PROSPECTS FOR USING COMBINED METALLURGICAL
PRODUCTION TECHNOGENIC RAW MATERIAL
IN THE REFRACTORY INDUSTRY
V. V. Sharapova
Translated from Novye Ogneupory, No. 5, pp. 9 – 15, May, 2013.
Original article submitted February 25, 2013.
Features are provided for the chemical and mineral composition of standard electrocorundum sludge and
transformation of its components during oxidation firing, and also analysis of chamotte based on combined
technogenic raw material and kaolin. Properties are indicated for the mullite and glass phase formed, and
mullite refractoriness based on different components. An indispensable condition for obtaining high quality
chamotte and mullite in poured layers is oxidation of the lower titanium compounds contained in sludge. The
temperature for liquid phase appearance is 830 – 1130°C. Mineralizer admixtures reduce aluminosilicate melt
Keywords: technogenic raw material, standard electrocorundum sludge (SES), mullite, chamotte, refrac-
tories, nonstoichiometric composition, degree of mullitization, mineral admixture, viscosity, lower compounds.
In view of the shortage of some forms of raw material,
used in manufacture of aluminosilicate refractories, in order
to save and reduce the cost of finished objects, and also tak-
ing account of a comprehensive approach to resolving the
problem of using industrial wastes and environmental pro
tection, it is interesting to study the possibility of using
technogenic sources of mineral resources [1 – 4]. Develop
ment of fundamentally new and improvement of existing
production schemes for aluminosilicate refractories based on
synthesizing mullite with use of standard electrocorundum
sludge (SES) [2, 3] requires profound study of features of
chemical and mineral composition of both starting materials
and their transformation products during firing.
Results are provided in this work for petrographic studies
of mineral and phase composition of SES, features of the
microstructure and phase composition of finished objects
MKRA, MKS-72, MLS-62 obtained using SES. Studies
were carried out using contemporary methods of technical
petrography in microscopes in reflected and transmitted light
with a standard selection of immersion liquids IZh-98 with
400 – 1450-fold magnification. High-temperature petrogra
phy was used with application of an MNO-2 microscope. In
addition, diagnostic etching in fluoric and hydrochloric acids
was used, and mullite refractoriness was determined accord-
ing to GOST 4070–2000 (ISO 1893–89).
It is well known that the chemical and phase composition
of aluminosilicate objects is determined by raw material
composition and properties. Refractoriness and temperature
for the start of softening of aluminosilicate objects depends
not only on the amount of Al
within them, but also on the
total sum of melts and often on their chemical nature .
With respect to physicochemical properties SES formed in
OAO Zaporozhabraziv in an amount of 250 – 300 tons is a
valuable complex technogenic deposit and is in open storage.
According to TU U 268-0022222-056:2006 within SES there
is not less than 86% Al
, 3.82% TiO
, 2.51% Fe
. A distinguishing feature of the raw material is
presence of mineralizer impurities, i.e., iron and titanium
compounds in an amount not exceeding their content in natu
ral raw material, and crude alumina. As microscope studies
show, the mineralizer impurities are both in the form of indi
vidual sludge components, and they also form inclusions,
coarse dispersions, and solid solutions in corundum. Sludge
is gray in color with violet shades, and consists mainly of
fine particles with a size less than 50 mm. However, lumps of
Refractories and Industrial Ceramics Vol. 54, No. 3, September, 2013
1083-4877/13/05403-0160 © 2013 Springer Science+Business Media New York
Zaporozh’e National Technical University, Zaporozh’e, Ukraine.