Spinel-Coated Graphite for Carbon Containing Refractory Castables

Oxidation resistance and water wettability of graphite flakes have been improved by a thin sol-gel film of magnesium aluminate spinel (MgAl2O4) over its surface. The hydrosol has been synthesized by less expensive precursors and the spinel formation has been studied by scanning electron microscopy (SEM), supplemented with energy dispersive spectral analysis. After an easy-to-use mixing procedure, drying (110 degrees C), and subsequent calcination (550 degrees C), coated graphites were sieved to below 75 mu m. The coating over the powder contained 1.5 wt% MgAl2O4, which enormously increased the oxidation resistance (performed at 600 degrees, 900 degrees, and 1200 degrees C) and water wettability, as revealed by hydrophilic functional groups from infrared spectra. Defective, intermediate spinel structure of fine, lamellar Mg-doped gamma-Al2O3 has been considered to be significant for this improvement. An approximate (1:2) stoichiometry of (Mg:Al) in the coating composition was confirmed by an X-ray photoelectron spectroscopy test. Castables prepared by this graphite remarkably improved their bulk density and apparent porosity compared with those prepared by the as-received graphite. Casting water was reduced along with the amount of antioxidants. This also enhanced the resistance toward the basic slag by retaining the graphite in the refractory.