Alumina-chrome refractories can significantly improve wear resistance in high-wear areas of anode refining vessels compared to traditional magnesia-chrome refractories. Specifically, replacing rebonded fused grain magnesia-chrome brick with alumina-chrome refractory at the tuyeres, skimming mouth, and taphole led to up to 250% increased refractory life and allowed for increased annual copper production of 16,000 metric tons due to reduced vessel downtime for repair. Testing also showed no increased leaching of soluble chrome from the alumina-chrome refractory compared to magnesia-chrome.

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.

5. 10mm.
DIRECT BONDED MAGNESIA-CHROME

6. 10mm.
REBONDED FUSED MAGNESIA-CHROME

7. REBONDED FUSED GRAIN CONVERTER TUYERE BRICK

8. MAGNESIA-CHROME BRICK FROM AN ANODE REFINING VESSEL

10. 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

11. 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)

14. ALUMINA-CHROME CASTABLE
CONTAINING 30% Cr2O3 WITH
CuO AT 1400o
C FOR 5 HOURS

15. ALUMINA-CHROME CASTABLE CONTAINING 30% Cr2O3

21. ANODE MOUTH OVERLAY

23. 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

24. 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.