Skip to main content
SpringerLink
Log in

Interactions of Alumina-Based and Magnesia-Based Refractories with Iron Melts and Slags: A Review

  • Published:
Metallurgical and Materials Transactions B Aims and scope Submit manuscript

Abstract

A novel flash ironmaking technology (FIT) based on the direct reduction of iron ore concentrate with a reductant gas (such as hydrogen, natural gas, coal gas, or a combination thereof) in a flash furnace is being developed at the University of Utah. This technology which is undergoing large-scale laboratory testing aims at overcoming the limitations of blast furnace ironmaking by bypassing the problematic pelletization/sintering and cokemaking steps.[1,2,3,4,5] Refractory selection is expected to play an important step in the development of FIT and its proposed scale-up. For nominating an appropriate refractory for the FIT, understanding the interactions of candidate refractories with iron/iron oxide and slags under H2/CO/CO2/H2O environments is necessary. This work is undertaken to review the existing literature on the interactions of important refractories with iron melts and relevant slags with an emphasis on two of the most commonly used refractories in ironmaking and steelmaking applications: the alumina-based refractories (used widely in blast furnace operations) and the magnesia-based refractories (used extensively in primary as well as secondary steelmaking). First, a comprehensive review on the interactions of alumina-based refractories with iron melts and slags has been done. Next the existing literature on the interactions of magnesia-based refractories with iron melts and relevant slags has been reviewed. Summaries have been included after each section and sub-section along with comments and critical insights from the authors. Finally, in the concluding remarks the differences in operating conditions between existing iron and steelmaking practices and the novel FIT have been highlighted. On the basis of these differences, it has been argued that the results and conclusions available from previous studies on refractory–metal–slag interactions are of little significance to flash ironmaking. Thus, there exists a need to carry out laboratory experiments for evaluating refractory performance in flash ironmaking under conditions relevant to the current process (FIT).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

References

  1. H.K. Pinegar, M.S. Moats and H.Y. Sohn: Ironmaking & Steelmaking, 2012, vol. 39, pp. 398-408.

    Article  Google Scholar 

  2. M.E. Choi and H.Y. Sohn: Ironmaking & Steelmaking, 2010, vol. 37, pp. 81-88.

    Article  Google Scholar 

  3. H. Wang and H.Y. Sohn: Metallurgical and Materials Transactions B, 2013, vol. 44, pp. 133-45.

    Article  Google Scholar 

  4. H.Y. Sohn: Steel Times International, 2007, vol. 31, pp. 68-72.

    Google Scholar 

  5. M.Y. Mohassab-Ahmed and H.Y. Sohn: JOM, 2013, vol. 65, pp. 1559-65.

    Article  Google Scholar 

  6. D.H.Hubble: in The Making Shaping and Treating of Steel, R.J. Fruehan, ed., The AISI Steel Foundation, Pittsburgh, PA, 1998, pp. 159-226.

    Google Scholar 

  7. E. Kapilashrami: Investigation of Interactions between Liquid Iron Containing Oxygen and Aluminosilicate Refractories, Materialvetenskap, Stockholm, Sweden, 2003, pp.1-20.

    Google Scholar 

  8. E. Kapilashrami, A. Jakobsson, S. Seetharaman and A. Lahiri: Metallurgical and Materials Transactions B, 2003, vol. 34, pp. 193-99.

    Article  Google Scholar 

  9. E. Kapilashrami, S. Seetharaman, A.K. Lahiri and A.W. Cramb: Metallurgical and Materials Transactions B, 2003, vol. 34, pp. 647-52.

