The Evaluation of Chemical Wear of Carbon-Based Tap-Hole Refractories in Ferrochrome Production

In ferrochrome (FeCr) production, the tap-hole refractory represents the highest wear area. Preliminary desktop FactSage modelling work conducted by Steenkamp (J South Afr Inst Min Metall 119(8):537-544, 2019) indicated that both alloy and slag had the potential to chemically wear the carbon-based tap-hole refractory material. The current study sought to build on the modelling work, by performing laboratory-scale experiments aimed at validating the modelling outcomes. Experimental work was conducted using a cup test approach, in an induction furnace, at 1450-1650 degrees C for the alloy-refractory, and 1550-1700 degrees C for the slag-refractory. Experimental results confirmed the potential for both FeCr alloy and slag to chemically wear the refractory. Tapping temperature was also found to have a marked effect on the extent of the wear.