Mining of Mineral Deposits

DNIPRO UNIVERSITY Volume 15 (2021), Issue 3, 71-77

MMD
JOURNAL / MINING.IN.UA
of TECHNOLOGY
1899

UDC 66.043.1 https://doi.org/10.33271/mining15.03.071

Substantiation of refractory lining influence on the electric

furnace efficiency for the production of ferronickel

Nurten Deva1 , Izet Ibrahimi1*

1University
Isa Boletini in Mitrovice, Mitrovice, 40000, Kosovo
*Corresponding author: email: [email protected], tel. +38344174266

Abstract
Purpose. The purpose of the research is to substantiate the possibility of replacing existing MgO bricks with the MgO-C
bricks due to their resistance to the slag aggressiveness of the electric furnace and the Si content in the resulting metal,
which can have a positive effect on reducing the consumption of refractory materials.
Methods. This research will be presented as the results of theoretical and experimental data determining the dependence of
the electric furnace on the type of refractory material, walls construction, operating parameters and the electric furnace lin-
ing, that are expected to have a major impact on the cost output of production process.
Findings. Based on the presented results, it has been revealed that MgO-C bricks are more effective in terms of preventing
the furnace damage depending on refractory materials. Therefore, to optimize the production process, it is recommended to
improve the composition of melted metal and slag, as well as to strengthen the control of the process parameters.
Originality. Laboratory analyses are conducted in specialized laboratories, and the presented data have been obtained
through the use of devices and equipment required for experimental research.
Practical implications. The refractory materials are one of the main indicators of technical performance and production
costs at NewCo Ferronickel in Kosovo. Therefore, the higher performance of the refractory lining will have a positive effect
on the furnace durability and the quality of the final product.
Keywords: ferronickel, refractory materials, slag, optimization, graphite blocks

1. Introduction The proposed replacement of magnesite bricks with

MgO-C bricks is related to an increase in the chemical stabi-
Laterite nickel ores are a very important part of the
lity of graphite blocks and, in general, with the optimization
world’s nickel reserves. The nickel content in laterite ore is
of the production process. Therefore, it is recommended to
usually low and is in the range of 0.8-3% [1].
improve the composition of the melted metal and slag, as
The pyrometallurgical process for ferronickel production
well as to strengthen the control of process parameters.
at NewCo Ferronickel foundry is very complex as it is ac-
This research provides some important recommendations
companied by high temperature, use of metal with a high Si-
for ferronickel production when smelting in RKEF and indi-
content, low C-content, very aggressive immiscible slag
cates the importance of refractory lining wear in electric
layers with huge consumption of refractory materials and low
furnaces. The conditions have been determined, including
level of production capacity utilization. The conventional
reducing parameters (temperature and time of roasting) and
Rotary kiln-electric furnace (RKEF) is now a worldwide
smelting parameters (coke dosage, CaO dosage, temperature
widespread process for ferronickel production from nickel
and time of smelting).
oxide laterite ore, despite its high power consumption. The
The electric furnace is a main equipment used in this
same production process for ferronickel production is used in
chain of Fe-Ni production. Therefore, refractories materials
the Ferronickel foundry in Drenas [2].
that are used in an electric furnace must fulfill the following
The pyrometallurgical method for obtaining ferronickel
basic functions, such as:
from oxide-laterite ores, regardless of the degree of technical
– to act as a thermal barrier between a hot medium (e.g.,
and technological improvement, even in newer processes, has
flue gases, liquid metal, molten slags and molten salts) and
many unresolved technical and technological problems. The
the wall of the containing furnace;
company faced a number of problems related to the influence
– to represent a chemical protective barrier against corrosion;
of refractory lining on the efficiency of electric furnace.
________________________________
Received: 8 June 2021. Accepted: 7 August 2021. Available online: 22 September 2021
© 2021. N. Deva, I. Ibrahimi
Published by the Dnipro University of Technology on behalf of Mining of Mineral Deposits. ISSN 2415-3443 (Online) | ISSN 2415-3435 (Print)
This is an Open Access article distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0/),
which permits unrestricted reuse, distribution, and reproduction in any medium, provided the original work is properly cited.