    Article  Google Scholar 

  10. E. Kapilashrami, V. Sahajwalla and S. Seetharaman: ISIJ international, 2004, vol. 44, pp. 653-59.

    Article  Google Scholar 

  11. E. Kapilashrami, V. Sahajwalla and S. Seetharaman: Ironmaking & Steelmaking, 2004, vol. 31, pp. 509-13.

    Article  Google Scholar 

  12. E. Kapilashrami and S. Seetharaman: Journal of materials science, 2005, vol. 40, pp. 2371-75.

    Article  Google Scholar 

  13. I. Jimbo and A.W. Cramb: ISIJ International, 1992, vol. 32, pp. 26-35.

    Article  Google Scholar 

  14. B.C.Allen: Trans AIME, 1959, vol. 215, pp. 30-37.

    Google Scholar 

  15. M. Humenik and W.D. Kingery: Journal of the American Ceramic Society, 1954, vol. 37, pp. 18-23.

    Article  Google Scholar 

  16. K. Nogi and K. Ogino: Canadian Metallurgical Quarterly, 1983, vol. 22, pp. 19-28.

    Article  Google Scholar 

  17. L. Espié, B. Drevet and N. Eustathopoulos: Metallurgical and Materials Transactions A, 1994, vol. 25, pp. 599-605.

    Article  Google Scholar 

  18. V. Sahajwalla, R. Khanna, E. Kapilashrami and S. Seetharaman: Canadian metallurgical quarterly, 2007, vol. 46, pp. 25-32.

    Article  Google Scholar 

  19. L. Zhao and V. Sahajwalla: ISIJ international, 2003, vol. 43, pp. 1-6.

    Article  Google Scholar 

  20. R. Khanna, V. Sahajwalla, B. Rodgers and F. McCarthy: Metallurgical and Materials Transactions B, 2006, vol. 37, pp. 623-32.

    Article  Google Scholar 

  21. M. Ikram-ul-Haq, R. Khanna, P. Koshy and V. Sahajwalla: ISIJ international, 2010, vol. 50, pp. 804-12.

    Article  Google Scholar 

  22. M. Ikram-Ul-Haq, R. Khanna, S. Kongkarat and V. Sahajwalla: ISIJ international, 2012, vol. 52, pp. 1801-08.

    Article  Google Scholar 

  23. R. Khanna, M. Ikram-Ul Haq, Y. Wang, S. Seetharaman and V. Sahajwalla: Metallurgical and Materials Transactions B, 2011, vol. 42, pp. 677-84.

    Article  Google Scholar 

  24. R. Khanna, S. Kongkarat, S. Seetharaman and V. Sahajwalla: ISIJ international, 2012, vol. 52, pp. 992-99.

    Article  Google Scholar 

  25. R. Khanna, M. Ikram-Ul-Haq, S. Seetharaman and V. Sahajwalla: ISIJ International, 2016, vol. 56, pp. 1300-02.

    Article  Google Scholar 

  26. S. Orsten and F. Oeters : W.O. Philbrook Memorial Symposium Proceedings, Iron and Steel Society, Warrendale, PA, 1988, pp. 27-38.

