Refractories

		Identification of a Product Substitute for the Refractory Lining of a Top Blown Rotary Converter (TBRC) Smelter
		Customer: Xstrata Metallurgy inc.
		Mandate submitted to CIR Laboratory:
		Identify a type of basic bricks allowing the service life increase of the TBRC smelter refractory lining.
		Work conducted by CIR Laboratoy:
		1) Sampling and analysis
		Various cored samples were taken from the used TBRC smelter refractory lining at strategic locations.
		These samples were analysed by quantitative XRF analysis to determine the variation of their composition with respect to the distance from their hot face.
		2) Corrosion mechanism identification
		The XRF analysis results were used to conduct thermodynamic calculations allowing the identification of the corrosion mechanism intervening in service.
		3) Selection criteria establishment
		According to the identified corrosion mechanism,  basic bricks selection criteria were established in function of their chemical composition.
		4) Identification of refracoty product substitutes
		WIth reference to the established criteria, various types of basic bricks from different suppliers were selected based on their technical data sheet.
		5) Physical simulation tests
		To validate the established corrosion mechanism and for identifying the best type of brick from the selected product substitutes, samples of each product were submitted to a dynamic corrosion test by means of the C.A.T.-CIREP physical simulation set-up.
		Appearance of the samples: Before (left) and after (right) the simulation test
		Global view of a corroded sample after the simulation test
		Zooming of zone 2
		Zooming of zone 1
		Deliverables:
		Among the various tested product substitutes, the one that showed the best performance during the simulation test was reported to the customer. A mathematical model, executable on EXCEL, was also delivered. This model, applicable to the case of TBRC smelters, allows to predict the corrosion resistance of basic bricks by referring to their chemical composition, as provided on their technical data sheet.