Overview of wear phenomena in lead processing furnaces

The main wear parameters influencing the refractory lining life in vessels used in the Pb/Zn industry (e.g., QSL reactor, KIVCET furnace, Ausmelt/Isasmelter™, Kaldo furnace, short rotary furnace) can be subdivided into chemical, thermal and mechanical stresses. In the present work the main wear parameters, such as corrosion by slag attack, high sulfur, soda and iron oxide supply as well as reduction, non-oxidic infiltration and brick damage by hydration, are briefly introduced and discussed. Additionally, the extraordinarily high SiO2 supply caused by the uncontrolled addition of silica sand results in a massive forsterite formation and in a volume expansion (“forsterite bursting”). Increased operation temperatures in the furnace support also microstructural brick degeneration. All these mentioned wear phenomena lead to a severe degradation of the brick microstructure and consequently to a decreased lining life. Therefore, a detailed understanding of the wear mechanisms through “post mortem studies” is an important prerequisite for the refractory producer.