بهینه‌سازی خواص مکانیکی جرم نسوز ریختنی آلومینا بالا از طریق اصلاح فرمولاسیون/ مطالعه کاربردی در صنعت گاز و پتروشیمی

In reformer units of gas and petrochemical industries, refractory components surrounding nozzles are exposed to high temperatures, thermal shocks, and corrosive environments, and dependence on imported refractory materials represents a major industrial challenge. In this study, reverse engineering of a high alumina refractory castable was performed to achieve localization and improve mechanical performance, and its formulation was optimized using a techno economic approach. Andalusite was used as the primary alumina source, and 2.2 wt% TiO₂ was added as a mineralizing agent to accelerate mullite formation. Furthermore, nano bonding systems were employed instead of conventional cement binders, leading to reduced CaO content and improved microstructural densification. The produced samples were evaluated according to ASTM C133, ASTM C113, and ISO 5017 standards. Results showed that the developed composition maintained a service temperature of 1700 °C, with a bulk density of 2.53 g/cm³, cold crushing strength exceeding 1000 kg/cm², and permanent linear change of 0.8% at 1450 °C. Additionally, approximately 33% cost reduction was achieved compared to the imported sample. These findings indicate that the proposed composition can serve as a reliable and cost effective alternative for high temperature applications in the petrochemical industry.