Abstract

Particle interlocking plays the most important role in the formation of physical and mechanical properties and is dependent on optimized particle distribution in size and shape composing in the refractory monolithic formulation. The aim of the project is to define a procedure that allows individual adjustments for the grain size distribution with special consideration to the aspect ratio of the grain size, that are analysed with computerized particle analysis (CPA). In this early project stage, sinter and fused corundum and sintered and fused mullite were adjusted to the best possible packing and interlocking of particles. The optimization process was investigated by means of working properties e.g. mixing properties by measuring the energy input, water demand, rheology, densification, drying shrinkage and green strength. The detailed and quantified results of this optimization process provided a much deeper understanding of how the particle size, shape and surface roughness influence the working properties of refractory monolithics and therefore provide comprehensive information about improved particle size distribution. The systematically correlation of the particles’ nature with the optimized grain size distributions result in optimized workability to obtain refractory monolithics with the best possible physical and mechanical properties. Furthermore, the results of this project will enable flexible reaction of refractory producers to changes in particle shape of raw materials, which already ran through a process (recyclate).