Intelligent refractory materials represent a new generation of high-temperature functional materials that significantly enhance the service performance of traditional refractories in extreme environments through integ...Intelligent refractory materials represent a new generation of high-temperature functional materials that significantly enhance the service performance of traditional refractories in extreme environments through integrated sensing,response,and adaptive mechanisms.A comprehensive overview of intelligent refractory materials was provided,focusing on their classification,preparation techniques,and industrial applications.Firstly,the categories and design principles of intelligent refractory materials are introduced,including self-healing,self-regulating,and self-diagnosing types,which enhance durability and performance under extreme conditions.Subsequently,advanced preparation technologies are discussed,such as 3D printing for complex geometries,nanocomposite engineering for improved mechanical and thermal properties,gradient design for optimized thermal stress resistance and information technology including machine learning,health monitoring,digital twin.Finally,the industrial applications of these materials are highlighted,particularly in steel metallurgy,building materials industry,and energy.It aims to bridge the gap between research advancements and practical implementation,offering insights into future trends in intelligent refractory material development.展开更多
The Si_(3)N_(4)-bonded silicon carbide(SiC)bricks in the sloped zone of dry quenching coke ovens support the weight of upper refractory materials and equipment.These bricks endure frequent temperature fluctuations and...The Si_(3)N_(4)-bonded silicon carbide(SiC)bricks in the sloped zone of dry quenching coke ovens support the weight of upper refractory materials and equipment.These bricks endure frequent temperature fluctuations and intense abrasion from coke dust,demanding extremely high performance.After three years of service,an analysis of the Si_(3)N_(4)-bonded SiC bricks revealed that oxidation,which reduces thermal shock resistance,is the primary cause of degradation.In the unused Si_(3)N_(4)-bonded SiC bricks,short columnar β-Si_(3)N_(4) forms an interwoven network around SiC particles and contains a small amount of plate-like Si_(2)N_(2)O.Under the complex N_(2)(84.42 vol.%)-CO_(2)(10.44 vol.%)-CO(4.43 vol.%)-H_(2)(0.56 vol.%)-O_(2)(0.15 vol.%)atmosphere in the dry quenching coke oven,O_(2)(0.15 vol.%)exhibits a stronger oxidizing effect than CO_(2)(10.44 vol.%)and CO(4.43 vol.%),making it the primary oxidizing agent.The short columnarβ-Si_(3)N_(4) is more susceptible to oxidation than the particulate SiC.Based on thermodynamic and kinetic analyses,the chemical stability of the phases in Si_(3)N_(4)-bonded SiC bricks ranks from strongest to weakest as follows:Si_(2)N_(2)O,SiC,Si_(3)N_(4).Future development of Si_(2)N_(2)O-bonded SiC bricks could improve the longevity of refractory materials in the sloped zone of dry quenching coke ovens.展开更多
High-quality steel production requires superior-performance refractories.To meet the requirements of quality enhancement and efficiency improvement in the steelmaking industry,the application of the novel microporous ...High-quality steel production requires superior-performance refractories.To meet the requirements of quality enhancement and efficiency improvement in the steelmaking industry,the application of the novel microporous magnesia with high strength,remarkable slag resistance,and excellent thermal insulation is promoted.The interface reaction between H13 steel and novel microporous magnesia castable was investigated by using the crucible method,to elucidate the molten steel purification mechanism.The interface microstructure was observed by scanning electron microscopy,and the composition,size,and amount of inclusions were statistically analyzed.A thermal calculation was conducted to gain a deeper understanding of the modification process of inclusions.Fused magnesia castables were used as the blank control.The results show that the average number density and size of inclusions were reduced by 5.99 mm^(−2) and 0.28μm respectively after the same reaction time because the micropores enhanced the inclusion adsorption.The size of inclusions caused by erosion decreased.Also,more[Mg]dissolved into molten steel over 60 min reaction time and resulted in a 0.49 wt.%increase in inclusion Mg content,which modified the inclusion by decreasing their melting point.Therefore,applying novel microporous magnesia was beneficial for purifying H13 steel.展开更多
The accelerated shift toward high efficiency and sustainability of the iron and steel is driving the advancement of green,low-carbon and high-quality carbon-containing refractories used for ladles.It is undoubtedly a ...The accelerated shift toward high efficiency and sustainability of the iron and steel is driving the advancement of green,low-carbon and high-quality carbon-containing refractories used for ladles.It is undoubtedly a significant challenge,since the addition of graphite enables refractories to possess superior thermal shock resistance and slag corrosion resistance.To develop low carbon-containing refractories with excellent properties,researchers over the past decades have endeavored to seek additives which can mitigate the adverse effects associated with the decrease in carbon in refractories.These additives can promote the occurrence of various