    Google Scholar 

  27. J.H. Cox and L.M. Pidgeon: Canadian Journal of Chemistry, 1963, vol. 41, pp. 671-83.

    Article  Google Scholar 

  28. R.J. Fruehan: Metallurgical Transactions, 1970, vol. 1, pp. 3403-10.

    Article  Google Scholar 

  29. R.A. Frank, C.W. Finn and J.F. Elliott: Metallurgical and Materials Transactions B, 1989, vol. 20, pp. 161-73.

    Article  Google Scholar 

  30. R. Khanna and V. Sahajwalla: Acta materialia, 2005, vol. 53, pp. 1205-14.

    Article  Google Scholar 

  31. V. Sahajwalla and R. Khanna: Scandinavian journal of metallurgy, 2000, vol. 29, pp. 114-20.

    Article  Google Scholar 

  32. V. Sahajwalla and R. Khanna: Scandinavian journal of metallurgy, 2003, vol. 32, pp. 53-57.

    Article  Google Scholar 

  33. V. Sahajwalla and R. Khanna: Acta Materialia, 1999, vol. 47, pp. 793-800.

    Article  Google Scholar 

  34. V. Sahajwalla and R. Khanna: Acta Materialia, 2002, vol. 50, pp. 663-71.

    Article  Google Scholar 

  35. R. Khanna and V. Sahajwalla: Scripta Materialia, 1999, vol. 40, pp. 1289-94.

    Article  Google Scholar 

  36. Y. Oishi, A.R. Cooper and W.D. Kingery: Journal of the American Ceramic Society, 1965, vol. 48, pp. 88-95.

    Article  Google Scholar 

  37. A.R. Cooper and W.D. Kingery: Journal of the American Ceramic Society, 1964, vol. 47, pp. 37-43.

    Article  Google Scholar 

  38. B.N. Samaddar, W.D. Kingery and A.R. Cooper: Journal of the American Ceramic Society, 1964, vol. 47, pp. 249-54.

    Article  Google Scholar 

  39. J.P. Guha: British ceramic transactions, 1997, vol. 96, pp. 231-36.

    Google Scholar 

  40. J.L. Bates: Journal of the American Ceramic Society, 1987, vol. 70, pp.C-55-C-57.

    Article  Google Scholar 

  41. L. Reed and L. Barrett: Trans. Brit. Ceram. Soc, 1955, vol. 54, pp. 671-76.

    Google Scholar 

  42. L. Reed and L. Barrett: Trans. Brit. Ceram. Soc, 1964, vol. 63, pp. 509-34.

    Google Scholar 

  43. N. McCallum and L. Barrett: Trans. Brit. Ceram. Soc, 1952, vol. 51, pp. 523-48.

    Google Scholar 

  44. B. Levich: Discussions of the Faraday Society, 1947, vol. 1, pp. 37-49.

    Article  Google Scholar 

  45. S. Zhang, H.R. Rezaie, H. Sarpoolaky and W.E. Lee: Journal of the American Ceramic Society, 2000, vol. 83, pp. 897-903.

    Article  Google Scholar 

  46. J.A. Bonar, C.R. Kennedy and R.B. Swaroop: Am. Ceram. Soc. Bull.(United States), 1980, vol. 59, pp. 473-78.

    Google Scholar 

  47. K.H. Sandhage and G.J. Yurek: Journal of the American Ceramic Society, 1988, vol. 71, pp. 478-89.

    Article  Google Scholar 

  48. K.H. Sandhage and G.J. Yurek: Journal of the American Ceramic Society, 1990, vol. 73, pp. 3633-42.

    Article  Google Scholar 

  49. K.H. Sandhage and G.J. Yurek: Journal of the American Ceramic Society, 1990, vol. 73, pp. 3643-49.

    Article  Google Scholar 

  50. K.H. Sandhage and G.J. Yurek: Journal of the American Ceramic Society, 1991, vol. 74, pp. 1941-54.

    Article  Google Scholar 

  51. K. Nagata: Tetsu-to-Hagane, 1982, vol. 68, pp. 1694-1705.

    Article  Google Scholar 

  52. T. Dan, N. Aritomi, K. Ogawa, K. Honma and T. Kimura: Materials Transactions, JIM, 1993, vol. 34, pp. 460-66.

    Article  Google Scholar 

  53. Z. Li, K. Mukai and Z. Tao: ISIJ International, 2000, vol. 40, pp. S101-S05.

    Article  Google Scholar 

  54. V. Brabie: Steel research international, 1997, vol. 68, pp. 54-60.

    Article  Google Scholar 

  55. W. Yang, L. Zhang, H. Duan, Y. Ren, J. Wang, and X. Liu: EPD Congress 2014, Wiley, 2014, pp. 267–76.

  56. K. Beskow, N.N. Tripathi, M. Nzotta, A. Sandberg and D. Sichen: Ironmaking & steelmaking, 2004, vol. 31, pp. 514-18.

    Article  Google Scholar 

  57. J. Lehmann, M. Boher and M. Kaerle: CIM bulletin, 1997, vol. 90, pp. 69-74.

    Google Scholar 

  58. M. Mantovani, L. Moraes, R. Leandro da Silva, E. Cabral, E. Possente, C. Barbosa and B. Ramos: Ironmaking & Steelmaking, 2013, vol. 40, pp. 319-25.

    Article  Google Scholar 

  59. P.Yan, M.A.Van Ende, E. Zinngrebe, S. van der Laan, B. Blanpain and M. Guo: ISIJ International, 2014, vol. 54, pp. 2551-58.

    Article  Google Scholar 

  60. J. Poirier: Metallurgical Research & Technology, 2015, vol. 112, pp. 410.

    Article  Google Scholar 

  61. F. Huang, C. Liu, N. Maruoka and S.-Y. Kitamura: Ironmaking & Steelmaking, 2015, vol. 42, pp. 553-60.

    Article  Google Scholar 

  62. J. Bygden, T. DebRoy and S. Seetharaman: Ironmaking and Steelmaking, 1994, vol. 21, pp. 318-23.

    Google Scholar 

  63. P. Zhang and S. Seetharaman: Journal of the American Ceramic Society, 1994, vol. 77, pp. 970-76.

    Article  Google Scholar 

  64. S. Zhang, H. Sarpoolaky, N. Marriott and W. Lee: British ceramic transactions, 2000, vol. 99, pp. 248-55.

    Article  Google Scholar 

  65. S.A. Nightingale, B.J. Monaghan and G.A. Brooks: Metallurgical and Materials transactions B, 2005, vol. 36, pp. 453-61.

