Research and Development of Recycling Utilization of Used Refractories: A Review

doi:10.19691/j.cnki.1004-4493.2020.03.007

China's Refractories ›› 2020, Vol. 29 ›› Issue (3): 38-47.DOI: 10.19691/j.cnki.1004-4493.2020.03.007

• Original article • Previous Articles

Research and Development of Recycling Utilization of Used Refractories: A Review

Xiaowen WU, Peng CHI, Bohao CHENG, Yuena ZHANG, Wei SU, Xin MIN, Minghao FANG, Yan’gai LIU, Zhaohui HUANG^*()

Beijing Key Laboratory of Materials Utilization of Nonmetallic Minerals and Solid Wastes, National Laboratory of Mineral Materials, School of Materials Science and Technology, China University of Geosciences, Beijing 100083, China

Online:2020-09-15 Published:2020-09-15
Contact: Zhaohui HUANG
About author:WU Xiaowen, born in 1980, obtained his master’s degree and PhD in materials science from Beihang University in 2005 and 2009, respectively. He worked as a visiting scholar in University College London from 2015 to 2016 cooperating with Prof. Mohan Edirisinghe, FREng. So far he has been working in China University of Geosciences (Beijing) for over 11 years after getting his PhD and is doing the research work on the new carbon materials as well as high-performance refractories using natural minerals or industrial solid-waste.

Abstract

Abstract:

Due to the good thermal stability and excellent resistance to slag erosion, used refractories can be recycled as the main raw materials for some refractories. In this article the latest development about used refractories in metallurgical industry has been reviewed, focusing on the results reported in the past decade. The research and reutilization methods of used refractories were discussed. For the research of used refractories, two aspects, the performance and the surface erosion characteristics, were summarized. Then, the advances in research on recycling technology of several main kinds of used refractories, such as MgO-C, Al₂O₃-SiC-C, Al₂O₃-MgO-C, magnesia-chrome, and corundum-spinel refractories were summarized and discussed in detail. Some results of the author’s group were reported accompanied by these comments. The microstructure and the chemical composition were studied by scanning electron microscopy and energy dispersion spectra, and the properties of the refractories were analyzed. Afterwards, the application scope of the materials was determined according to the classification and the analysis of refractories. Finally, the large-scale application of used refractories and an outlook were given to future developments of the entire recycling industry.

Key words: used refractories in metallurgy, erosion characteristics, recycling utilization, magnesia-carbon, corundum-spinel

Xiaowen WU, Peng CHI, Bohao CHENG, Yuena ZHANG, Wei SU, Xin MIN, Minghao FANG, Yan’gai LIU, Zhaohui HUANG. Research and Development of Recycling Utilization of Used Refractories: A Review[J]. China's Refractories, 2020, 29(3): 38-47.