mechanisms about toughening,which depends on inherent properties of additives or reacting with refractories to in situ form different ceramic phases,thereby responding the challenge of low-carbonization in refractories.The latest advances in additives used for low carbon-containing refractories from metal/alloys,oxide,non-oxide and composite powders four aspects were comprehensively overviewed in this review.Oxide additives exhibit a moderate effect on improving thermal shock resistance of refractories but show limited efficacy in improving oxidation resistance.In contrast,non-oxide additives demonstrate remarkable advantages in enhancing both oxidation and slag corrosion resistance.Composite powders combine the advantageous properties of their individual components.These additives often require combination with antioxidants such as Al,Si,or B4C not only to reduce costs but also to achieve optimal properties.Furthermore,future perspectives of these additives are discussed,with the aim of providing useful insights for the continuous progress and practical application of low carbon-containing refractories.展开更多
To resolve severe slag penetration and erosion in Al_(2)O_(3)-SiC-C refractories during high scrap ratio iron ladle operation,a novel strategy utilizing exogenous MgAl_(2)O_(4) spinel as a sacrificial FeO_(x) scavenge...To resolve severe slag penetration and erosion in Al_(2)O_(3)-SiC-C refractories during high scrap ratio iron ladle operation,a novel strategy utilizing exogenous MgAl_(2)O_(4) spinel as a sacrificial FeO_(x) scavenger was proposed.Al_(2)O_(3)-SiC-C refractories produced with plate-like corundum,silicon carbide,and flake graphite incorporating MgAl_(2)O_(4) additives were cured at 1400℃ in the condition of carbon embedding.The impacts of additives on phase composition,microscopic morphology,and performance of materials were studied.The results indicated that Al_(2)O_(3)-SiC-C refractories with the addition of 2 wt.%MgAl_(2)O_(4) exhibited a smaller oxidation area after oxidation tests compared to samples without MgAl_(2)O_(4),resulting in 28%improvement in oxidation resistance compared to blank samples.In the erosion test,the results informed that adding 4 wt.%MgAl_(2)O_(4) induced significant interfacial slag modification:MgAl_(2)O_(4) dynamically dissolved FeO_(x) to form protective Mg(Fe,Al)_(2)O_(4) solid solution on the slag-refractory interface.This sacrificial dissolution effectively immobilized FeO_(x),elevated local slag viscosity,and fundamentally inhibited slag penetration and matrix dissolution.The erosion index decreased from 50%in the blank group to 27.4%.展开更多
基金supported by the Natural Science Foundation of Shaanxi Province(No.2023-JC-QN-0615)the National Natural Science Foundation of China(Nos.52272027 and 52372034).
文摘Intelligent refractory materials represent a new generation of high-temperature functional materials that significantly enhance the service performance of traditional refractories in extreme environments through integrated sensing,response,and adaptive mechanisms.A comprehensive overview of intelligent refractory materials was provided,focusing on their classification,preparation techniques,and industrial applications.Firstly,the categories and design principles of intelligent refractory materials are introduced,including self-healing,self-regulating,and self-diagnosing types,which enhance durability and performance under extreme conditions.Subsequently,advanced preparation technologies are discussed,such as 3D printing for complex geometries,nanocomposite engineering for improved mechanical and thermal properties,gradient design for optimized thermal stress resistance and information technology including machine learning,health monitoring,digital twin.Finally,the industrial applications of these materials are highlighted,particularly in steel metallurgy,building materials industry,and energy.It aims to bridge the gap between research advancements and practical implementation,offering insights into future trends in intelligent refractory material development.
基金support from the National Natural Science Foundation of China(52172023 and 52302027).
文摘The Si_(3)N_(4)-bonded silicon carbide(SiC)bricks in the sloped zone of dry quenching coke ovens support the weight of upper refractory materials and equipment.These bricks endure frequent temperature fluctuations and intense abrasion from coke dust,demanding extremely high performance.After three years of service,an analysis of the Si_(3)N_(4)-bonded SiC bricks revealed that oxidation,which reduces thermal shock resistance,is the primary cause of degradation.In the unused Si_(3)N_(4)-bonded SiC bricks,short columnar β-Si_(3)N_(4) forms an interwoven network around SiC particles and contains a small amount of plate-like Si_(2)N_(2)O.Under the complex N_(2)(84.42 vol.%)-CO_(2)(10.44 vol.%)-CO(4.43 vol.%)-H_(2)(0.56 vol.%)-O_(2)(0.15 vol.%)atmosphere in the dry quenching coke oven,O_(2)(0.15 vol.%)exhibits a stronger oxidizing effect than CO_(2)(10.44 vol.%)and CO(4.43 vol.%),making it the primary oxidizing agent.The short columnarβ-Si_(3)N_(4) is more susceptible to oxidation than the particulate SiC.Based on thermodynamic and kinetic analyses,the chemical stability of the phases in Si_(3)N_(4)-bonded SiC bricks ranks from strongest to weakest as follows:Si_(2)N_(2)O,SiC,Si_(3)N_(4).Future development of Si_(2)N_(2)O-bonded SiC bricks could improve the longevity of refractory materials in the sloped zone of dry quenching coke ovens.
