Development and Deployment of Shotcrete Refractories for Aluminium Rotary Furnace Application

Jeffrey D. Smith1, Kelley O’Hara1, James G. Hemrick2, Angela Rodrigues-Schroer3, Dominick Colavito3

1 Missouri University of Science and Technology,Rolla MO, 65409-0330/USA
2 Oak Ridge National Laboratory, Oak Ridge TN, 37831-6069/USA
3 Minteq International Inc., Easton, PA, 18042/USA


Volume 5, Issue 1, Pages 73 - 78


Work was performed by Oak Ridge National Laboratory (ORNL) in the United States, in collaboration with the industrial refractory manufacturer Minteq International, Inc. (MINTEQ), academic research partnerMissouri University of Science and Technology (MS&T) and end users to employ novel refractory systems and techniques to reduce energy consumption of refractory lined vessels found in the aluminum industry. The project aim was to address factors that limit the applicability of currently available refractory materials such as chemical attack, mechanical degradation, use temperature, and installation or repair issues. To this end, as part of the overall project, shotcretable refractory compositions were developed based on alumino-silicate based structures utilizing new aggregate materials, bond systems, protective coatings, and phase formation techniques for use in rotary dross furnaces. Additionally a shotcretable high strength insulating back-up lining material was also developed for use in this and other applications. Development efforts, materials validation, and results from industrial validation trials are discussed.


shotcrete, aluminum, rotary, furnace


[1] Hemrick, J.G.; Headrick, W.L.; Peters, K.M.: Development and application of refractory materials for molten aluminum applications. Int. J. of Appl. Ceram. Technol. 5 (2008) [3] 265–277

[2] Hemrick, J.G.; Rodrigues-Schroer, A.; Colavito, D.; Smith, J.D.: Improved furnace efficiency through the use of refractory materials, light metals 2011: Furnace efficiency – energy and throughput. Hoboken, NJ, 2011, 1211

[3] Hemrick, J.G.; Peters, K.M.; Damiano, J.: Energy saving strategies for the use of refractory materials in molten material contact. Energy technology perspectives: conservation, carbon dioxide reduction and production from alternative sources. Hoboken, NJ, 2009, 225

[4] O’Hara, K.R.; Smith, J.D.; Sander, T.P.; Hemrick, J.G.: Solid solution effects on the MgAl2O4– MgGa2O4 system. Proc. of UNITECR’ 11, Kyoto, Japan (2011) 420–423

[5] O’Hara, K.; Smith, J.D.; Hemrick, J.G.: Solid solution effects on the MgAl2O4 system. Proc. of the 46th Symposium on Refractories, St. Louis, MO, 2010, 150–156

[6] O’Hara, K.; Smith, J.D.; Hemrick, J.G.: Solid solution effects on the MgAl2O4 system. UNITECR’ 09 Proc., Salvador, Brazil, 2009, 137–141



Göller Velag GmbH