Refractory Challenges in Lead and Zinc
Furnaces
D. Gregurek, K. Reinharter, J. Schmidl and A. Spanring
Abstract Refractory linings in primary or secondary lead and zinc furnaces
like QSL reactor, KIVCET furnace, Top Submerged Lance Technology (Outotec
Ausmelt
TM /Isasmelter
TM ), TBRC/Kaldo furnaces, reverberatory furnace, and short
rotary furnace, as well as Waelz kiln, are exposed to several stresses rather complex in their interaction. In the present work, the main wear parameters, such as
corrosion by slag, high sulfur, soda and iron oxide supply as well as reduction,
are briefly introduced and discussed. The extraordinarily high SiO 2 supply results
in “forsterite bursting” combined with volume expansion. High operation temperatures in the furnace support microstructural brick degeneration. All mentioned wear
phenomena result in severe degradation of brick microstructure and consequently to
decreased lining performance. The obtained information and insights serve as a basis
for improving refractory materials to provide the best solutions for RHI Magnesita’s
customers.
Keywords Refractories · Lead and zinc metallurgy · Wear phenomena
Introduction
The profitable primary or secondary pyrometallurgical operation depends on many
factors such as furnace type, process conditions, lining design, and selection of
refractory types. Depending on the nature of the input materials, various technologies
are available for lead production, and generally primary and secondary production
routes can be distinguished. The primary route uses mainly sulfidic lead concentrates,
also with the addition of zinc plant residues or battery scrap, whereas the secondary
route processes only materials from secondary sources, especially batteries. The
traditional primary lead route is roasting-reduction/smelting (roast-reduction, i.e.,
D. Gregurek (B) · K. Reinharter
RHI Magnesita, TC Leoben, Magnesitstrasse 2, Leoben 8700, Austria
e-mail: dean.gregurek@rhimagnesita.com
J. Schmidl · A. Spanring
RHI Magnesita, Kranichberggasse 6, Vienna 1120, Austria
© The Minerals, Metals & Materials Society 2020
A. Siegmund et al. (eds.), PbZn 2020: 9th International Symposium
on Lead and Zinc Processing, The Minerals, Metals & Materials Series,
https://doi.org/10.1007/978-3-030-37070-1_2
19
Furnaces
D. Gregurek, K. Reinharter, J. Schmidl and A. Spanring
Abstract Refractory linings in primary or secondary lead and zinc furnaces
like QSL reactor, KIVCET furnace, Top Submerged Lance Technology (Outotec
Ausmelt
TM /Isasmelter
TM ), TBRC/Kaldo furnaces, reverberatory furnace, and short
rotary furnace, as well as Waelz kiln, are exposed to several stresses rather complex in their interaction. In the present work, the main wear parameters, such as
corrosion by slag, high sulfur, soda and iron oxide supply as well as reduction,
are briefly introduced and discussed. The extraordinarily high SiO 2 supply results
in “forsterite bursting” combined with volume expansion. High operation temperatures in the furnace support microstructural brick degeneration. All mentioned wear
phenomena result in severe degradation of brick microstructure and consequently to
decreased lining performance. The obtained information and insights serve as a basis
for improving refractory materials to provide the best solutions for RHI Magnesita’s
customers.
Keywords Refractories · Lead and zinc metallurgy · Wear phenomena
Introduction
The profitable primary or secondary pyrometallurgical operation depends on many
factors such as furnace type, process conditions, lining design, and selection of
refractory types. Depending on the nature of the input materials, various technologies
are available for lead production, and generally primary and secondary production
routes can be distinguished. The primary route uses mainly sulfidic lead concentrates,
also with the addition of zinc plant residues or battery scrap, whereas the secondary
route processes only materials from secondary sources, especially batteries. The
traditional primary lead route is roasting-reduction/smelting (roast-reduction, i.e.,
D. Gregurek (B) · K. Reinharter
RHI Magnesita, TC Leoben, Magnesitstrasse 2, Leoben 8700, Austria
e-mail: dean.gregurek@rhimagnesita.com
J. Schmidl · A. Spanring
RHI Magnesita, Kranichberggasse 6, Vienna 1120, Austria
© The Minerals, Metals & Materials Society 2020
A. Siegmund et al. (eds.), PbZn 2020: 9th International Symposium
on Lead and Zinc Processing, The Minerals, Metals & Materials Series,
https://doi.org/10.1007/978-3-030-37070-1_2
19