Refractory in the context of "Materials science"

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⭐ Core Definition: Refractory

In materials science, a refractory (or refractory material) is a material that is resistant to decomposition by heat or chemical attack and that retains its strength and rigidity at high temperatures. They are inorganic, non-metallic compounds that may be porous or non-porous, and their crystallinity varies widely: they may be crystalline, polycrystalline, amorphous, or composite. They are typically composed of oxides, carbides or nitrides of the following elements: silicon, aluminium, magnesium, calcium, boron, chromium and zirconium. Many refractories are ceramics, but some such as graphite are not, and some ceramics such as clay pottery are not considered refractory. Refractories are distinguished from the refractory metals, which are elemental metals and their alloys that have high melting temperatures.

Refractories are defined by ASTM C71 as "non-metallic materials having those chemical and physical properties that make them applicable for structures, or as components of systems, that are exposed to environments above 1,000 °F (811 K; 538 °C)". Refractory materials are used in furnaces, kilns, incinerators, and reactors. Refractories are also used to make crucibles and molds for casting glass and metals. The iron and steel industry and metal casting sectors use approximately 70% of all refractories produced.

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In this Dossier

Refractory in the context of Stoneware

Stoneware is a broad class of pottery fired at a relatively high temperature, to be impervious to water. A modern definition is a vitreous or semi-vitreous ceramic made primarily from stoneware clay or non-refractory fire clay. This definition excludes stone vessels that are carved from a solid chunk of stone. End applications of stoneware include tableware and decorative ware such as vases.

Stoneware is fired at between about 1,100 °C (2,010 °F) to 1,300 °C (2,370 °F). Historically, reaching such temperatures was a long-lasting challenge, and temperatures somewhat below these were used for a long time.

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Refractory in the context of Solid

Solid is a state of matter in which atoms are closely packed and are difficult to move past each other. Solids resist compression, expansion, or external forces that would alter its shape, with the degree of resistance being dependent upon the specific material under consideration. Solids also always possess the least amount of kinetic energy per atom/molecule relative to other phases or, equivalently stated, solids are formed when matter in the liquid / gas phase is cooled below a certain temperature. This temperature is called the melting point of the substance and is an intrinsic property; i.e. independent of how much of the matter there is. The vast majority of substances, when in the solid state, can be arranged in one of a few ubiquitous structures.

Solids are characterized by structural rigidity and resistance to applied external forces and pressure. Unlike liquids, solids do not flow to take on the shape of their container, nor do they expand to fill the entire available volume like a gas. Much like the other three fundamental phases, solids also expand when heated, the thermal energy put into increasing the distance and reducing the potential energy between atoms. However, solids do this to a much lesser extent. When heated to their melting point or sublimation point, solids melt into a liquid or sublimate directly into a gas, respectively. For solids that directly sublimate into a gas, the melting point is replaced by the sublimation point. As a rule of thumb, melting will occur if the subjected pressure is higher than the substance's triple point pressure, and sublimation will occur otherwise. Melting and melting points refer exclusively to transitions between solids and liquids. Melting occurs across a great extent of temperatures, ranging from 0.10 K for helium-3 under 30 bars (3 MPa) of pressure, to around 4,100 K at 1 atm for the composite refractory material hafnium carbonitride.

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Refractory in the context of Bioleaching

Bioleaching is the extraction or liberation of metals from their ores through the use of living organisms. Bioleaching is one of several applications within biohydrometallurgy and several methods are used to treat ores or concentrates containing copper, zinc, lead, arsenic, antimony, nickel, molybdenum, gold, silver, and cobalt.

Bioleaching falls into two broad categories. The first, is the use of microorganisms to oxidize refractory minerals to release valuable metals such and gold and silver. Most commonly the minerals that are the target of oxidization are pyrite and arsenopyrite.

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Refractory in the context of Aluminium oxide

Aluminium oxide (or aluminium(III) oxide) is a chemical compound of aluminium and oxygen with the chemical formula Al2O3. It is the most commonly occurring of several aluminium oxides, and specifically identified as aluminium oxide. It is commonly called alumina and may also be called aloxide, aloxite, ALOX or alundum in various forms and applications and alumina is refined from bauxite. It occurs naturally in its crystalline polymorphic phase α-Al2O3 as the mineral corundum, varieties of which form the precious gemstones ruby and sapphire, which have an alumina content approaching 100%. Al2O3 is used as feedstock to produce aluminium metal, as an abrasive owing to its hardness, and as a refractory material owing to its high melting point.

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Refractory in the context of Investment casting

Investment casting is an industrial process based on lost-wax casting, one of the oldest known metal-forming techniques. The term "lost-wax casting" can also refer to modern investment casting processes.

Investment casting has been used in various forms for the last 5,000 years. In its earliest forms, beeswax was used to form patterns necessary for the casting process. Today, more advanced waxes, refractory materials and specialist alloys are typically used for making patterns. Investment casting is valued for its ability to produce components with accuracy, repeatability, versatility and integrity in a variety of metals and high-performance alloys.

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Refractory in the context of Zirconium

Zirconium is a chemical element; it has symbol Zr and atomic number 40. First identified in 1789, isolated in impure form in 1824, and manufactured at scale by 1925, pure zirconium is a lustrous transition metal with a greyish-white color that closely resembles hafnium and, to a lesser extent, titanium. It is solid at room temperature, ductile, malleable and corrosion-resistant. The name zirconium is derived from the name of the mineral zircon, the most important source of zirconium. The word is related to Persian zargun (zircon; zar-gun, "gold-like" or "as gold"). Besides zircon, zirconium occurs in over 140 other minerals, including baddeleyite and eudialyte; most zirconium is produced as a byproduct of minerals mined for titanium and tin.

Zirconium forms a variety of inorganic compounds, such as zirconium dioxide, and organometallic compounds, such as zirconocene dichloride. Five isotopes occur naturally, four of which are stable. The metal and its alloys are mainly used as a refractory and opacifier; zirconium alloys are used to clad nuclear fuel rods due to their low neutron absorption and strong resistance to corrosion, and in space vehicles and turbine blades where high heat resistance is necessary. Zirconium also finds uses in flashbulbs, biomedical applications such as dental implants and prosthetics, deodorant, and water purification systems.

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Refractory in the context of Rotary kiln

A rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process. Materials produced using rotary kilns include:

They are also used for roasting a wide variety of sulfide ores prior to metal extraction.

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Refractory in the context of Black carbon

Black carbon (BC) is the light-absorbing refractory form of elemental carbon remaining after pyrolysis (e.g., charcoal) or produced by incomplete combustion (e.g. soot).

Tihomir Novakov originated the term black carbon in the 1970s, after identifying black carbon as fine particulate matter (PM ≤ 2.5 μm aerodynamic diameter) in aerosols. Aerosol black carbon occurs in several linked forms. Formed through the incomplete combustion of fossil fuels, biofuel, and biomass, black carbon is one of the main types of soot particle in both anthropogenic and naturally occurring soot. As soot, black carbon causes disease and premature death. Because of these human health impacts, many countries have worked to reduce their emissions.

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