Figures/Tables 8

References 42

[1]	German Ferreira, Ana M Lopezsabiron, Juan Aranda, M D Mainartoledo, Alfonso Arandauson. Environmental analysis for identifying challenges to recover used reinforced refractories in industrial furnaces. Journal of Cleaner Production, 2015,88:242-253.
[2]	Wangzhi Zhou, Li Liu. Status and progress of study on recycling the used refractory materials. WISCO Technology (in Chinese), 2013,51(2):4-7
[3]	A. N. Conejo, R. G. Lule, F. Lopéz, R. Rodriguez. Recycling MgO-C refractory in electric arc furnaces. Resources, Conservation and Recycling, 2006,49(1):14-31.
[4]	Zhang Guanghui. Development of refractory industry in China. China Building Materials (in Chinese), 2007(2):63-65.
[5]	Ao Huang, Yajie Wang, Yongshun Zou, Huazhi Gu, Lvping Fu. Dynamic interaction of refractory and molten steel: Corrosion mechanism of alumina-magnesia castable. Ceramics International, 2018,44(12):14617-14624.
[6]	Yu Yanwen. A study on slag resistance and anti-hydration properties of calcia-rich magnesia-calcia refractories used for VOD [Dissertation, (in Chinese)]. Tianjin: Tianjin University, 2005.
[7]	Wang Xianghui. Research on the corrosion of metallurgical slags to chromium corundum refractories [Dissertation, (in Chinese)]. Wuhan: Wuhan University of Science and Technology, 2019.
[8]	Chen Yu, Zhang Likuan. Experimental study on the erosion on the magnesia carbon brick in a converter by slag. Energy Research and Information (in Chinese), 2019,35(3):163-168.
[9]	Wu Chunfeng, Gao Licun. Application status and progress of industrial waste in refractories. Naihuo Cailiao (Refractories,in Chinese), 2007,41(4):298-301.
[10]	Jiang Hua. Research and comprehensive utilization of used refractory at Baosteel. Baosteel Technology (in Chinese) 2005(3): 9-11+30.
[11]	Fan Zhihui, Chen Jianxiong, Xu Yanqing, Li Yuanbing, Yuan Tianyi, Liu Fang. Status and thoughts on refractories utilization. Naihuo Cailiao (Refractories,in Chinese), 2011,45(6):466-469.
[12]	Chen Yuanjun, Yao Jinfu, Tian Shouxin, Zhang Yongming, Feng Huijun. Development and recycling research on used main trough castables. Baosteel Technology (in Chinese), 2008(2):77-80.
[13]	Tian Shouxin, Tian Jinfu. Research on reproducing MgO-C brick with used MgO-C brick. Naihuo Cailiao (Refractories,in Chinese), 2005,39(4):253-254.
[14]	Yuan Haojie. Reuse of waste material in ladle lining. Naihuo Cailiao (Refractories,in Chinese), 2006,40(5):394-395.
[15]	H. Fang, J. D. Smith, K. D. Peaslee. Study of spent refractory waste recycling from metal manufacturers in Missouri. Resources, Conservation and Recycling, 1999,25(2):111-124.
[16]	Daniele Fonseca de Lima, Aloyso de Oliveira Figuereido Junior, Carolina Coelho Novais, Manuel Gustavo Lutkenhaus. Recycling of MgO-C scrap from BOF with high Al content. Proceedings of UNITECR 2011,Kyoto, 2011: 1-A-11.
[17]	Tian Shouxin. Discussion on reuse of MgO-C brick. Naihuo Cailiao (Refractories,in Chinese), 2010,44(4):305-306.
[18]	Zhang Guodong, Liu Haixiao, Luo Xudong, You Jiegang. Research on carbon-bearing magnesia refractory regeneration. Journal of Wuhan University of Technology, 2010,32(22):192-195.
[19]	Wang Jianzhu, Zhao Junxue. Characterization methods and anti-erosion mechanism of recycled MgO-C. Bulletin of the Chinese Ceramic Society (in Chinese), 2016,35(4):1067-1073.
[20]	An Jianhuai. Research on the key technology of recycling MgO-C refractory. Scientific & Technical Information of Gansu (in Chinese), 2019,48(3):37-39.
[21]	A. L. Rivas, D. Gutiérrez-Campos, J. D. Smith, T. P. Sander. Oxidation behavior of MgO-based castable prepared using crushed-bricks aggregates. Proceedings of UNITECR 2011, Kyoto, 1-A-15.
[22]	Kyeising Kwong, James P. Bennett. Recycling practices of spent MgO-C refractories. Journal of Minerals and Materials Characterization and Engineering, 2002,1(2):69-78.
[23]	Feng Huijun, Tian Shouxin. Recycling used MgO-C bricks at Baosteel. Baosteel Technology (in Chinese), 2006(1):17-19.
