DEVELOPMENT OF NEW REFRACTORY MATERIALS
BY SHS-TECHNOLOGY BASED ON KAZAKHSTAN REPUBLIC
RAW MATERIAL RESOURCES
A. A. Zharmenov, B. N. Satbaev,
S. Sh. Kazhikenova,
and O. A. Nurkenov
Translated from Novye Ogneupory, No. 6, pp. 47 – 54, June, 2012.
Original article submitted January 11, 2012.
Studies are performed with the aim of developing scientific bases and creation of preparation methods based
on local raw material resources for a new generation of SHS-refractory materials with high operating proper
ties, making it possible to increase service life (resistance) of metallurgical heating unit linings, and also to im
prove the quality of metal obtained. A novelty of this research consists of development of scientifically based
approaches for resolving this problem, which make it possible to reveal features of unmolded and molded re
fractory formation, required for effective control of complex physicochemical and production processes for
preparing new grades of refractories.
Keywords: refractories, SHS-technology, self-sintering composition, self-sintering refractory mix, spinelids,
thermal shock resistance, chromite ore, chamotte, exothermic reaction.
Stimulation of production processes and provision of in-
novative ways of developing metallurgical, chemical, oil
processing industry, power generation, cement, and other
products is unthinkable without creating new materials with
improved operating properties, for example refractory ob-
jects for lining high-temperature units. A severe shortage of
refractories in internal and external markets, and the steady
growth in their requirement in metallurgical and cement in
dustries, give rise to increasing interest for preparing
high-quality refractory objects with prescribed properties. In
this connection development and introduction of resource
and energy saving, and ecologically clean technology, pro
viding improvement in refractory material production based
on raw material resources of Kazakhstan is important.
One of the leading research areas in the field of creating
new refractories for metallurgical units is preparation of
highly resistant materials related to multicomponent chro
mium-containing oxide systems. The high refractoriness and
chemical inertness of chromium oxide has served as a basis
for creating sintered chromium oxide refractories containing
up to 95% Cr
and having extremely high corrosion resis-
tance; with respect to the same index chromium oxide
refractories markedly surpass all known refractory materials
used in practice.
We have proposed prescriptions for refractory composi-
tions [1 – 16] for preparation of refractory materials by
SHS-technology based on aluminum and chromium oxides.
An advantage of the compositions developed is use of pro
duction waste, for example those of no ecological impor
tance, such as dump slag from copper production, and cheap
local natural raw material that considerably cheapen prepara
tion of refractory object with good operating properties.
Composition 1 for preparation of refractory objects in
cludes aluminum-chromium phosphate binder, sulfide-yeast
mash, and magnesite chromite material. In order to prepare a
self-sintering composition the existence of exothermic reac
tions is necessary:
+ 2Al ® Al
+ 2Cr, (1)
Active aluminum oxide reacts with calcium oxide of
ferrochromium slag with formation of aluminum-calcium
Refractories and Industrial Ceramics Vol. 53, No. 3, September, 2012
1083-4877/12/05303-0199 © 2012 Springer Science+Business Media New York
RGP National Center for Complex Processing of Kazakhstan Re
public Mineral Raw Material, Almaty, Kazakhstan.
E. A. Buketov Karaganda State University, Karaganda, Kazakh
Institute of Organic Synthesis and Carbon Chemistry, Karaganda,