Slag Characterization: A Necessary Tool for Modeling and Simulating Refractory Corrosion on a Pilot Scale

Abstract

The slag in pyrometallurgical operations plays a major role affecting the life of furnace refractory. As such, comprehensive mineralogical and chemical slag examination, physical property determination including the slag melting point or liquidus, and viscosity are necessary for precise understanding of a slag. At the RHI Technology Center Leoben, Austria, the main objective of slag characterization work is to reach a better understanding of refractory corrosion. This corrosion testwork is performed at the laboratory and pilot scale. Typically, corrosion tests are performed in an induction furnace or rotary kiln, with the main purpose being the improved selection of the most suitable refractory products to improve refractory performance in operating metallurgical furnaces. This article focuses on characterization of samples of six non-ferrous, customer-provided slags. This includes slag from a copper Peirce-Smith converter, a short rotary furnace for lead smelting, a titania-processing furnace, and a Ni-Cu top blowing rotary converter (TBRC) plant.

Overview of wear phenomena in lead processing furnaces

“…In addition to post mortem studies, laboratory work and experimental testing carried out in the pilot plant of RHI's Technology Center Leoben enable the best possible understanding of the brick wear on the pilot scale. 5,6 Combining all these facts, the adequate choice of refractory is always essential for a successful furnace campaign.…”

Postmortem Study of a Magnesia-Chromite Brick from a Lead Recycling Furnace

“…Furthermore, postmortem studies provide an important basis for customer recommendations enabling efficient and economic furnace operation. 1,2 In the nonferrous metals industry, particularly in secondary lead smelting furnaces, the refractory lining based on the magnesia-chromite bricks is exposed to complex and mutual wear caused by chemical, thermal, and mechanical stresses. 3,4 A general overview of wear phenomena in the lead melting furnaces is given in several papers.…”

The benefits and knowledge gained in refractory testing with slag and nickel matte

“…The importance of good slag-making can be typically summed up by the old adage in smelting lore, 'look after your slag and the metal will look after itself ' (Colclough, 1925). However, it is not only the plant operators who acknowledge the importance of the slag; it is also the furnace designers and refractory suppliers, who realize that knowledge of slag chemistry and the impact of the slag on the refractory are important for the optimization of refractory campaigns to improve equipment availability (Colclough, 1925;Sorokin et al, 1994;Gregurek et al, 2014). The detail in these ideas is discussed in this paper.…”