CN108059448B - Fireproof self-flow castable - Google Patents
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- CN108059448B CN108059448B CN201810149788.0A CN201810149788A CN108059448B CN 108059448 B CN108059448 B CN 108059448B CN 201810149788 A CN201810149788 A CN 201810149788A CN 108059448 B CN108059448 B CN 108059448B
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
- C04B2235/3206—Magnesium oxides or oxide-forming salts thereof
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3418—Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/52—Constituents or additives characterised by their shapes
- C04B2235/528—Spheres
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
Abstract
The invention provides a refractory self-flow castable which is prepared from the following raw materials in parts by weight: 5-40 parts of corundum, 5-20 parts of alumina hollow spheres, 5-20 parts of alpha-alumina powder, 1-15 parts of silica micropowder, 1-15 parts of magnesia and 5-10 parts of a bonding agent, wherein the bonding agent is silica sol and a silane coupling agent. According to the invention, through the matching of the specific components and the using amount, the performances of the castable such as fluidity, refractoriness and strength are obviously improved, so that the service life of the castable is prolonged.
Description
Technical Field
The invention relates to the technical field of refractory materials, in particular to a refractory self-flow castable.
Background
The refractory castable is a mixture composed of refractory aggregate, a bonding agent, an additive and the like, is mixed by adding water or a liquid bonding agent, and is a pug constructed by a casting method. The refractory castable has simple production process, saves labor and energy, and can be prepared on site according to requirements, so the refractory castable is a medium and amorphous refractory material with larger usage amount and wide application range in furnace construction engineering. Due to the advantages of strong operability, low capital investment, convenient construction and the like, the method is widely applied to industries such as metallurgy and the like.
According to different construction modes, the refractory castable can be divided into two types, namely vibration construction type castable and self-flow type refractory castable. Compared with a vibration construction type castable, the self-flow castable has the following advantages: 1. the pouring material can flow under the action of self weight without vibration, 2, the pouring material can be automatically spread and spread to reach the position where the vibration pouring material can not reach, and 3, the pouring material can be pumped for construction, so that the labor intensity is reduced, the construction period is shortened, and the construction noise pollution is reduced. Compared with the prior art, the self-flowing castable is more suitable for casting conditions with thin walls and complex shapes.
However, it is difficult to find a balance between the composition and the proportion of the raw materials of the free-flowing castable and the performance of the castable, so that the design difficulty of the formula of the castable is large, and when a corresponding auxiliary agent is added to improve the performance of one aspect, the performance of the other aspect is often damaged, for example, when a fluidity auxiliary agent is added to improve the free-flowing property, the strength, the thermal stability and the like of the castable are often influenced. Various additives are often added into the existing self-flowing refractory castable to adjust the performance of the castable, but the defects of poor temperature resistance, poor fluidity, slow construction solidification and the like still exist; in order to increase the construction speed, vibration or large amount of water is often required to be added for realization, so that the castable has large porosity, low strength and poor thermal stability, and the service life of the castable is shortened. Therefore, the research and development of a self-popular castable with good fluidity, convenient construction, high refractoriness, high strength and other physical and mechanical properties becomes a problem to be solved in the field.
Disclosure of Invention
In view of the above, the present invention aims to provide a refractory self-flow castable, which has excellent self-flow property, strength and refractoriness, and is beneficial to increase of the service life of the castable.
The invention provides a refractory self-flow castable which is prepared from the following raw materials in parts by weight:
the binding agent is silica sol and a silane coupling agent.
Preferably, in the bonding agent, the mass ratio of the silica sol to the silane coupling agent is 10 to (0.08-0.12).
Preferably, the particle size of the alumina hollow sphere is 0.1-0.3 mm.
Preferably, the particle size of the alpha-alumina powder is 325-800 meshes.
Preferably, the particle size of the magnesite is 200-600 meshes.
Preferably, the corundum is sintered corundum.
Preferably, the magnesite is fused magnesite.
Preferably, the silane coupling agent comprises one or more of trimethoxy silane, triethoxy silane and gamma-glycidoxypropyl trimethoxy silane.
