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Refractory Wear Mechanisms in the Nonferrous Metal Industry: Testing and Modeling Results

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Abstract

Nonferrous pyrometallurgical processes today operate at a high intensity requiring the best standards for the furnace refractory systems. From one plant to another, there is a range of process conditions such as temperature, slag chemistry, and feed types, and each of these parameters can influence refractory life. It is generally understood that process changes at plants can impact refractory life. The ability to test and understand refractory responses to a wide range of furnace operating conditions is therefore important. The RHI Technology Centre in Leoben, Austria is well equipped with laboratory and pilot plant facilities to evaluate refractory suitability over the range of conditions encountered in modern nonferrous pyrometallurgical systems. This article describes refractory testing at the RHI Technology Centre of the impact of two metallurgical slags on a number of different RHI test bricks. The slags were a fayalite slag and a calcium ferrite slag supplied by two smelter plants. High-temperature corrosion tests were carried out in a 250-mm-diameter induction furnace and a 165-mm-diameter short rotary kiln; each unit was lined with a number of refractory bricks and tested against attack by the particular slag. After testing, the refractory bricks were subjected to several laboratory tests to determine the extent of corrosion. Optimal refractory choices for the customers’ plants were developed based on the test results.

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Acknowledgements

Thanks are given to our industrial research partners Boliden Minerals AB and Stillwater Mining Company for industrial support and providing the RHI Technology Center with the metallurgical slag samples. Thanks are also expressed for the opportunity for fruitful technical discussions which contributed to the success of the current study.

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Authors and Affiliations

  1. RHI AG, TC Leoben, Magnesitstrasse 2, 8700, Leoben, Austria

    D. Gregurek, A. Ressler & V. Reiter

  2. RHI AG, Wienerbergerstrasse 9, 1100, Vienna, Austria

    A. Franzkowiak, A. Spanring & T. Prietl

Authors
  1. D. Gregurek
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  2. A. Ressler
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  3. V. Reiter
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  4. A. Franzkowiak
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  5. A. Spanring
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  6. T. Prietl
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Correspondence to D. Gregurek.

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Gregurek, D., Ressler, A., Reiter, V. et al. Refractory Wear Mechanisms in the Nonferrous Metal Industry: Testing and Modeling Results. JOM 65, 1622–1630 (2013). https://doi.org/10.1007/s11837-013-0758-1

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  • DOI: https://doi.org/10.1007/s11837-013-0758-1

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