REFRACTORY COATINGS BASED ON NONFERROUS
METALLURGY WASTE PRODUCTS
D. Yu. Denisov
and V. Z. Abdrakhimov
Translated from Novye Ogneupory, No. 11, pp. 33 – 37, November 2011.
Original article submitted September 17, 2011.
Use of salt waste products from secondary processing of aluminum-containing slags and scrap calcined at
950°C are used to prepare a refractory coating (unmolded refractory). This expands considerably the raw ma
terial base for refractory material production, and makes it possible to utilize industrial waste products.
Keywords: refractory coating, salt waste products from secondary processing of aluminum-containing slags,
kaolin clay, element-by-element chemical analysis, metallographic analysis, ceramic rollers, engobe.
Use of waste products for manufacture of ceramic mate-
rials is currently of particular importance . Due to the high
degree of wear for heating units, and also a lack of high qual-
ity local refractory materials there has been a sharp increase
in demand by domestic industrial enterprises since they can-
not provide output of competitive products.
In order to increase furnace life it is necessary to apply
refractory coatings to ceramic rollers . Currently in order
to prepare them various high-alumina and magnesite are
used, whose components are expensive and do not always
guarantee prolonged operation of transporting refractory ma
terial. The authors of this article have developed a refractory
coating composition, i.e., an engobe based on salt waste
products from secondary reprocessing of aluminum-contain
ing slag and scrap fired at 950°C, and also technology for
coating application on previously dried plate and transport
ing rollers, followed by their operation in a firing zone at
1200 – 1300°C. Aluminum salt slags are waste products of
aluminum production [3, 4]. According to the index for acute
toxicity in an experiment on warm-blooded animals (mice)
and two forms of aquatic life (Ostrocoda Daphnia magna
Straus and Protococcacae Scenedesmus guadricauda) salt
waste products relate to hazard class III with respect to the
degree of action on an organism, and to hazard class IV for
the environment. Aluminum salt slags have the following
chemical composition, wt.%: NaCl 10.25, (CaO + CaCO
14.28, (MgO + MgCO
) 15.30, FeCl
41.282; KCl 5.35, CuCl
0.001, alkylmercaptites Al
0.545, saturated hydrocarbons 0.001, aluminum (metal) 9.89.
Refractories and Industrial Ceramics Vol. 52, No. 6, March, 2012
1083-4877/12/05206-0398 © 2012 Springer Science+Business Media, Inc.
Samara Academy of State and Municipal Management, Samara,
Fig. 1. Results of element-by-element chemical analysis: a) unfired
aluminum salt slag; b ) fired aluminum salt slag; c) Chapaev clay.