The effect of phase formation during use on the chemical corrosion of magnesia–chromite refractories in contact with a non-ferrous PbO–SiO2 based slag

One of the main factors limiting the lining lifetime in pyrometallurgical smelters is continuous refractory oxides dissolution in the slag bath. The overall wear is accelerated when the slag infiltrates the porous brick and the dissolution thus occurs in a larger part of the lining. This work investigates the possibility of preventing deep infiltration by sealing off the pores with newly formed phases. Static finger tests at constant temperature (1200 °C) were performed in contact with a synthetic non-ferrous PbO–SiO2–MgO slag, showing the formation of forsterite (Mg2SiO4) throughout the refractory sample by the reaction between SiO2 (slag) and MgO (refractory). This phase grows with time, eventually sealing off the pores near the interface with the bath. The phase grows too slow to prevent full infiltration of the refractory but creates an equilibrium state in the sealed off part of the sample, ceasing the chemical corrosion in that part of the sample.