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N. Deva, I. Ibrahimi. (2021). Mining of Mineral Deposits, 15(3), 71-77

– to ensure a reliable physical protection, preventing the Ore analyses

CaCO 3 Reductant
analyses analyses
walls from erosion by the circulating hot medium;
– to act as thermal insulation, providing heat retention [3].
The practice of using refractory lining in electric furnaces Rotary furnace
is solely based on the behavior of various refractories used in
different parts of the furnace at elevated temperatures. The
selection of the correct refractory lining pattern is usually Electric furnce
based on conventional concepts; therefore, this element of Tem peratures analyses
Metal Slag analyses (acidity (cover, lining tem p.
the furnace is the most important factor, ensuring high pro- analyses of furnace slag) sidelining and bottom)
duction efficiency [4].

2. Methodology
The refractory lining of the electric furnace consists of Refractory certifications/attests
three main parts: floor/bottom, vertical walls and roof.
According to the engineering specification, the permanent Chemical and physical Mineralogical examination
ex amination of the lifespan/
bottom of lining is made of magnesia bricks (Sitmag-N, durability of the refractory wear
of fire -resistant wear
IL-76, Keiltein, I-76, SA-I), while the working layer of the
lining bottom is made of magnesia bricks (KELL). The lower Figure 1. Flowchart for the research methodology
part of the vertical wall is made of special magnesia bricks
The verification of these performance indicators is based
(ANKERDIB/B, ANKER-WIH/B, Sit Mag. VPK “S”). The
on certificates/attests of refractory materials, chemical analy-
smelting bath is made of graphite blocks, while the upper
sis of the charge, electric furnace products and other techno-
part of the vertical wall is made of magnesia bricks (Sitmag
logical materials. Other indicators of the production process
VPK and SA-O). The roof, which is under the exposure of
performance at the Ferronickel foundry in Drenas have been
erosive and chemical gasses, is mostly made of magnesia
also determined by a comparative method. Comparison of
bricks (MSA4, HI4DA-300, MSA2, etc.) SGL Carbon Group
outputs, process parameters and production practices is based
and NewCo Ferronikeli [5].
on an analysis of production period from October 2019 to
Each of these zones has its own specificity and diversity
May 2020. Given the fact that refractory materials after elec-
of strains, but the most specific zone of operation is the
tricity are the main indicators that affect the EF optimization
smelting zone – the working bath. This zone is exposed to
and in general the optimization of the ferronickel production
mechanical strains, high temperatures, extreme influence of
process, then, to determine the lifespan/durability of the
vibrations and corrosion of metal with a low C-content, high
refractory cover, the operating parameters (chemical, thermal
Si-content and a very aggressive acidic slag. Thus, as a result
and technological), as well as the quality/properties and the
of this concentration of molten crude metal, the three zones
content of refractory materials, have been studied.
of the electric furnace are exposed to the influence of a
strong oxidizing environment. Although the carbon oxidation
of graphite in the burnt ore zone is minimal, at a temperature 3. Results and discussion
of 1300°C this reaction begins to develop rapidly, which 3.1. Features of the wear of the electric furnace refractory
affects the extreme corrosion of graphite blocks and magne- Magnesia (MgO) bricks are known as refractory mate-
sia or magnesia-chrome bricks in the zone between the slag rials with a magnesium oxide content of more than 90% and
and the crude metal. The digestion of carbon from graphite are made of periclase. Periclase is the only stable MgO modi-
and magnesite occurs due to the formation of carbides: SiC, fication. These refractory materials are resistance to the ac-
CoC and CrC of metals. Si, Co, and Cr are impurities of tion of alkaline slags and melts containing iron oxides. This
crude metal of the electric furnace. Decarburization of refrac- property is based on the phase conditions in the MgO-FeO
tory lining with carbon composition in the smelting zone is and MgO-Fe2O3 systems. MgO creates with FeO a full range
one of many difficult problems. Although decarburization of of magnesiowustite solid solutions ((Mg, Fe)O). In the sys-
the refractory materials still depends on many unresolved tem, CaO is replaced by MgO, since it is also a highly alka-
issues, it has allowed limited use of graphite blocks and line, technically pure, readily available oxide with high sta-
MgO-C bricks in the electric furnace for the ferronickel pro- bility and a smelting point of 2625°C. Depending on the
duction in Drenas-Kosovo. degree of reactivity, technical magnesium oxide can be di-
The smelting point of magnesia (MgO) or magnesia- vided into calcined, sintered, melted [7].
chromite refractories ranges from 1700 to 2100°C, with the The similar problems are associated with magnesia-
exception of carbon-based and graphite-based materials chrome refractory bricks, which are composed of MgO-Cr2O3
which can withstand temperatures from 2200 to 3000°C. with 17-20% of Cr2O3. Carbon-graphite refractory materials
A special characteristic is a metal with a high Si-content are ceramic materials composed of only one chemical ele-
(on average 2.2-2.8%) and a low C-content (on average ment. Carbon materials are amorphous, while graphite has a
0.3-0.6%). Occasional peak values of 3.5% Si are possi- specific crystalline structure. Graphite refractory materials
ble [6]. Due to the high Si-content in the crude metal, the can be natural and artificial. As a raw material for the pro-
furnace slag has a high acidity. Determining the dependence duction of carbon refractories, metallurgical coke, petroleum
of the electric furnace (EF) efficiency on the type of refracto- coke, heat-treated coal tar pitches and like can be used. These
ry material, the composition of the melted products, as well types of refractory are graphitized – manufactured in Ache-
as other operating parameters, will be performed on the basis son resistance furnace or by graphitization with a direct cur-
shown in Figure 1. rent flow in a continuous graphitization furnace [8].
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N. Deva, I. Ibrahimi. (2021). Mining of Mineral Deposits, 15(3), 71-77

