Abstract
A thermodynamic model, based on SimuSage, was developed to simulate refractory corrosion between a magnesia-based refractory material and ferronickel (FeNi) slags. The model considers a theoretical cross-section of a refractory material to simulate a ferronickel smelter application. The current model is structured into 10 zones, which characterize different sectors in the brick (hot to cold side) perpendicular to the refractory surface with an underlying temperature gradient. In each zone, the model calculates the equilibrium between the slag and a specified amount of refractory material. The emerging liquid phases are transferred to subsequent zones. Meanwhile, all solids remain in the calculated zone. This computational process repeats until a steady state is reached in each zone. The simulation results show that when FeNi slag infiltrates into the refractory material, the melt dissolves the magnesia-based refractory and forms silicates (Mg,Fe,Ca)2SiO4 and Al spinel ((Mg,Fe)Al2O4). Furthermore, it was observed that iron oxide from the slag reacts with the refractory and generates magnesiowustite (Mg,Fe)O. Practical lab-scale tests and scanning electron microscopy (SEM)/Energy Dispersive X-ray Spectroscopy (EDS) characterization confirmed the formation of these minerals. Finally, the refractory corrosion model (RCM) ultimately provides a pathway for improving refractory lifetimes and performance.
Highlights
HIGH chemical refractory stability constitutes an essential factor in the pyrometallurgical industry
This paper presents a refractory corrosion model (RCM) developed by using the software packages SimuSageTM[16] and FactSage7.3TM[17]
The amount and chemical composition of slag/melt, refractory material, and solid oxides depends directly on several input parameters and the current status of the simulation
Summary
HIGH chemical refractory stability constitutes an essential factor in the pyrometallurgical industry. The great advantage of the described corrosion model is the investigation of local corrosion of the refractory material It considers the shift of the liquid phase’s chemical composition during its way from the outside (initial slag) through the individual zones of the refractory. The free pore volume of the refractory is taken into account, which represents the main reason of infiltration.[6] The consideration of the temperature gradient in the refractory and selectable amounts of liquid phase and refractory for the equilibrium calculations in each zone are only some advantages of this simulation model. The compiled application allows the determination of corrosion for different chemical composition of refractory and slag at the ferronickel production. VOLUME 52B, APRIL 2021—1053 expand the knowledge of actual corrosion mechanisms, which is necessary for improved refractory performance and extended lifetimes
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