Any proportion of mixture such as fireclay-silica-ganister mixture or fireclay mixed with crushed brick or fireclay–silica sand is known as refractory cement.[2]

In Refractory cement, a bulk refractory grain mass is initially bonded with a fired bond, which is fired with reaction component Si3N4 and/or Si2ON2 which protects the ultimate high temperature sintered cement from the effect of erosion at the time of using the cement as a liner for furnace walls, troughs.

Standard

ASTM E136-79 flammability test.

Materials Consisting of Refractory Cement [3][6]

  • Calcareous Materials.
  • Aluminous Materials (mainly Al2O3).
  • Magnesium Chloride/Calcium Chloride/Barium Chloride/Sodium Chloride.
  • A mixture of binder or clinker and coarse aggregate: Clinker is a fused mineral or mineral mixture used as alumina-lime (bauxite-lime), crushed into a fine powder. It obtained from aluminous materials. Coarse aggregates are like granular materials which impart some special properties, for example, refractoriness and erosion or oxidation resistance. 
  • Alumina ceramics, fire clay, bricks, precast shapes, aluminate cement and monolithic. 
  • Asbestos.  
  • Burned spinel. 
  • Magnesia.  
  • Reactive magnesia. 
  • Organic acid.

To produce cement from those components mixture, calcination is done at a temperature within the range of from 1,500 to 1,550 C. [7]

Applications of Refractory Cement [8][10]

Refractory cement is mixed with refractory aggregates such as:

  • Bauxite.
  • Tabular alumina.
  • White Fused Alumina. 
  • Brown Fused Alumina.  
  • Andalusite. 
  • Sillimanite. 
  • Chamotte. 
  • Alag. 
  • Perlite. 
  • Vermiculite. 
  • Bubble alumina.

Refractory cement can be used in various places. Example:

  • Fireplaces and Wood burning stoves where the temperature is very high refractory cement can be used.
  • Refractory cement is a good material to patch Furnaces and Incinerators.  
  • At the time of Setting and bonding firebrick in firebox chambers, it can play a good character. 
  • Electrical or thermal insulation. For providing thermal insulation from any type of heat it can do a better role.  
  • To seal air and gas leaking refractory cement act good.

Installation technique of Refractory Cement [4][5]

  1. Vibration Casting
  2. Pump Casting. 
  3. Dry Gunning. 
  4. Wet Gunning or Shotcrete. 
  5. Self-flow Casting.

Exception From normal Formula[1]

Refractory properties of a cement can be imparted to it from non-refractory CaSO4. This can be done by incorporation of a primary fluxing component. This exception can be used as a Structural board, for forming a refractory mass and as oil well casing cement.

References

  1. Burr, H. Refractory cement incorporating fluxing component. U.S. Patent 3841886A filed December 15, 1972, and issued October 15, 1974.
  2. Jones, C. M., Washburn, M. E., Trostel, L. J., Jr. Refractory cement. U.S. Patent 4476234A filed August 12, 1983, and issued October 9, 1984.
  3. Burrows, O. Refractory cement lining for coreless induction furnaces. U.S. Patent 3751571A filed March 29, 1972, and issued August 7, 1973.
  4. MonolithicRefractory.pdf [Link - https://www.scribd.com/document/355595828/MonolithicRefractory-pdf]
  5. Refractory-Installation-and-Maintenance-F.S.-Sperry
  6. Mathieu, A. High alumina refractory cement and a process for producing the same. U.S. Patent 4217144A filed August 4, 1978, and issued August 12, 1980.
  7. Nudelman, B. I., Bikbau, M. Y., Oborin, P. A., Kuznetsova, T. V. Raw mixture for the production of refractory high-alumina cement. U.S. Patent 4204878A filed November 7, 1978, and issued May 27, 1980.
  8. Refractory Cement - high alumina cement - complete refractory solution - SECAR®, solutions for refractories
  9. Refractory Cement | Asbestos Product and Mesothelioma Hazard
  10. Refractory Cement and Raw Materials Information | Engineering360
 

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