[24]	Ma Gang, Yue Changsheng, Guo Min, Zhang Mei, Wang Xidong, Yin bat'er, Liao Hongqiang. Synthesis of β-SiAlON from wasted Al₂O₃-SiC-C castables and coal gangue. Naihuo Cailiao (Refractories, in Chinese), 2008(4):274-278.
[25]	Wang Luoxia, Shen Mingke, Gao Bin. Recycling of used Al₂O₃-SiC-C bricks. Naihuo Cailiao (Refractories,in Chinese), 2011,45(6):440-442.
[26]	Ouyang Degang, Jiang Yanghu, Li Minghui, Zhu Shanhe, Wang Qingfang, Luo Wei. Development and application of low cost castables for hot metal ladle edge. Naihuo Cailiao (Refractories,in Chinese), 2011,45(3):203-205.
[27]	Chen Jiageng, Li Sanli, Guo Lianyou. Unfired alumina-magnesia-carbon ladle lining bricks. Hebei Metallurgy (in Chinese), 1991(2):43-47.
[28]	Wang Yilong, Bu Jinglong, Wang Ronglin, Wang Zhifa. Research on application of recycled alumina-magnesia-carbon bricks in Al₂O₃-SiC-C casting materials. Journal of Hebei Polytechnic University of Technology: Natural Science Edition (in Chinese), 2010,32(4):98-102.
[29]	Deng Liangkui. Application research of used Al₂O₃-MgO-C bricks to medium and small blast furnace trough [Dissertation, (in Chinese)]. Wuhan: Wuhan University of Science and Technology, 2010.
[30]	Sun Feng. Study and application of recycled MgO-C and Al₂O₃-MgO-C bricks [Dissertation, (in Chinese)]. Wuhan: Wuhan University of Science and Technology, 2011.
[31]	Li Xinjian. Recycling and using of dumped Al₂O₃-MgO-C bricks [Dissertation, (in Chinese)]. Wuhan: Wuhan University of Science and Technology, 2006.
[32]	Wang Changbao, Gao Shan, Zhang Ningguo. Research of preparing RH snorkel gunning refractories by waste magnesia-chrome bricks. China Resources Comprehensive Utilization (in Chinese), 2014,32(7):18-21.
[33]	Zhang Li. A new way to produce refractory castables by recycling waste magnesia-chrome bricks. Refractory and Lime (in Chinese), 2006,31(2):12-14.
[34]	Zhuo Sheng. Application of waste magnesite-chrome brick fine powder to environmental protection type dry vibrating material for tundish. Tianjin Metallurgy (in Chinese), 2015(1):20-21.
[35]	Luo Xudong, Zhang Guodong, Qu Dianli, Xu Yanhao, Chen Lili, Min Zhenxing. Influence of corundum-chrome slag on the property of magnesite-chrome castable prepared with used magnesite-chrome brick. Bulletin of the Chinese Ceramic Society (in Chinese), 2012(5):302-306.
[36]	Li Zhihui, Li Jing, Luan Xu, et al. The application of magnesia-chrome bricks used in cement kilns in converter gunning materials. Proceedings of the Sixth International Refractory Conference. 2012: 80-82.
[37]	Chen Yuanjun, Feng Huijun, Zhang Yongming. Research on the comprehensive utilization of used corundum-spinel castables Baosteel Metallurgical Waste Resources Comprehensive Utilization Technology Forum. 2006.
[38]	Huan Chen, Feng Liang, Wei Fang, Hui Chen, Xing Du, Fucheng Wang, Lei Zhao. Fabrication of microporous corundum-spinel refractory castables by foam-gelcasting methods. Journal of Materials Engineering and Performance, 2015,24(8):3049-3055.
[39]	Huan Chen, Lei Zhao, Xuan He, Wei Fang, Zhongxing Lei, Hui Chen. The fabrication of porous corundum spheres with core-shell structure for corundum-spinel castables. Materials & Design, 2015,85:574-581.
[40]	Xiaochao Li, Shusen Chen, Hao Ding, Zhaohui Huang, Minghao Fang, Yan’gai Liu, Xiaowen Wu. Preparation and characterization of corundum-mullite-spinel refractories from low-grade bauxite and magnesite ores. Journal of the Ceramic Society of Japan, 2016,124(1):88-91.
[41]	Li Hongbo, Zhang Jianchao, Liu Lei, Liu Jie. Effects of spinel additions on properties of corundum-spinel castables. Naihuo Cailiao (Refractories,in Chinese), 2010,44(4):298-301.
[42]	Wang Juntao, Chen Songlin, Yuan Lin, Zhao Hongliang, Zeng Luju, Liu Xijun, Chen Xuefeng. Effect of zirconia on thermal shock resistance of corundum-spinel castables. Journal of the Chinese Ceramic Society (in Chinese), 2011,39(8):1317-1322.

