Use of dilatometer to screen refractory raw materials

Sudden shortage of a particular raw material due to freight disruptions, competitive market, and COVID restrictions have frequently forced the refractory industry to rapidly develop alternative formulations using available low‐cost materials. These alternative ingredients might cursorily appear to have similar total impurity content, but the presence of certain impurity combinations depending on the refractory type can produce more fluid liquid phase at high temperature, thereby drastically reducing hot strength. Undetected by the commonly used X‐ray fluorescence (XRF) analysis, the low‐cost material might differ in mineral‐phase content, whose phase transformations during firing might create excessive expansion producing warpage of the refractory along with a high porosity reducing strength and corrosion resistance. Finally, those cheap raw materials might have similar sieve analysis to that of the standard ingredient but might have much lower tapped density, which would introduce detrimental porosity into the resulting refractory. Hence, time‐consuming trials are often performed. Dilatometer studies on pressed or cast samples in a single test can identify reaction temperatures of spinel or mullite formation, which expand during firing, along with the amount of expansion and exact times at which firing needs to be done. It can also compare relative shrinkage due to liquid‐phase formation among impure raw materials like recycled grogs or low‐grade ores. Finally, dilatometric step scan is shown as a fast technique to prepare in‐house, low‐cost reactive spinel powder, which can also work for mullite.