Naturally occurring flake graphite or artificial graphite is 3.2. Operating mechanisms and their influence
sometimes mixed with amorphous carbon to achieve the on the refractory lining efficiency
desired thermal conductivity. These materials are combined Direct smelting technology is used in electric furnace of
with high-carbon resins or pitch and formed into blocks and NewCo Ferronickel foundry. After electricity, refractory
slabs [3]. These materials have been used as refractory lining materials are the main indicators of technical performance
for blast furnaces, electric furnaces, and other metallurgical and production costs at NewCo Ferronickel in Kosovo. The
equipment. Due to excellent corrosion resistance, high thermal traditional method of refractory masonry in an electric fur-
conductivity, low thermal expansion, high thermal shock re- nace is based on magnesia (MgO), magnesia-chromite
sistance and chemical inertness to slag, these materials are used bricks, and graphic blocks, which have a positive effect on
for bottoms of refractory lining: Si, FeSi, FeNi, FeMn etc. [9]. the service life of the furnace. However, the performance of
Table 1 and 2 show several properties of magnesia-carbon the refractory lining depends on the composition of the melt-
bricks and graphite blocks. These data correspond to technical ed products, operating parameters and the construction of the
information by SGL Carbon Group and Magnezit Group. electric furnace lining. Figure 2 shows charge analysis and
Table 1. Technical data of MgO-C bricks Table 3 shows the typical operational indicators of the crude
Description A B C ferronickel production process.
MgO, % 98 > 97 > 96 50
Al2O3, % 0.1 < 0.2 < 0.2 45
Fe2O3, % 0.4 < 0.6 < 0.6 40
CaO, % 1.1 > 0.8 > 0.8