Preferably, the content of the magnesite is 5-10 parts.
Preferably, the raw materials comprise the following components in parts by weight:
the invention provides a refractory self-flow castable which is prepared from the following raw materials in parts by weight: 5-40 parts of corundum, 5-20 parts of alumina hollow spheres, 5-20 parts of alpha-alumina powder, 1-15 parts of silica micropowder, 1-15 parts of magnesia and 5-10 parts of a bonding agent, wherein the bonding agent is silica sol and a silane coupling agent. The invention provides a refractory self-flow castable which is hollow by aluminaThe ball is used as aggregate, the alpha-alumina powder can be well combined with corundum, the silicon micropowder and the compound bonding agent are matched to well fill gaps among solid particles in the castable, so that the castable has good fluidity and can not bring various low-melting impurities, and meanwhile, magnesia and Mg are added2+The condensation reaction among silica sol particles in the compound binding agent is promoted to form siloxane, and Si-O-Mg-O-Si bonds are formed at the same time, so that the castable can obtain high strength in a short time on the basis of not influencing the fluidity of the castable, has good refractoriness, does not cause the reduction of thermal shock resistance, and has good thermal stability, thereby being beneficial to prolonging the service life of the castable refractory.
Detailed Description
The invention provides a refractory self-flow castable which is prepared from the following raw materials in parts by weight:
the binding agent is silica sol and a silane coupling agent.
The refractory self-flow castable provided by the invention takes the alumina hollow spheres as the aggregate, can well combine alpha-alumina powder with corundum, is matched with the silica micropowder and the compound bonding agent, well fills gaps among solid particles in the castable, enables the castable to have good fluidity, can not bring various low-melting impurities, and is added with magnesia and Mg2+The condensation reaction among silica sol particles in the compound binding agent is promoted to form siloxane, and Si-O-Mg-O-Si bonds are formed at the same time, so that the castable can obtain high strength in a short time on the basis of not influencing the fluidity of the castable, has good refractoriness, does not cause the reduction of thermal shock resistance, and has good thermal stability, thereby being beneficial to prolonging the service life of the castable refractory.
The raw materials of the refractory self-flow castable provided by the invention comprise corundum. In the invention, the corundum is preferably sintered corundum, the sintered corundum is introduced into the castable system of the invention, and can be better matched with other components to generate good fluidity, and if other types of corundum such as fused corundum is adopted, the fluidity of the castable is easily influenced. The corundum is not particularly limited in source, and can be obtained by general commercial products or conventional preparation methods in the field.
In the present invention, the corundum content is 5 to 40 parts by weight, preferably 15 to 30 parts by weight.
The raw materials of the refractory self-flow castable provided by the invention also comprise alumina hollow spheres. The alumina hollow sphere is introduced into the castable system, has high specific surface area and hollow interior, can well combine alpha-alumina powder and corundum, and is favorable for improving the refractoriness and heat preservation of the castable. In the invention, the particle size of the alumina hollow sphere is preferably 0.1-0.3 mm; the alumina hollow spheres in the particle size range are beneficial to improving the fluidity and the strength performance of the castable, if the particle size exceeds 0.3mm, the strength of the castable is easily deteriorated, and if the particle size is less than 0.1mm, the fluidity and the refractoriness of the castable are easily influenced. The source of the alumina hollow sphere is not particularly limited, and the alumina hollow sphere is a general commercial product.
In the invention, the content of the alumina hollow spheres is 5 to 20 parts by weight, preferably 15 to 20 parts by weight.
The raw materials of the refractory self-flow castable provided by the invention also comprise alpha-alumina powder. The invention introduces alumina powder, adopts specific alpha-alumina powder, can better combine with alumina hollow spheres and corundum compared with other types of powder or other crystal forms of alumina powder (such as gamma-alumina powder and the like), and improves the strength, the refractoriness and the fluidity of the castable material under the synergistic action of silica powder, magnesia and a bonding agent. The source of the alpha-alumina powder is not particularly limited, and the alpha-alumina powder can be a general commercial product.
