steel Corporation, have integrated monolithic refractories into their operations. Despite the lack of standardized classification for new refractory castables in Russia and international standards, it is advisable to follow the U.S. and European approaches, which classify materials based on CaO content. This classification reflects the growing application of these advanced castables, driven by their superior properties—such as enhanced resistance to erosion and deformation, higher strength at both low and high temperatures, and reduced porosity compared to traditional castables.
Another advantage of low-cement castables is their fine pore structure, which minimizes micro-crack formation during thermal cycling, improving thermal shock resistance. These materials have also replaced traditional coal-tar and resin-based binders in taphole linings of large and medium blast furnaces, significantly extending service life—up to 100,000 tons of iron without intermediate repairs, and even more with proper maintenance. However, the use of organic binders can raise environmental concerns.
The rapid construction and easy repair of iron channels using these materials have attracted considerable interest. Companies like Basalt-Feuerfest GmbH (Germany), Veitseher (Austria), Kurosaki, Shinagawa (Japan), and others are well-known for supplying such products. The main components include flake alumina from ALCOA and brown flake alumina from ACC, offering excellent performance in blast furnace applications. As these materials become more common, the casting and maintenance processes for blast furnace linings must evolve accordingly.
In blast furnace linings, low-cement castables serve as auxiliary materials, often used in spray coatings for quick repairs and extended service life. Their application in iron ladles and torpedo-type transport vessels has also increased, reducing refractory and labor consumption. The installation process involves pouring the bucket bottom, reserving grooves for injection and tapping devices, installing formwork, and vibrating the castable with an internal electric vibrator. After demolding, the lining is dried for 36–48 hours and then fired at 1100–1200°C.
Special attention is given to moisture control during the process, requiring precise equipment and monitoring systems. Low-cement castables are widely used in various parts of electric furnaces, including the top, door, steel trough, and water-cooled sections. They are also used in ordinary roofs, feed doors, and tapping troughs, proving their reliability in steelmaking operations. Similar applications extend to ladle furnaces and furnace lids.
Burner bricks for furnaces and coke ovens, made with low-cement castables, exhibit improved thermal shock resistance, lower porosity, and better gas erosion resistance. These products are now produced in refractory plants or metallurgical facilities using vibratory or self-diffusing castables. With the rise of low-cement castables, new innovations in spraying techniques have also emerged, further expanding their applications.
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