Concentration , %
35
SiO2, % 0.4 < 0.4 < 0.4 30
C-residual, wt % 14 > 12 >7 25
Bulk density, g/cm3 2.97 > 2.99 > 2.90 20
Apparent porosity, vol % 4 <5 <7 15
10
Cold crushing strength, N/mm2 > 30 > 30 > 30
5
Thermal mechanical properties
0
500ºC 11 Ni Co SiO 2 Fe 2O3 CaO MgO Al2 O3 Cr 2O3 S, P, C
Thermal conductivity, W/(m⋅K)
1000ºC 9 Charge 1.24 0.07 47 24 0.27 8 2 1.1 0 .027
Coefficients of linear
8.6-11.3 · 10 -6
Figure 2. Analysis of the dosed charge in an electric furnace
thermal expansion, (K-1)
Table 2. Technical data of carbon and graphite blocks Table 3. Typical operational indicators of the ferronickel produc-
Semi High thermal tion process in the foundry
Graphite
Description graphite conductivity Content value
block
block block No. Operational indicators
min max
Fixed carbon, max % 78 98 –
1 Specific power, KW/m2 167.5
Ash, max % 8 0.5 –
2 Dry ore capacity, t/24 h 1476
Bulk density, g/cm3 1.50 1.52 1.65
The composition of the dry ore:
Open porosity, % 20 20 18
Compressive strength, Ni + Co, % 1.39
30 19.6 30 3
max MPa Fe, % 18
Bending strength, max MPa 8 7.8 8 SiO2, % 46
Thermal conductivity, W/m·K – – > 30 The composition of the crude metal:
Coefficients of linear Ni, % 11.33 15.3
8.6-11.3 · 10-6 Co, % 0.30 0.40
thermal expansion (K-1)
Melting index of liquid iron, max % 32 4 Si, % 2.0 3.5
C, % 0.3 0.6
Carbon is a preferable element for use in refractory mate- S, % 1.3 2.02
rials, since it is not wetted by most molten metals and slags, Fe, % 78 73
has excellent resistance to thermal shock and its strength is The composition of the EF-slag:
increased when heated [3]. These types of materials have a SiO2, % 52 62
5
tendency to oxidize, so this refractory should be used under FeO, % 17 20
reducing conditions. According to theoretical data, under MgO2, % 7 15
conditions of a high oxidizing environment, the process of Temperature of:
carbon oxidation of the refractory lining begins at 350°C. To Fire ore, °C 750
minimize this oxidation effect of the refractory lining and for 6 Ferronickel, °C 1380
shaping, it is currently preferred to add oxidation inhibitors Slag, °C 1500
such as boron carbide, fine metals (Al, Si, and Mg) or by Gas, °C 900
coating the mold with a protective glaze. Metal smelting Specific energy
7 630
consumption, KW/t ore
crucibles made of clay-graphite were used as they had graphite
The composition of gas:
shapes such as stopper rods and sleeves. Clay-graphite shapes
CO, % 45-60
have been replaced, for the most part, by alumina-graphite 8 CO2, % 35-70
molds, which provide a longer service life. Clay-graphite SO2, SO3, % 0.1
shapes have been replaced, for the most part, by alumina- Other, % 2.9
graphite shapes which provide longer service life [3]. 9 Dust, g/mm3 50
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N. Deva, I. Ibrahimi. (2021). Mining of Mineral Deposits, 15(3), 71-77

Kosovo lignite is used as a reducing agent, which is

characterized by a low Cfix composition and a high ash com-
position. Among other things, this type of reducing agent
also has a low reducing capacity [10].
The low degree of reduction in an electric furnace is one
of the parameters that directly affects the operating environ-
ment and creates different phase relationships for the process
products. In cases where the low degree of reduction of metal
oxides and incomplete disintegration of Cfix and C of refrac-
tory lining prevail over the smelting process, one part of the
burnt ore in the furnace will be oxidized, while the other part
will be sintered. In this case, except for the Cfix reduction
from the reducing agent, a portion of C from the graphite
blocks will also be oxidized. In addition to graphite, the Figure 5. The damages of the refractory lining in the electric
carbonaceous binder system of magnesia bricks is also oxi- furnace No. 2
dized. As a result, refractory materials lose their ability to
inhibit wetting, and opened pores contribute to a more inten- It has been observed from industrial experience and
sive penetration of slag. It is well known that iron oxide is measurements that the resistance of the graphite blocks to the
able to dissolve in MgO crystals [11]. impact of water is very good. But, eventually, the water re-
Figure 3 shows the chemical composition of the slag mained in the electric furnace, and this amount was absorbed
from the smelting of nickel oxide ores in the electric furnaces by the magnesium material according to the reaction:
of the Ferronickel foundry in Drenas. MgO + H2O = Mg(OH)2. (1)
5.0 But, in many furnace environments oxygen activity is
4.5 high enough to be involved in the corrosion process of re-
4.0 fractory lining. High oxidation activity is associated with a
3.5
highly oxidizing environment, while low oxygen activity is
SiO2 /CaO+MgO