In the invention, the particle size of the alpha-alumina powder is preferably 325-800 meshes; if the particle size is more than 800 meshes, the flowability of the castable is easily deteriorated, and if the particle size is less than 325 meshes, a large amount of binding agent is needed, and phenomena such as sedimentation, hollowing and the like are easily caused, so that the strength, the refractoriness, the thermal stability and other properties of the castable are affected.
In the present invention, the content of the α -alumina powder is 5 to 20 parts by weight, preferably 15 to 20 parts by weight.
The raw materials of the refractory self-flow castable provided by the invention also comprise silica micropowder. The silicon micropowder is introduced into the castable system, so that gaps among particles in the castable can be well filled, and the improvement of the fluidity of the castable is facilitated. In the present invention, the source of the fine silica powder is not particularly limited, and may be any commercially available product.
In the present invention, the content of the fine silica powder is 1 to 15 parts by weight, preferably 5 to 10 parts by weight.
The raw materials of the refractory self-flow castable provided by the invention also comprise magnesia. In the invention, the magnesite is preferably fused magnesite, and the fused magnesite is magnesite formed by fusing magnesite through an electric arc furnace; in the castable system of the invention, compared with other types of magnesite such as sintered magnesite, fused magnesite can be better combined with alumina components, does not generate low-melting crystal phase with alumina at high temperature, and Mg in the castable system2+The silicon-containing castable can promote condensation reaction among silica sol particles in a binding agent to form siloxane and simultaneously form Si-O-Mg-O-Si bonds, so that the castable can obtain high strength in a short time on the basis of not influencing the fluidity of the castable, does not cause the reduction of thermal shock resistance, and shows excellent refractoriness and thermal stability.
In the invention, the particle size of the magnesite is preferably 200-600 meshes. If the particle size is larger than 600 meshes, the flowability of the castable is easily deteriorated, and if the particle size is smaller than 200 meshes, the strength improvement effect cannot be achieved, and the strength of the castable after curing is also easily influenced.
In the present invention, the content of the magnesia is 1 to 15 parts by weight, preferably 5 to 10 parts by weight. Controlling the amount of magnesia to be within the range is one of the keys affecting the performance of the castable, if the content of magnesia is lower than 1 part by weight, the strength performance of the castable is difficult to improve, and if the content of magnesia is higher than 15 parts by weight, the fluidity of the castable is obviously damaged.
The raw materials of the refractory free-flowing castable provided by the invention also comprise a bonding agent, wherein the bonding agent is a compound bonding agent of silica sol and a silane coupling agent. Compared with other types of bonding agents (such as calcium aluminate cement bonding agents and the like) in the prior art, the special compound bonding agent is adopted, so that the strength and the refractoriness of the castable can be obviously improved, and the construction fluidity and the operability are stronger, which is another key improvement of the invention.
In the invention, the mass ratio of the silica sol to the silane coupling agent in the binder is preferably 10 to (0.08-0.12), the performance of the castable can be better improved in the above ratio, if the ratio is higher than the range, the castable is easy to become mud-shaped, the fluidity is poor, the self-flow cannot be realized, and if the ratio is lower than the range, the silane coupling agent is increased, and the strength and the refractoriness of the castable are easily influenced.
In the present invention, the silane coupling agent preferably includes one or more of trimethoxysilane, triethoxysilane and gamma-glycidoxypropyltrimethoxysilane.
The invention provides a refractory self-flow castable which is prepared from the following raw materials in parts by weight: 5-40 parts of corundum, 5-20 parts of alumina hollow spheres, 5-20 parts of alpha-alumina powder, 1-15 parts of silica micropowder, 1-15 parts of magnesia and 5-10 parts of a bonding agent, wherein the bonding agent is silica sol and a silane coupling agent. According to the invention, through the matching of the specific components and the using amount, the performances of the castable such as fluidity, refractoriness and strength are obviously improved, so that the service life of the castable is prolonged.
The preparation method of the refractory self-flow castable is not particularly limited, and the castable can be prepared according to a preparation method well known to a person skilled in the art, and in some embodiments, can be prepared by the following steps: uniformly mixing corundum, alumina hollow spheres, alpha-alumina powder, silica micropowder and magnesia, adding a bonding agent, and uniformly stirring to obtain the castable.