Addition of used brick /mass%	97	97	80	80
MgO /mass%	80	76	80	77
C /mass%	12	14	11	14
Compressive strength /MPa	60	52	60	52
Bulk density /(g · cm^-3)	3.04	3.01	3.08	3.04
Apparent porosity /%	3	2	3	2
Hot modulus of rupture /MPa (1 400 ℃, 0.5 h)	13	12	13	12

Addition of used brick /mass%	97	97	80	80
MgO /mass%	80	76	80	77
C /mass%	12	14	11	14
Compressive strength /MPa	60	52	60	52
Bulk density /(g · cm^-3)	3.04	3.01	3.08	3.04
Apparent porosity /%	3	2	3	2
Hot modulus of rupture /MPa (1 400 ℃, 0.5 h)	13	12	13	12

Refractories	Mass percentage /%
Magnesia-carbon	18-20
Magnesia	10-15
Alumina-silicon carbide-carbon	20-25
Alumina-magnesia-carbon	4
Alumina-magnesia	10-12
Alumina-carbon	4-6
Clay	20-25
Bauxite/mullite	10

Refractories	Mass percentage /%
Magnesia-carbon	18-20
Magnesia	10-15
Alumina-silicon carbide-carbon	20-25
Alumina-magnesia-carbon	4
Alumina-magnesia	10-12
Alumina-carbon	4-6
Clay	20-25
Bauxite/mullite	10

Number	Spent MgO-C brick	Fused magnesite	Flake graphite	Bakelite	Silicon powder	Water
1	60	20	10	3.4	0.6	6
2	50	30	10	3.4	0.6	6
3	70	15	5	3.4	0.6	6
4-1	60	15	15	3.4	0.6	6
4-2	60	15	15	4.0	0	6

China's Refractories

Research and Development of Recycling Utilization of Used Refractories: A Review

RichHTML

PDF

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 8

References 42

Related Articles 15

Recommended Articles

Metrics

Comments

Number	Spent MgO-C brick	Fused magnesite	Flake graphite	Bakelite	Silicon powder	Water
1	60	20	10	3.4	0.6	6
2	50	30	10	3.4	0.6	6
3	70	15	5	3.4	0.6	6
4-1	60	15	15	3.4	0.6	6
4-2	60	15	15	4.0	0	6

Number	Spent MgO-C brick	Fused magnesite	Flake graphite	Bakelite	Silicon powder	Water
1	60	20	10	3.4	0.6	6
2	50	30	10	3.4	0.6	6
3	70	15	5	3.4	0.6	6
4-1	60	15	15	3.4	0.6	6
4-2	60	15	15	4.0	0	6

Project	1	2	3	4-1	4-2
Bulk density /(g · cm^-3)	2.497	2.384	2.389	2.277	2.269
Volume expansivity /%	0	0.07	0.55	1.45	-0.90
Compressive strength /MPa	26.10	30.64	28.47	26.12	20.37

