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An Insight Into the Properties of Magnesite and Magnesite-Chromite Refractories for Ferro-Chrome Industry

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An Insight Into the Properties of Magnesite and Magnesite-Chromite Refractories for Ferro-Chrome Industry An insight into the properties of magnesite and magnesite-chromite refractories for ferro-chrome industry T. Seetaramaiah A. K. Bose P. Bhattacharya P. V. Rao T. K. Ghose- ABSTRACT A few qualities of magnesite and magnesite-chromite bricks and magnesite ramming masses manufactured indigenously are being used in making ferro-chrome alloy in India. In this paper an attempt has been made for evaluating different qualities of magnesite and magnesite- chromite refractories by studying the relevant physico-chemical properties. As the bricks are to withstand severe corrosion and erosion by the molten metal and slag at high temperatures, the mineralogy, microstructure and the modulus of rupture at different temperatures were studied. The hot modulus of rupture values are correlated with the mineralogical compositions of the bricks. A ramming mass based on sea water magnesia has been developed for chute area appli- cation and the detailed properties of the same are given. Introduction nesite-chromite bricks, MCR, MCN, MCL and MCD qualities being commercially manufactured Basic refractories are one of the best suitable indigenously are taken up for a detailed investi- building materials for lining the ferro-chrome gation. Since there is a wide spread interest making furnaces and ladles. A few qualities of these days in the hot strength properties of basic magnesite and magnesite-chromite bricks and refractories, besides determining the physico- magnesite ramming masses manufactured indi- chemical properties, the microstructure and hot genously are being used in making ferro-chrome M. 0. R. at different temperatures for the bricks alloy. In this paper, an attempt has been made under study were also carried out. to evaluate some of the qualities of magnesite and magnesite-chromite refractories manufac- A number of workers have undertaken the tured in India. In magnesite bricks, MGR, study of hot strength properties of basic bricks MGW, MGD and MGD(I) qualities and in mag- and tried to correlate the high temperature * The authors are with M/s. Belpahar Refractories Ltd.. at Belpahar working respectively as Asstt. Research Et Development Engineer, General Manager (Tech.), Dy. Research ft Dev, Engineer, Senior Research Ceramist and Dy. General Manager (Operations). 152 strength data with chemical and mineralogical strength basic refractories to withstand severe composition of the bricks, firing temperature and service conditions in the ferro-chrome making other parameters of the manufacturing process. furnaces and ladles. In the indigenously availa- Attempts have also been made to find out corre- ble magnesites of Salem and Almora, the impu- lation between hot strength and service perfor- rity levels are high and the lime. silica propor- mance of the basic refractories. In this paper, tions are not adequate to get desirable mineralo- some of the important data from the published gical assemblage in the refractories. Sea water work on hot strength of basic bricks have been magnesia selected for making refractory bricks concised and these results have been compared is of high purity having very less amount of with the hot strength results of commercial boron. brands of indigenous magnesite and magnesite- chromite refractories which are found suitable The chrome ore occurring in Sukinda area for lining ferro-chrome making furnaces and of Orissa with moderate silica content is used ladles. in manufacturing magnesite-chromite bricks. Raw Materials and Refractory Brick The physico-chemical properties of magnesites Qualities and chrome ore are presented in Table 1. The major raw materials used in making the magne- Raw Materials site and magnesite chromite bricks are Salem, Selection of suitable raw materials is very Almora and Sea water D. B. M.s and Chrome much essential for manufacturing high hot ore of Sukinda. TABLE - 1 Physico-Chemical properties and Mineralogy of Raw materials Chemical Salem Almora Imported Sea Water D. B. M.s Chrome Ore Analysis% DBM DBM A A 1.0 1. 0.33 1.06 0.08 0.12 1.12 1.85 Mg0 90.52 89.40 99.03 98.10 13.61 14.00 Si% 5.82 2.54 0.22 0.44 2.24 4.62 Ca0 1.79 1.43 0.47 1.20 0.12 0.10 A1803 0.96 1.38 0.06 0.06 13.79 14.30 Fe203 0.48 4.20 0.06 0.07 11.98 12.50 8803 0.006 0.02 Cr203 .111=1■ 57.18 52 80 Total 99 90 100.01 99.926 100.01 100.04 100.17 Ca0/SiO2 ratio 0.29 0.52 1.99 2.54 0.02 0.05 A. P. 3.21 19.05 0.22 2.83 0.30 2.37 B.D.