3.0
associated with a reducing environment, which is controlled
2.5
by the ratio of CO/CO2 or H2/H2O in this environment [12].
2.0
Although from a practical point of view, such reactions
1.5
1.0
SiO 2/CaO +MgO would stimulate corrosion of graphite blocks, however, CO
0.5 due to the reduction of oxides and self-oxidation as a result
0.0 of the reaction has little effect; (2CO (g) ↔ C (s) + CO2),
corrosion of mortar and graphite blocks occurs. In this case,
Time, day
above all, the catalytic effect depends on Fe from a poor
Figure 3. Chemical analysis of slags metal with C, the catalytic ability of which depends on the
composition of C in the metal (the maximum catalytic effect
Figure 4 presents the thermal variations in furnace of Fe corresponds to the Fe3C form) [13].
components such are the sides and bottom of the furnace, Corrosion of a refractory material, the structures of which
which are influenced by temperature. are saturated with carbon, develops in two stages [14]; oxida-
tion of a brick matrix under the action of free oxygen during
2000 digestion and formation of a decarburization zone and de-
Co v er temper.
1800 composition of MgO, as well as oxidation of C from refrac-
Lin ing temperature sidelining tory materials with a C content in the decarburization zone.
1600
Lin ing temperature bottom At high temperatures, in addition to the corrosion of the
Temperature оC

1400 refractory material under the action of slag, simultaneously

1200 with 1450°C, different reactions may develop:
1000 C + SO2 = CO + SO; (2)
800
C + SiO2 = CO + SiO; (3)
600
CO2 + C = 2CO; (4)
400
9 19 9 0 20 20 0 0
t -1 v- c-1 n -2 b- ar- r-2 ay
-2 SiO + 3CO = SiC + 2CO2; (5)
Oc No De Ja Fe M Ap M
2SiO2 + SiC = 3SiO + CO; (6)
Figure 4. Temperature (°C) during the research period in the
three main parts of the furnace C + MgO = CO + Mg. (7)
The process, which would guarantee sufficient chemical
From density measurements in the temperature range of
stability of the graphite blocks, will take place when the
700-800°C, it follows that magnesium oxidation in this range
metal temperature is between 1450 and 1500°C, while the
is slow, while in the temperature range of 1000-1100°C this
slag temperature should be maintained at 50°C above the
oxide is very intense, and then chemical stability is observed.
metal temperature. The boundary between the temperature of
Figure 5 shows the damages of the refractory lining in the
a liquid and a solid is within narrow limits, which theoreti-
electric furnace 2.
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N. Deva, I. Ibrahimi. (2021). Mining of Mineral Deposits, 15(3), 71-77

cally stimulates SiO2 interaction with other basic oxides, and Figure 6 shows the BC – II1 and II3 samples taken from
especially the interaction between CaO and MgO. For tem- slag bath of electric furnace No. 2 (BC – is the symbol of the
peratures higher than the temperature of the liquid, the size blocks used in the company). A corrosive structure is ob-
of SiO4- and other smelting anions, as well as the electrostat- served at a depth of about 80 mm and a length of about
ic forces between cations and anions, play a decisive role in 400 mm from the face side between the graphite block and
the viscosity of the slag, especially for its reactivity. Ferro- the magnesia bricks. No penetration of crude metal is ob-
nickel with a composition below 1.25% is considered a poor served, but corrosion resulted from the digestion of carbon
carbon metal, which at a temperature of 1150°C (in the fire from the graphite block in the area of contact with the molten
zone) simulates the carbon digestion reaction in the metal, metal. This is presumably due to the fact that NewCo Ferro-
while a fast reaction begins at 1300°C. nickel crude metal has rather low carbon content, on average
The main reaction is Fe and Ni carbonation from graphite 0.3-0.5%, and in this case, the digestion of the refractory
carbon: material carbon in the molten metal will increase.
3Fe + 2CO = Fe3C + CO2; (8)
3Ni + C = Ni3C. (9)
These reactions occur at high temperatures, and nickel
carbide is unstable in an oxidizing environment because it
easily reacts with nickel oxide. In this case, dissolution oc-
curs of NiC and C on the refractory lining with the formation
of SiC, CoC and CrC, but the products of these reactions
have little effect on the corrosion of graphite blocks.
3.3. Influence of operating conditions
on the electric furnace lining Figure 6. Measurement of dissolution of graphite blocks II3 and
In fact, it is only in the slag zone of the furnace that II1 in contact with a metal with a low C-content
graphite blocks are used, which generally have highly acidic
slag resistance and other good mechanical properties, but Figure 7 shows the type of bricks on the bottom of the
show weak chemical stability in contact with molten metal, working lining without graphite blocks and the chemical
since it is characterized by a low C-content. From the results composition of these types of refractory bricks prior to use in
of research on the operating conditions influencing on the an electric furnace. Figure 8 shows structural roentgen analy-
service life of MgO, Mg-Cr and graphite bricks, is noted that sis of the brick face. For analysis, a brick sample is selected,
highly acidic slag and poor crude metal with carbon have the faces of which are in contact with molten products.
a major influence on corrosion and other proprieties of 100
refractory materials. 90
Table 4 compares the technical properties of graphite 80
Composition, %

