Drying behavior of dense refractory castables. Part 2 Drying agents and design of heating schedules

TL;DR

This paper reviews the drying process of dense refractory castables, focusing on drying agents and heating schedule design to prevent damage during initial heating, and discusses recent advances and future research opportunities.

Contribution

It highlights the effects of various drying agents and procedures on microstructure and introduces new experimental and modeling tools for optimizing drying strategies.

Findings

Drying agents influence castable microstructure and permeability.

Heating rate and procedure significantly affect drying behavior.

In-situ techniques and models can improve drying process predictions.

Abstract

Drying is the most critical process of the first heating cycle of monolithic dense refractories, as the reduced permeability of the resulting microstructure may lead to explosive spalling and mechanical damage associated with dewatering. The first part of this review series pointed out the various drying stages, the role of the binder components and the techniques that can be used to follow the water release in as-cast refractory materials, when they are exposed to heat. Although defining a suitable heating schedule is a great challenge, some tools can be applied to minimize the spalling risks associated with steam pressurization. In this context, this second review article points out (i) the main drying agents and how they affect the resulting castables' microstructure (organic fibers, metallic powders, permeability enhancing active compounds, silica-based additives and chelating agents), and (ii) the effects related to the procedures commonly applied during the designing of heating routine (i.e., the role of the heating rate, ramp versus holding time), as well as the influence of the castable's dimension on the overall drying behavior. Considering the recent advances regarding the design of refractory formulations and their processing, one may expect that incorporating suitable drying additives into the prepared composition should lead to a suitable and safer water release in such dense consolidated structures. Besides that, novel engineering opportunities, such as the use of in-situ based experimental techniques (i.e., neutron and X-ray tomography) to obtain more accurate data and the development of numerical models, might help in simulating and predicting the steam pressure developed in refractory systems during their first heating.