Alkali removal process development for spent refractory enhancement
A novel leaching and drying process for efficient alkali and sulphate removal from spent refractory, improving properties like RUL and creep. The method leverages rapid leaching cycles followed by drying, enhancing refractory material stability and performance while being scalable and cost-effective.
Overview
This innovative process focuses on the removal of alkali salts and sulphates from spent refractory materials using rapid leaching and drying techniques. The primary goal is to enhance the refractory properties such as refractoriness under load (RUL), creep, and hot modulus of rupture (HMoR). By effectively dissolving the unwanted salts and sulphates, the process retains mechanical, chemical, and dimensional stability, resulting in purer and more efficient refractory solids. This method offers a scalable and cost-effective solution for industries dealing with refractory waste.
Technical specifications
The process involves:
- Rapid leaching cycles: Designed to dissolve alkali salts and sulphates efficiently, avoiding complex hydration or reactions in components like MgO and CaO.
- Rapid drying: Following leaching, a rapid drying process ensures stability and retention of desirable refractory properties.
- Optimization of leaching parameters: Includes temperature, pH, solid-liquid ratio, and surface area to maximize alkali removal efficiency.
- Non-hazardous waste management: Ensures that the leaching solution is treated safely without generating hazardous waste.
This method applies modified TRGS standards and is adaptable to the specific chemistry and phase properties of different spent refractories.
Technology readiness level
The technology is currently at TRL 4, indicating that it is at the stage of technology development and validation in laboratory settings. Future work includes further process optimization and validation to enhance operational parameters and refractory properties.
About Wuhan University of Technology
Wuhan University of Technology is a state key public research university in Wuhan, directly affiliated with China’s Ministry of Education and jointly developed with the Ministry of Transport, with over 60,000 faculty and students across three campuses. Industry‑facing infrastructure includes state key laboratories and national engineering research centers, plus a university science park embedded in Optics Valley to support incubation and collaboration. The university also operates off‑campus research bases and industry‑education integration sites with local governments and enterprises, and benefits from proximity to Wuhan’s “China Auto Valley” and broader manufacturing corridors. Research is sustained by competitive national programs and ministerial initiatives. WHUT is recognized as a national intellectual property demonstration university and as a transformation and technology transfer base, providing structured IP, licensing, and commercialization support.
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