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Rigby copper2013 b

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Rigby copper2013 b

  1. 1. 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 Drive Moon Township, Pittsburgh, PA U.S.A.
  2. 2. 10mm. DIRECT BONDED MAGNESIA-CHROME
  3. 3. 10mm. REBONDED FUSED MAGNESIA-CHROME
  4. 4. REBONDED FUSED GRAIN CONVERTER TUYERE BRICK
  5. 5. MAGNESIA-CHROME BRICK FROM AN ANODE REFINING VESSEL
  6. 6. 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
  7. 7. 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)
  8. 8. ALUMINA-CHROME CASTABLE CONTAINING 30% Cr2O3 WITH CuO AT 1400o C FOR 5 HOURS
  9. 9. ALUMINA-CHROME CASTABLE CONTAINING 30% Cr2O3
  10. 10. ANODE MOUTH OVERLAY
  11. 11. 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 LINING WILL FURTHER IMPROVE LINING LIFE NO EVIDENCE OF ANY INCREASE DEVELOPMENT OF SOLUBLE CHROME DURING USE IN COMPARISON TO MAGNESIA-CHROME
  12. 12. CONCLUSIONS MOST SEVERE AREAS OF WEAR IN ANODE REFINING VESSELS WILL BENEFIT BY 2-2.5 TIMES IMPROVEMENT USING ALUMINA-CHROME REFRACTORY REDUCED DOWNTIME CAN ALLOW FOR SIGNIFICANT PRODUCTION INCREASE ALUMINA-CHROME NOW IN USE IN SLAGLINE OF SECONDARY RECYCLING FURNACES AND SHAFT SPENT ANODE REMELTING FURNACES.

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