70
blocks used in an electric furnace. Graphite blocks are pro- 60
duced by SGL Carbon Group. Blocks of this type have been 50
developed to improve corrosion resistance; their high corrosion 40
30
resistance is mainly due to the formation of a protective layer
20
on the hot face in direct contact with the molten metal [5]. 10
0
Table 4. Typical properties of used graphite blocks in Fe-Ni- Fir.Los. SiO 2 Fe 2O3 Al2O3 CaO MgO Cr2 O3 TiO2
electric furnace Mg brc. Kell 50 1.04 0. 66 10. 66 5. 04 1.54 62. 7 19 0. 21
Mg brc. VPK
Comprehensive

0. 1 3 2.76 0.2 2.38 91. 6 0.16 0.1

permeability
coefficient
Expansion

Mg brc. Kell DH 0.48 0. 54 0.01 0.1 2.15 96. 2 0.11 0.1

Samples

Thermal
Porosity

strength
Density
Block

Mg-Cr brc. Wacher 0 1 4. 1 3. 53 0. 9 77 14 0.1

Mg-Cr brc. Rad ex 0.12 0.9 13.1 5. 48 1.53 62 17.5 0. 27
Mg-Cr brc. VPS-K 0 2.4 7.15 4.3 1. 13 63. 1 21.7 0.1

DIN DIN DIN DIN DIN Figure 7. Type and chemical composition of refractory materials
Standards
51918 51918 51910 51909 59908 before use in an electric furnace
No. No. g/cm3 % N/mm2 µm/K-m) µm/K-m)
1.1 1.67 20 28.3 2.5 156 For structural analysis, samples are selected in the area of
1 1.2 1.67 20 26.6 2.3 the working bath between the carbon blocks and magnesia
1.3 1.66 20 25.3 2.4 bricks. Photomicrograph images of a RB KELL 50, GB in
2.1 1.68 20 35.1 2.9 contact with highly acidic slag and molten metal of FeNi in
2.2 1.65 20 32 2.9 151 the electric furnace. Distribution of Mg, Si, Fe, and Ni on the
2
2.3 1.66 20 28.5 2.9 observed surface of RF-1, 2 KELL 50 and BC in contact
2.4 1.67 20 29.1 3 with crude metal is shown in Figure 8.
3.1 1.65 21 29.1 2.7 As a result of chemical analysis of the refractory material
3.2 1.65 21 26.7 2.8 138 samples used in the electric bath (Fig. 9), one can see the RF-6
3
3.3 1.65 21 26.6 2.8 sample with a high FeC content, in which the face of the brick
3.4 1.64 21 23.3 2.7 or graphite block is in contact with molten metal. In this case,
Average 1.66 20.4 28.4 2.7 148 the molten metal has a high Si-content and low C-content.
75
N. Deva, I. Ibrahimi. (2021). Mining of Mineral Deposits, 15(3), 71-77

