Development of cost-efficient micro/nano alumina for refractory materials

The goal of the project is to produce spherical micro/nano alumina powder at an affordable cost, to make it available for multiple industrial applications. Based on previous investigations, the project has defined two possible process concepts that could be used for production of the product. Both concepts will be investigated fundamentally by mathematical modelling and verification by experimental tests in an iterative manner. The project is in an early phase. Initial modelling of both concepts are mad e, and experimetal tests for one of the concepts has been performed with promising results. THe amount of produced material has not been suffucient for application testing yet.

The project intends to make affordable, spherical micro/nano alumina powder available for multiple industrial applications. Such a material has been requested by the refractory industry for a long time for high temperature applications (> 1500 °C). Today, micro/nano alumina is only available at a prohibitively high price (~25 EUR/kg). Preliminary investigations by Elkem have revealed that the intended process is not easy to establish. Initial screening has, however, shown two possible production principl es that should be further investigated. A fundamental approach has been chosen where the two processes shall be described by mathematical models, which shall be verified by experiments. This will be an iterative process between modelling and experimental testing. Provided successful initial testing, the most promising alternative will be followed up by further modelling, laboratory process design, and testing. The product will be characterized and sufficient amounts will be produced to verify the posit ive effect when the powder is applied as an additive in refractory mixes, first in laboratory tests and later in real refractory mixes. If successful, the new product will reduce the water content in refractory mixes, improve their flowability, and impro ve the strength of the refractory. Hence, the material will get a longer life time and/or thinner refractory layers can be applied in the steel industry. The amount of refractory needed per ton of produced steel will be substantially reduced. Development beyond the project will introduce the material to other applications and the material will have a significant impact on the future sustainable process industry.