[1]	CHEN Yang, DENG Chengji, DING Jun, YU Chao, LOU Xiaoming. Effect of Ferric Nitrate Loading Mode on Properties of Si₃N₄ Composite MgO-C Refractories Prepared by Nitridation [J]. China's Refractories, 2023, 32(3): 6-9.
[2]	WANG Jingran, CHEN Xinming, KE Changming, ZHANG Jinhua, LIU Xuexin, LI Wen. Rheological and Sintering Properties of Two Kinds of Corundum-spinel Micropowders [J]. China's Refractories, 2022, 31(4): 7-11.
[3]	YAN Mingwei, YANG Yumin, TONG Shanghao, ZHANG Jiayu, SUN Guangchao, LIU Kaiqi. Phase Reconstruction and Microstructure Evolution of Magnesia-carbon Refractories at High Temperatures in Nitrogen [J]. China's Refractories, 2022, 31(3): 14-23.
[4]	GUO Zongqi, ZAMBONI Stefano, GAO Jianying, GAN Feifang. A Retrospective Review of Alumina-magnesia-carbon Refractories [J]. China's Refractories, 2021, 30(1): 41-48.
[5]	GUO Zongqi, ZAMBONI Stefano, GAO Jianying, GAN Feifang. Indispensability and Vulnerability of Magnesia-carbon Bricks for Steelmaking Process [J]. China's Refractories, 2021, 30(1): 7-16.
[6]	ZHANG Ju, LONG Bin, ZHOU Yunpeng, Andreas BUHR, WANG Feng, CUI Qingyang, XIE Guofeng, DING Dafei, JIA Quanli, YE Guotian. Relation Between Sintering Reactivity of Matrix and Thermal Shock Resistance of Ultra-low Cement Bonded Corundum-spinel Castables for Fired Purging Plugs [J]. , 2018, 27(4): 13-20.
[7]	ZHAO Hongbo, HUANG Jin, YU Tongshu, CHEN Lu, ZHANG Hui, LU Xiangyang. Effects of Tabular Corundum Types on Properties of Corundum-spinel Castables [J]. , 2017, 26(4): 50-52.
[8]	MA Sanbao, YAN Wen, LIN Xiaoli, ZHOU Wenying. Effect of TiO2 Addition on Slag Resistance of Lightweight Corundum-spinel Castables [J]. , 2017, 26(4): 44-49.
[9]	WANG Fucheng, WEI Guoping, LUO Ming, FANG Binxiang. Effects of Resins with Different Molecular Structures on Properties of MgO-C Bricks [J]. , 2017, 26(4): 31-36.
[10]	WANG Xian, ZHU Boquan, LI Xiangcheng, MA Zheng, WEI Ying. Effect of Spherical Ni Powder on Microstructure of Secondary Carbon in MgO-C Refractories Matrix [J]. , 2015, 24(2): 42-45.
[11]	WANG Junkai, DENG Xiangong, LI Faliang, ZHANG Haijun, ZHANG Shaowei. Recent Progress of Carbon Nanotubes Reinforced MgO-C and Al2O3-C Refractories [J]. , 2014, 23(4): 16-21.
[12]	ZHANG Ju, SUN Xiaogai, JIA Quanli, WU Ran. Progress and Developing Trend of Purging Plugs for Refining Ladle [J]. , 2014, 23(2): 39-42.
[13]	XIE Zhaohui, CHEN Liugang, ZHAI Pengtao, ZHANG Yang. Effect of ZnO on Oxidation Resistance of Low Carbon MgO-C Refractories [J]. , 2014, 23(2): 7-11.
[14]	LI Zhigang, YE Fangbao. Effect of Nano Calcium Carbonate on Properties of Corundum-spinel Castables [J]. , 2013, 22(4): 9-13.
[15]	REN Zhen, GE Tiezhu, ZHONG Xiangchong. Effects of Al-Si Addition on Thermomechanical Properties of Low-carbon MgO-C Materials [J]. , 2013, 22(2): 11-14.

Number	Spent MgO-C brick	Fused magnesite	Flake graphite	Bakelite	Silicon powder	Water
1	60	20	10	3.4	0.6	6
2	50	30	10	3.4	0.6	6
3	70	15	5	3.4	0.6	6
4-1	60	15	15	3.4	0.6	6
4-2	60	15	15	4.0	0	6

Number	Spent MgO-C brick	Fused magnesite	Flake graphite	Bakelite	Silicon powder	Water
1	60	20	10	3.4	0.6	6
2	50	30	10	3.4	0.6	6
3	70	15	5	3.4	0.6	6
4-1	60	15	15	3.4	0.6	6
4-2	60	15	15	4.0	0	6

Number	Spent MgO-C brick	Fused magnesite	Flake graphite	Bakelite	Silicon powder	Water
1	60	20	10	3.4	0.6	6
2	50	30	10	3.4	0.6	6
3	70	15	5	3.4	0.6	6
4-1	60	15	15	3.4	0.6	6
4-2	60	15	15	4.0	0	6

Number	Spent MgO-C brick	Fused magnesite	Flake graphite	Bakelite	Silicon powder	Water
1	60	20	10	3.4	0.6	6
2	50	30	10	3.4	0.6	6
3	70	15	5	3.4	0.6	6
4-1	60	15	15	3.4	0.6	6
4-2	60	15	15	4.0	0	6