    Article  Google Scholar 

  66. A. Luz, F. Leite, M. Brito and V. Pandolfelli: Ceramics International, 2013, vol. 39, pp. 7507-15.

    Article  Google Scholar 

  67. M. Guo, S. Parada, P.T. Jones, E. Boydens, J. Dyck, B. Blanpain and P. Wollants: Journal of the European Ceramic Society, 2009, vol. 29, pp. 1053-60.

    Article  Google Scholar 

  68. S. Smets, S. Parada, J. Weytjens, G. Heylen, P.T. Jones, M. Guo, B. Blanpain and P. Wollants: Ironmaking & steelmaking, 2003, vol. 30, pp. 293-300.

    Article  Google Scholar 

  69. S.M. Kim and W.K. Lu: Metallurgical Transactions B, 1978, vol. 9, pp. 353-64.

    Article  Google Scholar 

  70. M.H. Amin, A. Kazemzadeh, B. Arfaei, N. Saha-Chaudhury and V. Sahajwalla: International Journal of Iron & Steel Society of Iran, 2006, vol. 3, pp. 34-42.

    Google Scholar 

  71. S. Amini, M. Brungs, S. Jahanshahi and O. Ostrovski: ISIJ international, 2006, vol. 46, pp. 1554-59.

    Article  Google Scholar 

  72. S. Jansson, V. Brabie, and L. Bohlin : VII International Conference on Molten Slags Fluxes and Salts, The Southern African Institute of Mining and Metallurgy, Johannesburg, 2004, pp. 341–47.

  73. M. Guo, S. Parada, P.T. Jones, J. Van Dyck, E. Boydens, D. Durinck, B. Blanpain and P. Wollants: Ceramics international, 2007, vol. 33, pp. 1007-18.

    Article  Google Scholar 

  74. J. Liu, M. Guo, P.T. Jones, F. Verhaeghe, B. Blanpain and P. Wollants: Journal of the European Ceramic Society, 2007, vol. 27, pp. 1961-72.

    Article  Google Scholar 

  75. M. Umakoshi and Y. Kawai: Transactions of the Iron and Steel Institute of Japan, 1984, vol. 24, pp. 532-39.

    Article  Google Scholar 

  76. H. Um, K. Lee, J. Choi and Y. Chung: ISIJ international, 2012, vol. 52, pp. 62-67.

    Article  Google Scholar 

  77. M. Guo, S. Parada, S. Smets, P. Jones, J. Van Dyck, B. Blanpain, and P. Wollants: VII International Conference on Molten Slags Fluxes and Salts, The Southern African Institute of Mining and Metallurgy, Johannesburg, 2004, pp. 327–36.

  78. D.H. Quon and K. Bell: Journal of the Canadian Ceramic Society, 1987, vol. 56, pp. 39-44.

    Google Scholar 

  79. H. Ohta and H. Suito: Metallurgical and Materials Transactions B, 1998, vol. 29, pp. 119-29.

    Article  Google Scholar 

  80. K. Morita, M. Mori, M. Guo, T. Ikagawa and N. Sano: Steel Research, 1999, vol. 70, pp. 319-24.

    Article  Google Scholar 

  81. M. Sasabe, K. Kobayashi, M. Tate, Y. Kuwano and K. Suzuki: Transactions of the Iron and Steel Institute of Japan, 1982, vol. 22, pp. 794-98.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Metallurgical Engineering, University of Utah, Salt Lake City, UT, 84112, USA

    R. Sarkar & H. Y. Sohn

Authors
  1. R. Sarkar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. H. Y. Sohn
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to R. Sarkar.

Additional information

Manuscript submitted September 19, 2017.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sarkar, R., Sohn, H.Y. Interactions of Alumina-Based and Magnesia-Based Refractories with Iron Melts and Slags: A Review. Metall Mater Trans B 49, 1860–1882 (2018). https://doi.org/10.1007/s11663-018-1300-1

Download citation

  • Received:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11663-018-1300-1

Keywords

Search

Navigation