Development and application of improved shotctrete refractory for aluminum rotary furnace applications

Oak Ridge National Laboratory, in collaboration with refractory manufacturer Minteq International, Inc., academic partner Missouri University of Science and Technology and refractory end users have developed novel refractory systems and techniques to reduce energy consumption of refractory lined vessels. The objective of this U.S. DOE funded project was to address the need for innovative refractory compositions by developing novel gunnable refractory compositions for use in high temperature and high alkali environments. Developed materials utilized new aggregate materials, bond systems, protective coatings, and phase formation techniques. Under this project, materials were developed specifically for aluminum rotary dross furnace applications and a light-weight back-up refractory system was also developed to improve the thermal efficiency of the installed lining system. This paper discusses the systematic development of these materials, laboratory testing and evaluation of these materials, and the performance of several industrial trials performed using these newly developed materials. The success of the industrial trials will be highlighted and future areas of application of these materials discussed.