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Effect of Reactive Alumina on the Physico-Mechanical Properties of Refractory Castable

The effect of reactive alumina and its different proportions on physico-mechanical properties of conventional high alumina castables were studied. The castables with different percentages of reactive alumina were prepared by using calcium aluminate cement as a binder and various refractory properties of the prepared castables, i.e. apparent porosity, bulk density, cold crushing strength, hot modulus of rupture were studied. The mineralogical analysis was done by X-ray diffractometry, whereas morphological analysis was carried out by scanning electron microscopy. The results showed that the castable with high percentage of reactive alumina hydrated early as well as developed early sintered strength due to its faster rate of hydration and higher reactivity at lower temperature. The hot modulus of rupture was also found to be higher in the castable with more reactive alumina. Mineralogical analysis showed well developed mullite and corundum phases in the refractory concrete which was supported by morphological analysis.