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Prof. Emad Mohamed M. Ewais
Central Metallurgical R&D Institute, Egypt
High-alumina Phosphate-bonded castable refractories as potential replacement for cement-bonded castables used in boiler burners
It is well known that drying out of cement-bonded refractory castables is one of the critical factors that affect on their performance. Drying out of these castables and their flame impingent has negative repercussions on their physico-mechanical and thermal properties if it has not been completed in a good way suitable with each refractory castable type. Heating schedule involves raising of temperature with very slow rate and indirect heating source to avoid abrupt evaporization of water with high speed and crack formations.Such kind of heat schedule needs long time to be applied and in turn causes high consumption of energy in term of fuels or electricity. In this context and to minimize the cost, strenuous efforts were made to reduce cement ratios in refractory castables and in turn to reduce water-added ratio. Recently, low-cement, ultra low-cement, and no-cement castables were developed, where refractory cement used as binder is progressively brought down to withstand high temperatures without weakening the lining. Nevertheless, the cost of heating schedule of these brands was reduced compared by conventional cement bonded castables but still high. For these reasons, the success in processing of cement free refractory castables of the following criteria; 1-it can be thermally treated using short-term heating schedule, 2-it cannot affected by direct flame impingement, and 3-their physcio-mechanical and thermal properties improves during raising of heating during the schedule, is a huge development in this area. This research will be address the manufacture of phosphate-bonded refractory castables as potential replacement as well as a crack repair for cement-bonded castables of the burner boiler used in refining and petrochemical industry. Also, phosphate bonded castables overview will be presented in brief.
Emad Mohamed M. Ewais earned his BSc in Chemistry (1987) as well as his MSc (1992) and PhD in Inorganic Chemistry (Ceramics) at the Faculty of Science, Cairo University, Egypt. He is a Professor and Head of the Refractory and Ceramic Materials Division (RCMD) of the Central Metallurgical R&D Institute (CMRDI) in Cairo. He is also a member of the Institute of Materials, UK, and of other international Ceramic Societies. His wide-ranging research interests include the processing of ceramics (e.g. Glass ceramics, porous ceramics, optical ceramics, electroceramics, bioceramics, nanoceramics, functionally graded ceramics, traditional ceramics, …etc.), refractory cement, castables and, especially, the properties and applications of advanced materials, wastes and refractories in metallurgical processes, cement, glass, chemical and petrochemical industries. DrEwais has authored and co-authored numerous international publications and has widely lectured on an international basis. He is working as reviewer, editorial board member and editor-in-chief for several journals. He is leading for several national and international projects. He has extensive and comprehensive industrial and academic experiences in refractories and ceramics.
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