(gms/cc) 7.10 2.85 3.45 3 37 4.23 3.94 Ap.Sp.Gr. 3.487 3.50 3.50 3.47 4.248 4.04 X-Ray Diffraction results : Major - Periclase Periclase Periclase Periclase Chromite Chromite Minor - Forsterite Monticellite Dicalcium Dicalcium Serpentine Forsterite Silicate Silicate Traces - Monticellite Tricalcium Serpentine Quartz. Silicate 153 Refractory brick qualities The special quality dense magnesite bricks MGD MGD(I) are having low porosity of In the studies reported here, the bricks were maximum 17% with respectively 86.6% and manufactured with proportionate selection of 96.63% MgO contents, the latter being manu- suitable raw materials, grading, mixing pressing, factured with sea water magnesia. drying and firing procedures. Four commercial qualities of magnesite refractory bricks manufac- The properties of magnesite-chromite bricks tured in the author's company were taken up for are presented in Table 3. the investigation. The brand "R" brick consists of a little higher percentage of Fe303 and is being In magnesite-chromite bricks, the MCR, used in some of the Ferro-chrome slag making MCN, MCL and MCD bricks are having furnaces in India. The brand "W" is a low iron respectively 15.4% 17 4%, 8.5% and 8.7% magnesite brick with higher percentage of MgO minimum Cr2O3 contents with a porosity not when compared to brand "R". The bricks with exceeding 22%, 25%, 23% and 16%. brand names "D" and "D(I)" are special quality products with low porosity and high strength. Hot Strength Properties The brand "D(I)" is made with imported sea water magnesia. These qualities of bricks are While making ferro-chrome, the bricks are suitable for lining the slag furnaces for making to withstand severe corrosion and erosion by ferro chrome alloys. Similarly in magnesite- the molten metal and slag at high temperatures. chromite group of bricks also, four commercial The temperature in the reaction ladle where qualities of bricks manufactured in the author's magnesite-chromite bricks are being used may company namely MCR (roof quality), MCN exceed even 2000°C. To withstand these vaga- (normal quality), MCL (low chrome quality) and ries, the bricks should have good hot strength MCD (dense quality) bricks are taken up for properties. The modulus of rupture at different investigation. These qualities of magnesite- temperatures for all the qualities of bricks under chromite bricks are mostly suitable for reaction investigation were studied. There is a wide- ladle lining. Depending upon the composition r spread interest these days in the hot strength of the slag, the quality of the brick may be properties of refractories. The modulus of selected. rupture for all the qualities of bricks were carried at the room temperature and also at the tempe- Refractory Brick Properties ratures of 1260°C, 1400°C and 1500°C. The range of test results of M.O.R. reported in this Physico-chemical properties work are taken from the six different bricks obtained from each quality at the particular All the qualities of Magnesite and magne- temperature in question. The X-ray diffraction site-chrome bricks manufactured were tested studies for these bricks were carried out for cor- for their different properties like apparent poro- relating the hot strength properties with mine- sity, bulk density, refractoriness under load, ralogy of the bricks. The hot modulus of rupture permanent linear change on re-heating and properties at various temperatures and the X-ray chemical analysis. diffraction results for the magnesite and magne- The physico-chemical properties of the four site-chromite bricks are given in Table 4. qualities of magnesite bricks are given in Table 2. Red and white magnesite bricks consists of res- From the table, it is evident that the hot pectively 87.8% and 90 5% MgO contents with modulus of rupture of MGR and MGW quality a porosity range of 18 to 20 % in both the bricks at 1500°C is found to range between 100- qualities. 120 kg/cm2. TABLE - 2 Physico-Chemical Properties of Magnesite Refractories Physical Properties BRL-MGR BRL-MGW BRL- MGD BRL-MGD(I) A. P. (°/0) 18 - 20 18 - 20 14 - 16 15 - 17 B.D. Gms/CC (Min) 2.85 2.87 2.98 3.00 CCS (Kg/Cm2) 380-450 350-400 650-700 550-600 R.U.L. (t°C) 1600 1640 1620 + 1750 PLC at 1600°C/1 hr ± 0 8 ± 0.8 - 0.8 - 0.5 Chemical Analysis% Mg0 87.80 90.50 86.60 96.63 SiO, 5.91 6.00 5.97 0.43 Ca0 1.85 1.52 1.79 0.77 Fe,O, 3.28 0.54 1.48 0.13 Ca0 : SiO2 0.29 0.24 0.29 1.67 TABLE - 3 Physico-Chemical Properties of Magnesite Chromite Refractories Physical Properties BRL-MCR BRL-MCN BRL-MCL BRL-MCD A. P. (%) 19 - 21 23 - 25 21 -23 14 - 16 B.D. Gms/cc 2.95 2 87 2.80 3.00 CCS Kg/Cm' 350 - 400 200 - 250 200 - 280 450.- 500 R.U.L.
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