A Chromium‐Free Fe‐Added MgO–SiC–C Refractory With Superior Dynamic Matte Slag Corrosion Resistance

Abstract

ABSTRACT To develop a chromium‐free alternative to MgO–Cr 2 O 3 refractories for matte smelting furnaces, this study investigated three novel MgO–SiC–C refractories (with Fe, Si 3 N 4 , or Si 3 N 4 –Fe additions) via induction furnace tests simulating actual smelting. Results showed MgO–Cr 2 O 3 sample had poor slag penetration resistance due to a porous layer filled with low‐melting (Mg 1 − x , Fe x ) 2 SiO 4 , impairing stability and allowing partial Cu 2 S penetration. The Fe‐containing MgO–SiC–C sample exhibited superior dynamic corrosion resistance (comparable to MgO–Cr 2 O 3 , better in penetration resistance), attributed to low porosity, protective Mg(Fe, Al) 2 O 4 and MgAl 2 O 4 phases, Fe–Si alloy void filling, and graphite‐inhibited Cu 2 S penetration. Si 3 N 4 ‐containing samples degraded dynamically (despite good static slag resistance) as Si 3 N 4 formed low‐melting (Mg 1 − x , Fe x ) 2 SiO 4 , weakening stability. Overall, the Fe‐containing MgO–SiC–C refractory is a promising chromium‐free alternative for matte smelting furnaces.