rigby copper2013 b

THE USE OF ALUMINA-CHROME REFRACTORIES IN THE HIGH WEAR

AREAS OF ANODE REFINING VESSELS 

A. J. Rigby 

Harbison Walker Refractories, Cherrington Corporate Center,

400 Fairway DriveMoon Township, Pittsburgh, PA U.S.A.

10mm.

DIRECT BONDED MAGNESIA-CHROME

10mm.

REBONDED FUSED MAGNESIA-CHROME

REBONDED FUSED GRAIN CONVERTER TUYERE BRICK

MAGNESIA-CHROME BRICK FROM AN ANODE REFINING VESSEL

ALUMINA-CHROMIA REFRACTORY• AREAS OF SEVERE WEAR IN CONVERTER AND

ANODE VESSELS GENERALLY DUE TO PENETRATION AND SPALLING OF ALTERED BRICK

• IMPROVEMENTS IN REFRACTORY LIFE WILL BE DICTATED BY REDUCING OR ELIMINATING THIS PENETRATION

• LABORATORY TESTING CANNOT REPLICATE THESE WEAR MECHANISMS

ANODE REFINING VESSEL REFRACTORY ISSUES

• WEAR AREAS AT THE TUYERES, SKIMMING MOUTH AND TAPHOLE

• TYPICALLY NEED MAINTENANCE EVERY 3-4 MONTHS

• SPECIFICALLY FOR THREE VESSELS DOWNTIME TO REPAIR REQUIRES 8-9 WEEKS OF LOST PRODUCTION (IF THERE IS NO SPARE VESSEL)

ALUMINA-CHROME CASTABLE CONTAINING 30% Cr2O3 WITHCuO AT 1400oC FOR 5 HOURS

ALUMINA-CHROME CASTABLE CONTAINING 30% Cr2O3

ANODE MOUTH OVERLAY

REPLACEMENT OF REBONDED FUSED GRAIN MAGNESIA-CHROME BRICK BY ALUMINA-CHROME GAVE UP TO 250% PERFORMANCE INCREASE

INCREASED PRODUCTION IN THE PLANT OF ~16,000MT OF ANODE COPPER

EVIDENCE THAT HIGHER CHROMIC OXIDE LININGWILL FURTHER IMPROVE LINING LIFE

NO EVIDENCE OF ANY INCREASE DEVELOPMENTOF SOLUBLE CHROME DURING USE IN COMPARISON TO MAGNESIA-CHROME

CONCLUSIONS

MOST SEVERE AREAS OF WEAR IN ANODE REFININGVESSELS WILL BENEFIT BY 2-2.5 TIMES IMPROVEMENTUSING ALUMINA-CHROME REFRACTORY

REDUCED DOWNTIME CAN ALLOW FOR SIGNIFICANTPRODUCTION INCREASE

ALUMINA-CHROME NOW IN USE IN SLAGLINE OF SECONDARY RECYCLING FURNACES AND SHAFTSPENT ANODE REMELTING FURNACES.