For a further understanding of the invention, reference will now be made to the preferred embodiments of the invention by way of example, and it is to be understood that the description is intended to further illustrate features and advantages of the invention, and not to limit the scope of the claims.
Example 1
1.1 sample preparation
Raw materials:
25 parts of sintered corundum, 18 parts of alumina hollow spheres (with the particle size of 0.2mm), 18 parts of alpha-alumina powder (with the particle size of 500 meshes), 8 parts of silica micropowder, 8 parts of fused magnesia (with the particle size of 400 meshes) and 6 parts of a bonding agent (the mass ratio of silica sol to trimethoxy silane is 10: 0.1).
Preparation:
weighing and mixing the sintered corundum, the alumina hollow spheres, the alpha-alumina powder, the silicon micropowder and the fused magnesia, pouring the mixture into a stirrer, adding the binder, and uniformly stirring to obtain the refractory self-flowing castable.
1.2 Performance testing
The obtained castable refractory is tested at 20 ℃ (according to the self-flow method specified in the national standard GB/T3003-2006), the test results are shown in Table 1, and Table 1 shows the performance test results of the castable refractory obtained in the invention example and the comparative example.
Pouring, demolding and maintaining the refractory castable (the maintaining condition is executed according to GB/T17911-. After the obtained test bodies are treated at different temperatures, the compressive strength and the flexural strength of the test bodies are respectively tested, and the test results are shown in table 1.
Example 2
15 parts of sintered corundum, 15 parts of alumina hollow spheres (with the particle size of 0.1mm), 15 parts of alpha-alumina powder (with the particle size of 325 meshes), 5 parts of silica micropowder, 5 parts of fused magnesia (with the particle size of 200 meshes) and 5 parts of a bonding agent (the mass ratio of silica sol to triethoxysilane is 10: 0.08).
The refractory self-flow castable is prepared according to the formula in example 1.
The obtained refractory self-flow castable was subjected to a performance test according to the performance test method of example 1, and the test results are shown in table 1.
Example 3
30 parts of sintered corundum, 20 parts of alumina hollow spheres (with the particle size of 0.3mm), 20 parts of alpha-alumina powder (with the particle size of 800 meshes), 10 parts of silica micropowder, 10 parts of fused magnesia (with the particle size of 600 meshes) and 10 parts of a bonding agent (the mass ratio of silica sol to gamma-glycidyl ether oxypropyl trimethoxysilane is 10: 0.12).
The refractory self-flow castable is prepared according to the formula in example 1.
The obtained refractory self-flow castable was subjected to a performance test according to the performance test method of example 1, and the test results are shown in table 1.
Example 4
The raw materials and the preparation process of example 1 were followed, except that the mass ratio of the silica sol to the silane coupling agent in the binder was 10: 0.01.
The obtained refractory self-flow castable was subjected to a performance test according to the performance test method of example 1, and the test results are shown in table 1.
Example 5
The raw materials and the preparation process of example 2 were prepared, except that the mass ratio of the silica sol to the silane coupling agent in the binder was 10: 0.5.
The obtained refractory self-flow castable was subjected to a performance test according to the performance test method of example 1, and the test results are shown in table 1.
Example 6
The materials and preparation process of example 1 were followed except that the alumina hollow spheres had a particle size of 1 mm.
The obtained refractory self-flow castable was subjected to a performance test according to the performance test method of example 1, and the test results are shown in table 1.
Example 7
The raw materials and formulation procedure of example 2 were followed except that the alpha-alumina powder had a particle size of 50 mesh.
The obtained refractory self-flow castable was subjected to a performance test according to the performance test method of example 1, and the test results are shown in table 1.
Example 8
The raw materials and the preparation process of example 3 were carried out, except that the fused magnesia had a particle size of 900 mesh.
The obtained refractory self-flow castable was subjected to a performance test according to the performance test method of example 1, and the test results are shown in table 1.
Comparative example 1
The raw materials and formulation procedure of example 1 were followed except that the binder was replaced with calcium aluminate cement (provided by toronto metallurgy, inc., CA 80).
