Interfacial reaction between magnesia refractory and “FeO”-rich slag: Formation of magnesiowüstite layer

Abstract This study investigated the reaction between CaO-SiO2-Al2O3-xFeO-MgO-MnO (CaO/SiO2 = 1.2, x = 20–50 wt%) slag and magnesia refractory. Using SEM-EDS analysis, we confirmed the formation of a (Mg,Fe)Oss(solid_solution), called magesiowustite (MW), intermediate layer at the slag-refractory interface. MgO dissolved from refractory and reacted with the bulk slag to form MW layer at the interface. Simultaneously, slag penetrated through micro-pores and reacted with the refractory to form MW layer. In other words, the MW layer built up in both directions from initial refractory-slag interface. The thickness of the MW layer increased as the FeO content in the slag increased, and using EDS line scanning, a Mg and Fe concentration gradient was confirmed within the MW layer. The slag, which penetrated into the refractory, had a chemical composition of the CaO-SiO2-Al2O3-MgO system without FeO, indicating that FeO was consumed by forming a MW layer at the refractory hot face. The slag-refractory interfacial reaction was simulated using thermochemical software, FactSage™7.0. The results predicted a MW monoxide composed of MgO and FeO. A spinel phase was formed when FeO was greater than 40 wt%. These thermochemical computations were comparable to our experimental findings.