Figure 8. Photomicrograph images

100 Figure 10. New lining made of MgO - antioxidant bricks

90
80 According to the research results of the chemical corro-
Composition, %

70
60
sion of graphite blocks, it has been revealed that the main
50 damage is in the zone of the molten metal. This damage is
40 caused by the digestion of carbon from the graphite block in
30 molten metal with a low C-content.
20
10
4. Conclusions
0
SiC FeO T - FeC CaO MgO T - Ni
In terms of operational indicators, it can be concluded
RF K-1 9 3. 7 0.5 2.4 84.5 0.06
that the FeNi-electric furnace operates under the influence of
RF K -2 12.6 5.05 0.8 2. 88 71.3 0.04
slag with high SiO2-content, metal with low C-content and
RF K-3 0. 2 20.3 2.2 2. 33 58 1.02
high Si-content, high temperatures and a very high oxidizing
RF K-4 3 15 0.3 3. 26 72.5 2. 5 atmosphere. To optimize the process and increase the service
RF K-5 8. 4 5.61 0.6 2. 86 83 0.09 life of refractory lining, carbon blocks have been used in
RF K-6 2. 7 12 41. 1 6.1 52.7 0.25 electric furnaces for several years.
Under operating conditions, when the smelting bath oper-
Figure 9. SiC, FeC and other compositions of used refractory ates with metal of low C-content and has a high tendency to
materials in an electric furnace
dissolve the carbon of the graphite blocks, replacing the
current refractory materials with composite refractory mate-
The smelting bath of the electric furnace is constantly rials based on MgO-C to improve the electric furnace tech-
exposed to highly aggressive acidic slag, oxidizing environ- nical performance would be the best solution.
ment, high temperatures and corrosion of molten metal with Refractory wear is identified as sections of the refractory
low C-content. A specific feature of the NewCo Ferronikeli that are either delaminated or extensively immersed in molten
crude metal is a rather high SiO2 content, on average metal. Impregnation occurs when the molten material infil-
52-62%. These types of slags are acidic (on average FeO ~ trates into the refractory matrix. In this case, this leads to sev-
20%, MgO ~ 15%) and are characterized by a high degree of eral changes in the refractory material properties; therefore, to
aggressiveness. This aggressiveness depends on the content avoid such problems, it is necessary to carefully consider the
of SiO2, which is the main component of the slag. SiO2 inte- use of proper bricks in the smelting zones of electric furnace.
racts with oxides (CaO, FeO, MgO, MnO, etc.), forming the Regular inspections of the furnace refractory is proposed,
systems: MgO, SiO2, 2CaOFeSiO2, MgO-FeO-SiO2, etc., which provides information on the current situation, and, in
included in the mineralogical composition of galenite, acan- addition, shows the degree of wear and critical points of wear
thite, dicalcium silicate and other minerals [15]. of the damaged furnace lining. These results are important to
This attribute depends on the SiO2 content and is the the maintenance schedule and can improve the efficiency of
main component of electric furnace slag. SiO 2 content is the the process in terms of refractory materials.
main indicator influencing on the operating conditions of Based on theoretical aspects and from technical report
the refractory lining. When analyzing the thermophysical No. 98, this type of material and especially some of the car-
parameters of the electric furnace coating, when the furnace bon blocks have been developed through measures such as:
power exceeds 20 MVA during the process of burning or – addition of fine alumina, which has high resistance to
with a high SiO2 content, the magnesia bricks shown weak- hot metal;
ness in oxidizing environments. In particular, they show – reduction of pore diameters to prevent penetration of
poor resistance to water activity. The operating environ- foreign substances and the hot metal;
ment also negatively affects the chemical stability of even – increase in thermal conductivity to reduce the hot face
graphite blocks, especially when exposed to CO2, air, and temperature to improve corrosion resistance [10];
CO. Figure 10 shows a new lining made of MgO- – a flat floor will be a constructive solution for furnace bath;
antioxidant brick that has proven successful during applica- – use of lignite with a higher Cfix-content;
tion in furnace zones where the refractory lining is exposed – creation of a protective layer from a “solid metal”
to an oxidizing environment. covering the bath walls in the smelting zone.

