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Development of process of Castable Refractories - A key input for Steel Plants

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A class of unshaped and unfired refractories called “Castable” emerged and replaced the conventional fired bricks in many applications. Castable refractories are granular materials of desired composition which are to be mixed with water and applied. Materials used for preparation of castable may vary significantly from those used for equivalent shaped products and the method of preparation is also different. It does not need forming and firing. To fulfil the stringent requirement of process variation and operation parameters in Iron and Steel making a whole range of new generation castable refractories, i.e., conventional high cement and low cement castable have been developed at Champion Ceramics, Chapa to offer ways and means to reduce costs and meet the quality requirement. In recent advancement of castable refractory technology, new types of low and ultra-low cement castable having self-flow properties and spinel castable for specific application have also been developed at Champion Ceramics to meet the challenges. This paper deals with describing the physics and chemistry of castable and different raw materials used for making good quality castable. The development process of critical properties in low cement and ultralow cement castable as well as self-flow castable have been highlighted for proper application in steel plants.

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