Erosion Behavior and Longevity Technologies of Refractory Linings in Blast Furnaces for Ironmaking: A Review

Abstract

Erosion of the refractory materials in blast furnaces (BFs) greatly limits their campaign life, which seriously reduces the economic benefits of iron and steel plants and endangers workers. Therefore, it is important to detect and monitor the erosion process of refractory materials in the BF hearth. In this review, the mechanisms of physical damage, chemical corrosion, and mechanical erosion of BF hearths during BF operation are analyzed and summarized. In addition, the effects of hearth structure, refractory type, and protective layer on hearth erosion behavior and hearth life are analyzed and discussed. Some longevity technologies of BF hearths are analyzed and compared, such as reasonable hearth structure design, refractory selection, and technologies to form protective layers. Finally, some suggestions and prospects for the future development of long campaign life BF hearths are discussed.

Thermal conductivity of alumina-carbon composite brick and its related phase analysis in a dissected blast furnace

“…Table 2 displays some fundamental physical properties. In comparison with conventional carbon brick, the apparent porosity is a little bit lower, 10.9%; the bulk density is larger, 2.98 g/cm 3 ; the average pore diameter is greater, 0.238 mm; the pore volume (<1 mm) is relatively lower, 80.44%; and the compressive strength (room temperature) is higher, 78.4 MPa, respectively [20,21].…”

“…Apparent porosity, % 10.9 Bulk density, g/cm 3 2.98 Average pore diameter, mm 0.238 Pore volume (<1 mm), % 80.44 Compressive strength (Room temperature), MPa 78.4 samples of 346 mm in length, 150 mm in width and 98mm in height for thermal conductivity measurements, some powders for chemical composition analysis and X-ray diffraction (XRD) (Rigku SmartLab, Japan) detection after ground in agate mortar for 30 min, and some regular lumpy specimens for scanning electron microscope and energy dispersive spectrometer (SEM-EDS) (FEI Quanta 250, Holland) detection.…”

“…Low consumption, longevity, large-scale and high efficiency have gradually become the trend in development of blast furnace ironmaking technology [1][2][3][4]. From the perspective of the heat transfer structure of the blast furnace, the belly, bosh, hearth and bottom are the key areas of blast furnace longevity, and excellent performance of refractories is an important basis to extend the blast furnace campaign [5][6][7].…”

Formation Mechanism of the Brittle Layer in Carbon Brick of Blast Furnace Hearth

“…[ 3–5 ] It was found that a certain part of the hearth refractory was eroded, the molten iron would be enriched in the inner layer of this part, and a brittle layer appeared in the outer layer of the molten iron enrichment area. [ 6–8 ]…”

Evaluation, Prediction, and Feedback of Blast Furnace Hearth Activity Based on Data‐Driven Analysis and Process Metallurgy

“…[1][2][3][4] Hearth activity plays a crucial role in achieving high efficiency, high quality, low consumption, and long life in BF production, which directly affects the running and first-generation BF lifespan. [5][6][7][8][9][10] In recent years, BF-intensified smelting has become common, and the problem of hearth activity in BFs has attracted increasing attention; however, there has been little research on the quantitative evaluation of hearth activity. The traditional model for hearth activity evaluation is primarily based on mechanistic research.…”