Conference on Glass Problems (GPC) 2024

Abstract: Refractories Based on Designed Microstructure that Provide Excellent Corrosion and Mechanical Performance with a Low Carbon Footprint

SEFPRO’s redesigned range of WOOL refractories for use in insulation fiberglass melting represents an improvement in performance while minimizing the carbon footprint of their manufacture. The corrosion resistance of traditional chrome oxide-containing refractories, in which multiple dissimilar grain compositions are blended, is proportional to chrome oxide level. 

But, through proper design of a homogeneous chrome distribution within the low apparent porosity grains and the surrounding matrix, refractories are developed that provide both an even corrosion pattern and a lower overall corrosion rate at a lower chrome oxide level than required in traditional refractories. The redesigned range exhibits 10% lower corrosion rate than its predecessor, which already outperformed traditional refractories having similar or even higher chrome levels by around 30% in customer melter evaluations. Reducing the chrome oxide level required for corrosion resistance provides additional benefits.  The redesigned range exhibits a significant improvement in sag resistance, which is especially important for superstructure applications.  

The new product range is based on fused chrome-alumina grains, rather than sintered granules.  Thus, the carbon footprint of grains manufacture is reduced by more than 90% as hydroelectric power replaces natural gas firing. Grain formulation and processing has been designed to promote greater use of secondary raw materials, such that the new product range can contain more than twice the amount of recycled content than previous products. 

Finally, the redesigned product range, at lower chrome oxide level and homogeneous, well-bonded structure, can aid in the reduction of melter total chrome and hexavalent chrome emissions. The presentation will describe the method and advantages of designing the grain and matrix microstructures, as well as summarize corrosion resistance, thermomechanical, and electrical performance data. The redesigned WOOL range is an advancement in performance and decarbonization for the insulation fiberglass market.

About the speaker:

Andrea Kazmierczak - R&D Process Leader

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