Slag Resistance of Refractories for Direct Reduction of Laterite Nickel Ores in Rotary Kilns

doi:10.19691/j.cnki.1004-4493.2020.02.003

China's Refractories ›› 2020, Vol. 29 ›› Issue (2): 11-20.DOI: 10.19691/j.cnki.1004-4493.2020.02.003

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Slag Resistance of Refractories for Direct Reduction of Laterite Nickel Ores in Rotary Kilns

CHEN Wei¹^,²^,^*(), ZHANG Xiaohui¹, ZHANG Haijun²

1 Sinosteel Luoyang Institute of Refractories Research Co., Ltd., Luoyang 471039, China
2 Wuhan University of Science and Technology, Wuhan 430081, China

Revised:2021-05-13 Online:2020-06-15 Published:2020-06-15
Contact: CHEN Wei
About author:Chen Wei, born in 1983, obtained his bachelor's degree with the major of materials science and engineering from Xi'an University of Architecture and Technology in 2006 and master's degree with the major of materials science from Wuhan University of Science and Technology in 2018. Since 2006, he has been working in Sinosteel Luoyang Institute of Refractories Research Co., Ltd. At present, he is the deputy executive general manager of Sinosteel Nanjing Environmental Materials Technology Research Institute Co., Ltd., (in preparation) and the vice director of the National Quality Supervision and Inspection Center for Refractories. His research interest is the performance test and characterization of refractories. He, as the group leader, has set three national standards as well as one industry standard on refractory testing methods.

Abstract

Abstract:

Aiming at prolonging the service life of refractories for direct reduction of laterite nickel ores in rotary kilns, the slag resistance of ten materials (corundum bricks, chrome corundum bricks, silicon nitride bonded silicon carbide bricks, high alumina silicon carbide bricks, high alumina bricks, magnesia chrome bricks, magnesium aluminate spinel bricks, spinel chrome corundum bricks, chrome corundum castables and magnesia alumina chrome composite spinel bricks) was evaluated by rotary slag tests, which simulate the service conditions in rotary kilns. The corroded residual bricks were analyzed by SEM and EDS. The results show that the magnesia alumina chrome composite spinel brick possesses the advantages of magnesium aluminate spinel bricks and chrome corundum bricks; MgO-rich spinel can absorb the penetrated ferric oxide, and forms a dense zeylanite layer, which prevents the penetration of the molten laterite nickel ores; therefore, it is an ideal lining of rotary kilns for direct reduction of laterite nickel ores.

Key words: laterite nickel ore, direct reduction, refractories, rotary slag test, slag resistance

CHEN Wei, ZHANG Xiaohui, ZHANG Haijun. Slag Resistance of Refractories for Direct Reduction of Laterite Nickel Ores in Rotary Kilns[J]. China's Refractories, 2020, 29(2): 11-20.

Samples	AP /%	BD /(g · cm^-3)	CCS /MPa	RUL /℃	HMOR /MPa	Thermal shock resistance (1 100 ℃, water quenching) /cycles
High alumina bricks	19.1		138	1 550
Corundum bricks	18.6	3.22	111	>1 700		≥6
High alumina silicon carbide bricks	19.8	2.70	93.4
Chrome corundum bricks		3.45	335
Chrome corundum castable		3.32	151
Spinel chrome corundum bricks		3.43	220		17.4 (1 450 ℃×0.5 h)	>13
Magnesium aluminate spinel bricks		2.93	61.8	>1 700		>10
Magnesia chrome bricks		3.28	72.1		8.2 (1 450 ℃×0.5 h)	>10
Magnesia alumina chrome composite spinel bricks		3.03	61.1
Silicon nitride bonded silicon carbide bricks	16	2.66	190		61.1 (1 400 ℃×0.5 h)