The castable was tested for performance according to the performance test method of example 1, and the test results are shown in table 1.
Comparative example 2
The raw materials and formulation procedure of example 2 were followed except that the silica sol in the binder was omitted.
The castable was tested for performance according to the performance test method of example 1, and the test results are shown in table 1.
Comparative example 3
The raw materials and formulation procedure of example 2 were followed except that the silane coupling agent in the binder was omitted.
The castable was tested for performance according to the performance test method of example 1, and the test results are shown in table 1.
Comparative example 4
The formulation was prepared according to the procedure for preparation of example 3 except that 30 parts of magnesite was used.
The castable was tested for performance according to the performance test method of example 1, and the test results are shown in table 1.
TABLE 1 results of performance tests on castable materials obtained in inventive and comparative examples
According to the test results, the refractory self-flow castable provided by the invention has excellent fluidity, refractoriness and strength performance; wherein, by comparing the effects of examples 1 to 8 with comparative examples 1 to 3, it can be seen that when other types of binders (i.e. comparative example 1) are used or the specific combination of the complex binder of the invention is broken (i.e. comparative examples 2 to 3), the fluidity, strength and refractoriness of the castable are seriously reduced; it can be seen from comparative example 4 that breaking the range of the amount of magnesite, the fluidity, strength and refractoriness of the castable are also affected.
Comparing the effects of examples 1 to 8, it can be seen that controlling the ratio of silica sol to silane coupling agent in the binder at a specific ratio of 10:0.08 to 0.12 (i.e., examples 1 to 3) can further improve the fluidity, strength and refractoriness of the castable compared to other blending schemes (i.e., examples 4 to 5).
As can be seen from the comparison of the effects of examples 1 to 8, the alumina hollow spheres, the α -alumina powder, and the fused magnesia were controlled to have particle sizes within specific ranges (i.e., examples 1 to 3), and better fluidity, strength, and refractoriness were obtained than the other particle size selections (i.e., examples 6 to 8).
The foregoing examples are provided to facilitate an understanding of the principles of the invention and their core concepts, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. It should be noted that, for those skilled in the art, it is possible to make various improvements and modifications to the present invention without departing from the principle of the present invention, and those improvements and modifications also fall within the scope of the claims of the present invention. The scope of the invention is defined by the claims and may include other embodiments that occur to those skilled in the art. Such other embodiments are intended to be within the scope of the claims if they have structural elements that approximate the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Claims (1)
1. The refractory self-flow castable is characterized by being prepared from the following raw materials in parts by weight:
the binding agent is silica sol and trimethoxy silane; the mass ratio of the silica sol to the trimethoxy silane is 10: 0.1;
the particle size of the alumina hollow sphere is 0.2 mm;
the grain diameter of the alpha-alumina powder is 500 meshes;
the particle size of the fused magnesia is 400 meshes;
or
The composition is prepared from the following raw materials in parts by weight:
the binding agent is silica sol and triethoxy silane; the mass ratio of the silica sol to the trimethoxy silane is 10: 0.08;
the particle size of the alumina hollow sphere is 0.1 mm;
the particle size of the alpha-alumina powder is 325 meshes;
the particle size of the fused magnesia is 200 meshes.
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CN109401636B (en) * | 2018-11-28 | 2021-05-28 | 湖南镭目科技有限公司 | Sealant and preparation method thereof |
CN112408998A (en) * | 2020-11-19 | 2021-02-26 | 浙江自立高温科技股份有限公司 | Ladle permanent layer castable |
CN112794703A (en) * | 2021-02-20 | 2021-05-14 | 中冶武汉冶金建筑研究院有限公司 | High-aluminum self-flow castable and preparation method thereof |
CN113636830B (en) * | 2021-08-10 | 2022-12-09 | 山西禄纬堡太钢耐火材料有限公司 | Self-flowing castable containing recycled corundum castable and preparation method thereof |
EP4311817A1 (en) * | 2022-07-27 | 2024-01-31 | Nouryon Chemicals International B.V. | Colloidal silica-bonded mgo-containing refractory castables |
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