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Corrosion mechanism and kenetic behaviour of refactory materials in contact with CaO-Al2O3-MgO-SiO2. VII
International Conference on Molten Slags Fluxes and Salts, The South African Institute of Mining and Metallurgy, 2004.
The rate of dissolution of solid MgO-C and doloma into liquid in CaO-Al2O3-SiO2-MgO slag at
different temperatures was studied under conditions of forced convection by rotating cylindrical
refractory specimens in a stationary crucible containing the molten slag. The corrosion rate was
calculated from the change in diameter of the cylindrical specimens.
Refractory specimens were 13 mm in diameter and 70 mm long. The specimens were rotated for
15 to 120 minutes at speeds of 100 to 400 rpm in the molten slag.
The rate of corrosion increased with temperature and with the rotating speed of the rod, and
decreased when the slag was nearly saturated with MgO.
The experimental results confirm the assumption that the diffusion of magnesium oxide through
the slag phase boundary layer controls the corrosion process.
The corrosion mechanism seems to be the dissolution of the refractory materials into the slag,
followed by penetration of pores and grain boundaries and dispersion of the grains in the slag.
Keywords: MgO-C refractory, doloma refractory, molten slag, corrosion rate, corrosion
mechanism
Results
The temperature and immersion times of the refractory rods
are shown in Table III.
Table I
Chemical composition of the refractory test rods, mass %
Sample MgO CaO SiO2 Fe2O3 C
Magnesia 96.8 1.8 0.6 0.3 5.5
Doloma 38 59 1.1 1 -
Magnesia/doloma 62 36 0.8 0.8 -
Table II
Chemical composition of the slag, mass %.
CaO Al2O3 SiO2 MgO
56 33 11 0
53.2 31.35 10.45 5
Figure 1. Experimental apparatus 51.52 30.36 10.12 8
In order to verify the consistency of the experimental observed that the slag has infiltrated the pores of the
method some experiments were repeated at 1873 K. The refractory. The concentration of Al and Si in the infiltrated
results are in good agreement within the limits of the zone is not as high as it is in the glazy layer at the surface.
experimental errors for different experiments. This indicates that a reaction has occurred between the slag
The change of the rod diameter as a function of time for and the refractory material.
different refractory materials is shown in Figure 2. Figure 7 shows the same observation when MgO-C rods
It can be observed that a linear dependency exists for all are used. Here the slag has formed a thin glazy layer at the
three refractory materials and that the dolomite is mostly surface of the sample in the same way as in Figure 6, but
affected compared with the magnesia+carbon, which the infiltration depth is less than in the case of the
implies a very low corrosion rate. doloma/magnesia rods.
The effect of the rotation speed on corrosion rate was
examined by using a free MgO slag. The rate of rotation
was from 100 to 400 rpm at a temperature of 1873 K. The Discussion
results obtained are shown in Figure 3. The wear mechanism of different refractory materials by
The increasing of rotation speed from 200 to 400 rpm slag is a complex phenomenon. Our experimental results
affects much more doloma compared with indicate that apart from the chemical attack of the slag on
doloma/magnesia or magnesia+carbon refractory materials. the refractory material, penetration of the slag causes
The magnesia+carbon seems to be very little affected by serious direct loss of the refractories.
increasing of the rotation speed and this is in accordance
with the results reported by Bygden11, but in contradiction
The effect of temperature on the dissolution rate
with the earlier studies on the kinetics of refractory
materials corrosion. The effect of temperature on the dissolution rate was
The decrease of the dissolution rate with the increasing of investigated on magnesia-carbon rods in contact with free
MgO content in the slag is shown in Figure 4 and Figure 5. MgO slag at 200 rpm. By using the data from Table IV the
The low corrosion rate into slag with 8% MgO can be mass transfer coefficients shown in the table were
attributed to the lower driving force for the dissolution of calculated by using Equation [3].
magnesia and the large slag viscosity. Figure 8 shows the effect of temperature on the mass
In order to study how deep the penetrated zone was at the transfer coefficients. The apparent activation energy was
sample, the test rods were moulded in epoxy and later calculated from the slope to be 328 kJ/mol, which is in
examined in SEM/EDS (Figures 6 and 7). The mapping
quite good agreement with the values reported in the
shows that the slag penetrates the refractory material
through pores and cracks. There were also cavities at the literature.
surface on the rods, where entire refractory grains had come It must be observed that the mass transfer coefficients
loose by corrosion. On the test rod surfaces a glazy layer calculated in this paper are lower compared to those
was also observed. reported by Umakoshi et al. 12 when they used MgO
In Figure 6 it can be observed that a thin glazy layer has cylinder with 2636 % porosity. The explanation could be
formed on the surface of the sample when a found in the presence of the graphite in the present studies.
doloma/magnesia rod is rotated for 30 min at 1873 K with Mass transfer coefficients calculated for doloma rods are
200 rpm and 8% MgO content in the slag. It can also be nearly 10 times higher compared to the MgO-C rods.
Figure 2. Change of corrosion rate at different immersion times, Figure 3. Effect of rotation rate on the corrosion rate into free
in free MgO slag, at 1873 K, on 200 rpm MgO slag at 1873 K during 60 min
Effect of the revolution speed on the dissolution rate observed from Figures 4 and 5 that the diameter of the
It is evident from Figure 3 that the dissolution rates of samples decreases with an increase of MgO content of slag.
refractory materials depend upon the rotation rates. This The results show that if the reaction products are soluble or
fact shows that the dissolution rate is controlled by the mass dissociate in the molten slag, the active corrosion may
transport of solute in the molten slag around the refractory continue to the destruction of the refractory. Increasing of
rods. At the same time the results indicate that rotation rates the MgO content into the molten slag determines a
affect much more doloma and doloma/magnesia materials decreasing of the solubility of it into the molten slag and as
compared to the magnesia-carbon. a result it may form an impenetrable barrier so that, after its
Figure 9 shows the linear relationship between log V and formation, Figures 6 and 7, further attack is prevented. Now
log U for the materials used in the present experiments. the rate determining steps are the chemical reaction forming
the layer, diffusion through the layer, or diffusion through
According to Equation [1] and Figure 9 the lines can be
the slag.
expressed by the following equations:
For doloma -dr/dt = Ao U0.69 Penetration of slag into the refractory material rod
For magnesia/doloma -dr/dt = AoU0.625 According to Cooper13 the corrosion of oxides often occurs
For MgO-C -dr/dt = AoU0.59 not by dissolution or evaporation of the oxide, but by the
where Ao is constant. penetration of the solid by some or all the species from the
The above results are in good agreement with the results fluid. The liquid phase may be pulled into the open porosity
reported by Matsushima et al. 2 and support the of the solid by capillary forces, and species from the fluid
considerations that the dissolution of the refractory will diffuse both down the grain boundaries and into the
materials into the molten slag is a diffusion-controlled bulk of the solid.
process. This process can cause deterioration of the refractory
materials by:
The effect of slag composition on the dissolution rate Completely encasing solid particles by the molten slag
The effect of MgO content in the slag on the dissolution Causing either an expansion or contraction of solids
rate of different refractory materials was investigated by Diffusion of a slag species into the refractory material
changing the MgO content of molten slag (Table II). It is causing the change in the physical properties.
Figure 6. X-ray images of doloma/magnesia refractory/slag interface after immersion in slag containing 8% MgO at 1873 K on 200 rpm for
30 min
Figure 10. X-ray images of doloma refractory/slag interface after immersion in free MgO slag, at 1873 K on 100 rpm during 120 min