Mechanical properties of chemically bonded phosphate refractory castables

The knowledge of the phase transformations and the role of different parameters in the performance of phosphate-bonded systems are of utmost importance for the refractory field. The effect of the setting agent, phosphoric acid concentration and additives on the setting time, cold crush strength, hot modulus of rupture, abrasion resistance, and thermal shock resistance of the phosphate chemically bonded refractory systems was evaluated. The setting time was shorter for mixtures containing cement (CaO) and a lower acid concentration. Mixtures with a higher acid concentration presented better mechanical, abrasion and thermal shock resistance. In spite of increasing the cold mechanical resistance and abrasion of the materials, the Budit 6H negatively impacted the hot properties. For Fabutit761, there was no liquid phase formation at intermediate temperatures and this additive increased the cold mechanical strength, but it also negatively impacted the hot mechanical strength. Compositions containing cement as a setting agent, 40°Be phosphoric acid and Fabutit761 additive as an extra source of phosphate presented a better set of properties. (author)