Mechanical Property Optimization of High Alumina Castables via Formulation Adjustment in Petrochemical Applications

Document Type : Applied Article

Author
Alireza Rahimi
*Senior Mechanical Engineer, Reverse Engineering and Manufacturing Unit, Bushehr Petrochemical Company, Asaluyeh, Iran
20.1001.1/ijge.2026.2085531.1119
Abstract
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.
Keywords
Reverse Engineering
Castable Refractory
Reformer Nozzle
Alumina
Andalusite
Nano-bonded
Subjects
[1]    Smith JD, Fahrenholtz WG. Refractory Oxides. In: Shackelford JF, Doremus RH, editors. Ceramic and Glass Materials: Structure, Properties and Processing. Oxford, United Kingdom: Springer; 2008.
[2]    Liao G, He K, Li L, Jiang M. Study on application of alumina in high-purity andalusite-based refractory. Journal of Materials Science and Chemical Engineering. 2004;3(2):125–130. https://doi.org/10.4236/jmmce.2004.32009.
[3]    Zawrah MFM, Khalil NM. Effect of mullite formation on properties of refractory castables. Ceramics International. 2001;27(6):689–694. https://doi.org/10.1016/S0272-8842(01)00021-9.
[4]    Rebouillat L, Rigaud M. Andalusite-Based High-Alumina Castables. American Ceramic Society Bulletin. 2004;83(12):28-32. https://doi.org/10.1111/j.1151-2916.2002.tb00099.x.
[5]    Bhattacharyya A, Singh RK, Pradhan N, Kujur MK, Kain A, Prasanth P, et al. Study of the influence of andalusite on properties of 60% Al₂O₃-based bricks for steel plants. SN Applied Sciences. 2020;69:30–35. https://doi.org/10.1007/s42411-019-0062-3.
[6]    Khanmohammadi S, Mohtadinia M. Parameters influencing the characteristics of the nano-bonded aluminosilicate based refractory castables. Journal of the Australian Ceramic Society. 2025;61:21–29. https://doi.org/10.1007/s41779-024-01139-y.
[7]    Brochen E, Dannert C, Thiesen M, Ibarra T, Krause O, Abdelouhab S, Lang C. Thermomechanical and thermochemical behaviour of silica- and spinel-sol-bonded high-alumina refractory castables. Journal of Ceramic Science and Technology. 2025;16(3):107–116. https://doi.org/10.4416/JCST2024-00014.
[8]    Li M, Cai C, Qi G, Lv S, Li S, Chen R. A novel tar–silica sol bonded no-cement Al₂O₃–SiC–C castable with improved carbon dispersion and SiC whisker formation. International Journal of Applied Ceramic Technology. 2025;22(6): e70025. https://doi.org/10.1111/ijac.70025.
[9]    Nevřivová L, Zemánek D. Study of the mineralogical composition of an alumina-silica binder system formed by the sol-gel method. Materials. 2023;16(15):5466. https://doi.org/10.3390/ma16155466.
[10]    Lee WE, Vieira W, Zhang S, Ghanbari Ahari K. Castable refractory concretes. International Materials Reviews. 2001;46(3):145–167. https://doi.org/10.1179/095066001101528439.
[11]    Hou X, Chen J, Cao Y, Liu G, Wei G, Yan W, Wei Y, Li N, Zhang Y. Influence of bonding systems on the properties of Al₂O₃–MgO refractory castables: Aluminate cement and alumina–silica gel. Ceramics International. 2024;50(22):46695–46704. https://doi.org/10.1016/j.ceramint.2024.09.021.
[12]    Kashcheev ID, Rozhkov EV, Pivinskii YuE. Structurization of unshaped refractories. Refractories and Industrial Ceramics. 2003;44(1):37–41. https://doi.org/10.1023/A:1023967712104.
[13]    Roy J, Chandra S, Maitra S. Nanotechnology in castable refractory. Ceramics International. 2019;45(1):19–29. https://doi.org/10.1016/j.ceramint.2018.09.261.
[14]    Nouri Khezrabad M, Braulio MAL, Pandolfelli VC, Golestani Fard F, Rezaie HR. Nano-bonded refractory castables. Ceramics International. 2013;39(4):3479–3497. https://doi.org/10.1016/j.ceramint.2012.11.028.
[15]    López Perales JF, Díaz Tato L, González Carranza Y, Contreras de León JE, Gómez Rodríguez C, Fernández González D, Rodríguez Castellanos EA. Aluminum spent foundry sand as an emergent raw material in the production of a sustainable aluminosilicate refractory castable. Materials. 2025;18(24):5500. https://doi.org/10.3390/ma18245500.
[16]    Liu Y, Xu L, Chen M, Zhang D. Effects of andalusite and kyanite addition on the microstructure, thermo-mechanical properties and corrosion resistance of ultralow-cement bauxite-corundum castables. Ceramics International. 2022;48(10):14141–14150. https://doi.org/10.1016/j.ceramint.2022.01.300.
[17]    Li L, Wang Q, Liao G, Li K, Ye G. Densification behavior of mullite–Al₂TiO₅ composites by reaction sintering of natural andalusite and TiO₂. Ceramics International. 2018;44(4):3981–3986. https://doi.org/10.1016/j.ceramint.2017.11.191.
[18]    Singh AK, Sarkar R. Nano mullite bonded refractory castable composition for high temperature applications. Ceramics International. 2016;42(11):12937–12945. https://doi.org/10.1016/j.ceramint.2016.05.066.
[19]    Najafi A, Sarpoulaki H, Golestani-Fard F, Taqizadeh R. Investigation of the effect of TiO2 on the properties of alumina–spinel refractory castables. Int J Ind Eng Prod Manag. 2008;19(5):1–8. [In Persian].
[20]    Innocentini MDM, Silva MG, Menegazzo BA, Pandolfelli VC. Permeability of refractory castables at high temperatures. Journal of the American Ceramic Society. 2001;84(3):645–647. https://doi.org/10.1111/j.1151-2916.2001.tb00715.x.
[21]    ASTM International. Standard Test Method for Reheat Change of Refractory Brick (ASTM C113-14(2019)). West Conshohocken, PA: ASTM International; 2019.
[22]    ASTM International. Standard Classification of Alumina and Alumina-Silica Castable Refractories (ASTM C401-12). West Conshohocken, PA: ASTM International; 2022.
[23]    ASTM International. Standard Test Methods for Cold Crushing Strength and Modulus of Rupture of Refractories (ASTM C133-24). West Conshohocken, PA: ASTM International; 2024.
[24]    International Organization for Standardization. Dense shaped refractory products—Determination of bulk density, apparent porosity and true porosity (ISO 5017:2025). Geneva: International Organization for Standardization; 2025.
[25]    American Petroleum Institute. Refractory Installation Quality Control—Inspection and Testing Monolithic Refractory Linings and Materials (API STD 936-24). Washington, DC: American Petroleum Institute; 2024.

  • Receive Date 18 February 2026
  • Revise Date 07 June 2026
  • Accept Date 20 June 2026