基金support of this study by the National Natural Science Foundation of China(Grant Nos.U22A20173 and U21A2058).
文摘High-quality steel production requires superior-performance refractories.To meet the requirements of quality enhancement and efficiency improvement in the steelmaking industry,the application of the novel microporous magnesia with high strength,remarkable slag resistance,and excellent thermal insulation is promoted.The interface reaction between H13 steel and novel microporous magnesia castable was investigated by using the crucible method,to elucidate the molten steel purification mechanism.The interface microstructure was observed by scanning electron microscopy,and the composition,size,and amount of inclusions were statistically analyzed.A thermal calculation was conducted to gain a deeper understanding of the modification process of inclusions.Fused magnesia castables were used as the blank control.The results show that the average number density and size of inclusions were reduced by 5.99 mm^(−2) and 0.28μm respectively after the same reaction time because the micropores enhanced the inclusion adsorption.The size of inclusions caused by erosion decreased.Also,more[Mg]dissolved into molten steel over 60 min reaction time and resulted in a 0.49 wt.%increase in inclusion Mg content,which modified the inclusion by decreasing their melting point.Therefore,applying novel microporous magnesia was beneficial for purifying H13 steel.
基金support of the National Natural Science Foundation of China(Grant/Project Nos.52272027,52372034 and 52502016)the China Postdoctoral Science Foundation(Grant No.2025T180025)Postdoctoral Fellowship Program(Grant No.GZC20252393).
文摘The accelerated shift toward high efficiency and sustainability of the iron and steel is driving the advancement of green,low-carbon and high-quality carbon-containing refractories used for ladles.It is undoubtedly a significant challenge,since the addition of graphite enables refractories to possess superior thermal shock resistance and slag corrosion resistance.To develop low carbon-containing refractories with excellent properties,researchers over the past decades have endeavored to seek additives which can mitigate the adverse effects associated with the decrease in carbon in refractories.These additives can promote the occurrence of various mechanisms about toughening,which depends on inherent properties of additives or reacting with refractories to in situ form different ceramic phases,thereby responding the challenge of low-carbonization in refractories.The latest advances in additives used for low carbon-containing refractories from metal/alloys,oxide,non-oxide and composite powders four aspects were comprehensively overviewed in this review.Oxide additives exhibit a moderate effect on improving thermal shock resistance of refractories but show limited efficacy in improving oxidation resistance.In contrast,non-oxide additives demonstrate remarkable advantages in enhancing both oxidation and slag corrosion resistance.Composite powders combine the advantageous properties of their individual components.These additives often require combination with antioxidants such as Al,Si,or B4C not only to reduce costs but also to achieve optimal properties.Furthermore,future perspectives of these additives are discussed,with the aim of providing useful insights for the continuous progress and practical application of low carbon-containing refractories.
基金support from the project supported by the National Natural Science Foundation of China(Grant No.52402034)the Science and Technology Innovation Team Foundation of Hubei Province(Grant No.T2023001)+1 种基金the Natural Science Foundation of Hubei Province(Grant No.2023BAB106)the Natural Science Foundation of Wuhan(Grant No.2024040701010051).
文摘To resolve severe slag penetration and erosion in Al_(2)O_(3)-SiC-C refractories during high scrap ratio iron ladle operation,a novel strategy utilizing exogenous MgAl_(2)O_(4) spinel as a sacrificial FeO_(x) scavenger was proposed.Al_(2)O_(3)-SiC-C refractories produced with plate-like corundum,silicon carbide,and flake graphite incorporating MgAl_(2)O_(4) additives were cured at 1400℃ in the condition of carbon embedding.The impacts of additives on phase composition,microscopic morphology,and performance of materials were studied.The results indicated that Al_(2)O_(3)-SiC-C refractories with the addition of 2 wt.%MgAl_(2)O_(4) exhibited a smaller oxidation area after oxidation tests compared to samples without MgAl_(2)O_(4),resulting in 28%improvement in oxidation resistance compared to blank samples.In the erosion test,the results informed that adding 4 wt.%MgAl_(2)O_(4) induced significant interfacial slag modification:MgAl_(2)O_(4) dynamically dissolved FeO_(x) to form protective Mg(Fe,Al)_(2)O_(4) solid solution on the slag-refractory interface.This sacrificial dissolution effectively immobilized FeO_(x),elevated local slag viscosity,and fundamentally inhibited slag penetration and matrix dissolution.The erosion index decreased from 50%in the blank group to 27.4%.
