Development of waste derived nano-lakargiite bonded high alumina refractory castable for high temperature applications

Abstract This work provides a new binder system, i.e., nano-lakargiite (NL) [CaZrO3] for unshaped refractories. NL powder formulation is done through a green and facile route, i.e., solution mixing technique, which is easily capable of recycling the byproducts. The waste eggshells are practiced as a source of CaO for the preparation of NL. The characteristics such as differential thermal/thermogravimetric (DTA-TGA) analysis, X-ray diffraction (XRD), Raman spectroscopy, transmission electron microscopy (TEM) of the synthesized NL powder are accomplished. The single phase orthorhombic crystal structure with the Pnma space group of nano CaZrO3 (avg. crystallite size ∼19 nm) is attained at 1100 °C. High alumina castable specimens are formulated through the replacement of calcium aluminate cement (CAC) by the NL and heat treated at 1600 °C. The different physico-mechanical properties of the prepared castables are comprehensively investigated. The corrosion resistance in the molten glass at 1400 °C is also examined. The properties are also equated with the different advanced bonding systems of high alumina refractory castables. Significant progress in terms of densification, hot strength, and thermal shock resistance is achieved for the NL bonded refractory castables.