The world trends in the development and consumption of refractory materials are considered. A brief overview of the advance in the foreign production of zero-cement refractory castables (ceramic castables) is given. The importance of controlled gelation techniques for accelerated structure formation in refractories is emphasized.
TRENDS OF DEVELOPMENTDevelopment trends in the refractory industry are closely related to the needs of consuming sectors of industry that continually strive to increase productivity and update technologies aimed at saving resources and improving product quality. This state of affairs and the never-abating competition in the market for refractory material lead to a relation between manufacturers and consumers that can be characterized as the "dictate of the customer" [1]. Two main trends are clearly distinguished: on the one hand, one strives to minimize the specific consumption of refractory materials and, on the other hand, to increase the share of unshaped high-quality refractories.Despite the substantial increase in world steel output (amounting to about one billion tons per year), the volume of production of refractories (whose major consumer is the metallurgy) has decrease markedly in recent years. Thus, in Japan, the annual volume of production decreased over the last decade from 1.5 to 1.0 million tons. By way of example, the specific consumption of refractories in the steel-making industry dropped from 11 to 7 kg/ton. Simultaneously, the overall cost of production of refractories worldwide did not diminish; rather, it showed a tendency to increase.The demand for refractories by the end of the 20th century was estimated to be about 18 billion euros [2]. The decrease in output of refractories and increase in their overall cost were primarily due to the use of high-quality raw materials and introduction of sophisticated high-technology equipments. The general trend in the assortment of refractory products can be illustrated by the statistical data in Fig. 1. The bar chart in Fig. 1 shows that, over a period of 1993 to 2004, there has been a substantial increase in the output of basic unshaped refractory materials -refractory castables from 23 to 28.5% and gunning mixes from 10.2 to 16.7%.The output of all types of shaped refractories over the same period was observed to decrease significantly -