Effect of Carbon Black Content and Firing Atmosphere on the Properties and Microstructure of Al2O3-SiC-C Castables

Abstract

Al2O3-SiC-C (ASC) castables containing spherical asphalt are widely utilized in high-temperature metallurgical furnaces because of their good abrasive resistance and slag resistance; however, the release of hazardous benzopyrene during the pyrosis process in spherical asphalt is detrimental to the environment and to the health of furnace workers. Herein, nontoxic nano carbon black (CB) was selected as the carbon source for ASC castables, and the effects of the CB amount and sintering atmosphere on the properties of ASC castables were investigated in this work. The results show that on increasing CB from 0.5% to 2%, the cold strength of the samples after firing in the reducing atmosphere increased, the residual strength increased, and the slag penetrated depth decreased; the reasons can be ascribed to nano CB being able to fill the pores to reduce the apparent porosity of the castables. Furthermore, SiC whiskers were formed at elevated temperatures and generated a network structure, which was beneficial in improving their properties. When CB was 1%, the cold modulus of the rupture of the samples after firing in the oxidizing atmosphere and reducing atmosphere were higher (about 20 MPa), the retained strength ratio of the samples pre-fired in the reducing atmosphere was the highest (85.4%), the hot strength at 1400 °C of the samples tested in the oxidized atmosphere was the highest (5.3 MPa), and the slag resistance of the samples measured in the oxidizing atmosphere was the best. The castables heat-treated in the air atmosphere possessed higher hot strength and slag resistance; the reasons can be attributed to the formed SiO2 derived from the oxidation of SiC, which reacted with Al2O3 to form mullite, creating a strengthening effect and decreasing the porosity and increasing the viscosity of slag, thereby improving the hot strength and slag resistance.