Mg(OH)2 Nucleation and Growth Parameters Applicable for the Development of MgO-Based Refractory Castables

MgO is a very attractive raw material for refractory applications. However, its use has been mainly aimed at developing high‐magnesia and magnesia–carbon bricks due to the marked hydration likelihood of this oxide and the related drawbacks (volumetric expansion, crack formation) associated with this transformation. This work aims to evaluate some critical aspects that affect the MgO reaction with water (magnesia source, particle size, concentration of available sites for brucite nucleation, influence of a hydrating additive – acetic acid, and others) during the curing and drying steps of Al2O3–MgO binder‐free refractory castables. The attained experimental results were associated with the boundary nucleation and growth model proposed in the literature. According to the in situ elastic modulus measurements carried out at 110°C, the MgO particle size and reactivity present an important effect on the nucleation and growth of brucite crystals, highlighting that a proper site activation should be induced during the castables' curing process in order to effectively allow the use of magnesia as a binder source for refractories. Faster Mg(OH)2 nuclei generation also helps to minimize further growth of these crystals, leading to a decrease in the samples' porosity and, consequently, a continuous increase in the overall refractory stiffness (E values).