Wear Mechanisms of Carbon-Based Refractory Materials in SiMn Tap-Holes—Part II: In Situ Observation of Chemical Reactions

The purpose of the study presented here is to determine to what extent chemical reactions between carbon-based refractory and slag or metal in the tap-hole of a SiMn furnace can contribute to wear of tap-hole refractory. The results of the study are reported in two parts. In Part I, thermodynamic calculations suggested that reaction between silicomanganese slag and carbon-based tap-hole refractory is possible, and experiments with nominally pure materials support this. However, practical refractory materials are by no means pure materials and contain secondary phases and porosity which can be expected to affect reaction with slag. In Part II, such reactions are examined experimentally, in cup and wettability tests, using commercially available carbon block and cold-ramming paste refractory materials and mainly industrial SiMn slag. Clear evidence was found of chemical reaction at approximately 1870 K (approximately 1600 C), forming SiC and, it appears, metal droplets. Both carbon block and ramming paste refractory reacted with slag, with preferential attack on and penetration into the binder phase rather than aggregate particles. The two types of carbon-based refractory materials showed similar extents of chemical reaction observed as wetting and penetration in the laboratory tests. The differences in refractory life observed practically in industrial furnaces should therefore be attributed to wear mechanisms other than pure chemical wear as studied in this work.National Research Foundation of South Africa (Grant TP2011070800005).http://link.springer.com/journal/116632016-04-30hb201

Thermodynamic and Kinetic Behavior of B and Na Through the Contact of B-Doped Silicon with Na2O-SiO2 Slags

Boron (B) is the most problematic impurity to be removed in the processes applied for the production of solar grade silicon. Boron removal from liquid silicon by sodium-silicate slags is experimentally studied and it is indicated that B can be rapidly removed within short reaction times. The B removal rate is higher at higher temperatures and higher Na2O concentrations in the slag. Based on the experimental results and thermodynamic calculations, it is proposed that B removal from silicon phase takes place through its oxidation at the slag/Si interfacial area by Na2O and that the oxidized B is further gasified from the slag through the formation of sodium metaborate (Na2B2O4) at the slag/gas interfacial area. The overall rate of B removal is mainly controlled by these two chemical reactions. However, it is further proposed that the B removal rate from silicon depends on the mass transport of Na in the system. Sodium is transferred from slag to the molten silicon through the silicothermic reduction of Na2O at the slag/Si interface and it simultaneously evaporates at the Si/gas interfacial area. This causes a Na concentration rise in silicon and its further decline after reaching a maximum. A major part of the Na loss from the slag is due to its carbothermic reduction and formation of Na gas

Damring formation during rotary kiln chromite pre-reduction: Effects of pulverized carbonaceous fuel selection and partial pellet melting

Electricity consumption is the largest cost contributing factor in the production of ferrochrome. Currently the pelletized chromite pre-reduction process (solid-state reduction of chromite) is the process option with the lowest specific electricity consumption (MWh/ton). In this process, pelletized chromite is fed into a rotary kiln at 1573 K (1300 °C), where partial pre-reduction takes place. Damring formation (material build-up) in the rotary kiln causes routine shutdowns, resulting in loss of revenue. The damring formation is possibly caused by melting of the ash of the pulverized coal used to fire the kiln and/or the partial melting of the chromite pellets. Ash fusion temperatures of twenty different samples were evaluated to assess the temperature at which the pulverized coal ash will start to contribute to damring formation. Sessile drop tests were used to assess the softening behavior of different ore types (e.g., UG2, MG, and LG metgrade), as well as softening of composite chromite pellets made from these ores. Actual damrings were also analyzed using scanning electron microscopy with energy dispersive X-ray spectroscopy. Results indicate that it is mainly the pulverized coal ash that will contribute to damring formation, and not ore or pellet softening. Multiple-linear regression was used to derive equations to predict the ash fusion temperatures of the pulverized coal ash, which can be used by ferrochrome producers to optimize pulverized coal selection.publishedVersion© The Author(s) 2018 Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made