Kurzfassung

In an industrial context marked by the Clean Industrial Deal, process industries (such as steel, cement,
etc.) express an increased need for resilient refractory materials in extreme conditions to line their
high temperature furnaces/reactors. This demand becomes more relevant with the anticipated rise in
the use of hydrogen. Hence, extending the lifespan of refractory materials and their tolerance to
changes in high-temperature manufacturing processes becomes imperative to enhance the energy
...In an industrial context marked by the Clean Industrial Deal, process industries (such as steel, cement,
etc.) express an increased need for resilient refractory materials in extreme conditions to line their
high temperature furnaces/reactors. This demand becomes more relevant with the anticipated rise in
the use of hydrogen. Hence, extending the lifespan of refractory materials and their tolerance to
changes in high-temperature manufacturing processes becomes imperative to enhance the energy
efficiency of the process industry and to reduce the use of raw materials, e.g. by decreasing the fre-
quency of lining replacements. Simultaneously, reducing the carbon footprint and promoting circular-
ity of these materials is a challenge in response to the Clean Industrial Deal.
To anticipate changes in process industries and address these challenges, refractory manufacturing
companies, especially SMEs, are compelled to develop innovative materials. The exploration of refrac-
tory castables bonded with innovative alternative binders, such as colloidal spinel, promises to over-
come the limitations of currently used calcium aluminate cement (CAC) and colloidal silica (CS) bind-
ers. These innovative refractory castables have potential applications in extreme conditions, including
hydrogen-rich environments, while exhibiting a lower carbon footprint and a more pronounced circu-
lar character (because of the absence of cement) than their CAC-bonded counterparts.
For these innovative solutions to be adopted by SMEs in the sector and end-users, a holistic research
methodology is necessary, as envisaged in this CORNET project. The study will focus on optimising the
process of elaborating the spinel colloidal suspension (binder) and analysing its consolidation/gelation
mechanism to demonstrate the feasibility of large-scale production. It will also address aspects related
to optimising the properties of castables in terms of setting and mechanical characteristics in the green
state, while evaluating their behaviour during drying, compared to CAC and CS-bonded castables. The
goal is to meet the current industrial requirements thus enabling their implementation by the user
industries. Finally, the project will focus on a thorough understanding of their behaviour at high tem-
peratures through thermomechanical investigations and corrosion tests (including in a hydrogen-rich
environment), as well as post-mortem analyses. The aim is to demonstrate the resilience of the mate-
rial in extreme conditions compared to traditional binders.
Thus, the expected results of the project will enhance the competitiveness of refractory sector SMEs
through the formulation of innovative and durable refractory solutions. They will also contribute to a
transition to more sustainable materials with a low carbon footprint, circularity (without cement), and
energy efficiency (rapid drying).» weiterlesen» einklappen