Samples	AP /%	BD /(g · cm^-3)	CCS /MPa	RUL /℃	HMOR /MPa	Thermal shock resistance (1 100 ℃, water quenching) /cycles
High alumina bricks	19.1		138	1 550
Corundum bricks	18.6	3.22	111	>1 700		≥6
High alumina silicon carbide bricks	19.8	2.70	93.4
Chrome corundum bricks		3.45	335
Chrome corundum castable		3.32	151
Spinel chrome corundum bricks		3.43	220		17.4 (1 450 ℃×0.5 h)	>13
Magnesium aluminate spinel bricks		2.93	61.8	>1 700		>10
Magnesia chrome bricks		3.28	72.1		8.2 (1 450 ℃×0.5 h)	>10
Magnesia alumina chrome composite spinel bricks		3.03	61.1
Silicon nitride bonded silicon carbide bricks	16	2.66	190		61.1 (1 400 ℃×0.5 h)

Test bricks	Maximum corrosion depth
Magnesium aluminate spinel brick	18.6
Magnesia chrome brick	7.7
Spinel chrome corundum brick	7.2
Chrome corundum brick	4.4
Chrome corundum castable	5.9
Magnesia alumina chrome composite spinel brick	4.7

Test bricks	Maximum corrosion depth
Magnesium aluminate spinel brick	18.6
Magnesia chrome brick	7.7
Spinel chrome corundum brick	7.2
Chrome corundum brick	4.4
Chrome corundum castable	5.9
Magnesia alumina chrome composite spinel brick	4.7

Depth /mm	MgO	Al₂O₃	SiO₂	P₂O₅	Cr₂O₃	Fe₂O₃	ZrO₂
0	1.51	58.59	8.23	1.08	18.21	11.17	-
3	2.85	53.77	10.76	0.80	17.92	9.26	3.21
6	3.34	52.48	6.82	0.73	24.67	6.62	3.82
9	2.02	59.30	10.02	1.79	16.30	5.19	3.46
12	3.94	56.12	8.46	1.75	17.84	6.56	4.02
15	3.88	54.42	5.04	3.29	20.74	6.13	4.61
20	5.43	52.63	3.27	4.06	18.65	1.91	3.92

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Slag Resistance of Refractories for Direct Reduction of Laterite Nickel Ores in Rotary Kilns

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Depth /mm	MgO	Al₂O₃	SiO₂	P₂O₅	Cr₂O₃	MnO₂	Fe₂O₃	NiO
Slag	11.08	16.36	11.61	-	4.87	0.88	54.13	0.84
0	1.83	55.03	10.53	-	14.32	0.52	17.05	-
5	0.64	61.17	12.14	0.67	19.85	-	4.78	-
10	0.89	53.93	11.97	2.09	23.74	-	6.14	-
15	0.94	54.28	7.83	4.13	26.24	-	4.79	-
Original brick	1.28	53.59	1.89	0.80	35.52	-	6.36	-

Depth /mm	Na₂O	MgO	Al₂O₃	SiO₂	CaO	P₂O₅	Cr₂O₃	Fe₂O₃
Slag	0.38	8.58	13.17	17.67	0.36	-	6.11	52.24
0	0.40	1.03	57.52	8.06	0.37	-	22.62	10.00
5	0.74	0.53	54.86	10.36	2.01	-	25.37	6.14
10	0.67	0.19	59.30	5.68	3.05	0.63	26.60	3.87
15	0.67	-	55.14	4.34	4.68	1.82	28.95	4.17
20	-	-	54.52	0.59	2.79	0.74	37.56	3.80

Depth /mm	MgO	Al₂O₃	SiO₂	CaO	MnO₂	Cr₂O₃	Fe₂O₃	NiO
Slag	10.62	10.82	12.09	0.32	0.86	6.64	57.31	0.98
0	16.08	8.62	3.05	-	0.77	4.57	65.11	1.81
2	53.42	2.16	2.20	0.24	0.44	1.21	38.65	1.67
5	78.70	7.71	2.04	2.26	-	5.38	3.91	-
10	81.40	3.41	3.25	3.34	-	5.12	3.47	-
15	83.92	3.15	2.60	2.39	-	4.30	3.63	-
Original brick	83.30	3.58	2.30	3.67	-	3.41	3.74	-

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