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N. Deva, I. Ibrahimi. (2021). Mining of Mineral Deposits, 15(3), 71-77

Acknowledgements [6] Schemmel, T.H., Schade, L., Kouzoupis, P., & Beqiri, F. (2013).
Magnesia-carbon refractory lining for ferronickel converters-
The authors of this paper express their gratitude to the optimization and lining improvement at NewCo Ferronikeli (Kosovo).
Ferronickel Laboratory personnel and all other participants The Thirteen International Ferroalloy Congress, Efficient Technolo-
gies in Ferroalloy Industry. Almaty, Kazakhstan.
of this project for their support and assistance in the success- [7] Ovčačik, F., & Ovčačikova, H. (2015). Technology of refractory
ful completion of this research. We also express our deep materials and heat insulating materials. Ostrava, Czechia: Technical
respect and special gratitude to the editorial staff for the University of Ostrava.
opportunity to cooperate in the publication of this paper. We [8] Trisvetov, A. (2012). The use of graphite in the refractory. Industry
Magnezite Group.
are grateful to colleagues from NewCo Ferronickel for their [9] Geerdes, M., Chaigneau, R., & Kurunov, I. (2015). Modern blast
support and great help in research work. furnace ironmaking: An introduction. Amsterdam, the Netherlands:
IOS Press. https://doi.org/10.3233/978-1-61499-499-2-i
References [10] Ibrahimi, I., Deva, N., & Mehmeti, S. (2020). Optimalization of the
ferronickel production process through improving desulfurization ef-
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special melting technologies GmbH, Bruck/Mur, Austria. The Thir- https://doi.org/10.28991/cej-2020-03091516
teenth International Ferroalloys Congress Efficient Technologies in [11] Schacht, C.A. (2004). Refractories handbook. New York, United
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[2] Guanghui, L., Hao, J., Peng, Zh., Zang, Y., & Jiang, J. (2016). Ferro- [12] Meettham, G.W., & Van de Voorde, M.H. (2000). Materials for high
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[3] HARBISON-WALKER Handbook of refractory practice Harbison. [13] Wilkening, S. (2020). Testing of the alkali sensitivity of carbon and
(2005). Moon Township, United States: Walker Refractory Company. graphic martials. Bonn, Germany: Vereinigte Aluminium-Werke.
[4] Narasimham, A.V.L. (2007). Refractory lining failures in FECR fur- [14] Vullkov-Husovič, T. (2007). Vatrostalni materiali svojstva i primena.
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products for furnace linings. (2007). Made by SGL CARBON GROUP blocks for blast furnace hearths. Nippon Steel Technical Report No. 98.
dhe New Co “Ferronickel”, Glogovc.

Обґрунтування вогнетривкої футеровки, яка впливає на ефективність

використання електропечей для виробництва феронікелю
Н. Дева, І. Ібрагімі
Мета. Обґрунтування можливості заміни існуючої цегли MgO цеглою MgO-C через її стійкість до жорсткого впливу шлаків
електричної печі та вмісту Si в отриманому металі, що може позитивно вплинути на зменшення витрат вогнетривких матеріалів.
Методика. Дослідження представлене як результати теоретичних та експериментальних даних, що визначають залежність еле-
ктричної печі від типу вогнетривкого матеріалу, конструкції стін, експлуатаційних параметрів та футеровки електропечі, які, як
очікується, матимуть значний вплив на вартість виробничого процесу. Для визначення терміну служби/довговічності вогнетривко-
го покриття були вивчені робочі параметри (хімічні, термічні та технологічні), а також якість/властивості та вміст вогнетривких
матеріалів на заводах. Лабораторні аналізи проводилися у спеціалізованих лабораторіях.
Результати. Виявлено на основі проведених досліджень, що цегла MgO-C є більш ефективною з точки зору запобігання пош-
кодженню печі. Рекомендовано для оптимізації виробничого процесу поліпшити склад розплавленого металу та шлаку, а також
посилити контроль над основними параметрами процесу. Запропоновано регулярний огляд огнеупору печі, який надає інформацію
щодо поточної ситуації і, крім того, показує ступінь зносу та критичні точки зносу пошкодженої футеровки печі.
Наукова новизна. Вперше встановлено, що FeNi-електрична піч працює під впливом шлаку з високим вмістом SiO2, металу з
низьким вмістом C і високим вмістом Si, високих температур і дуже високої окисної атмосфери.
Практична значимість. Вогнетривкий матеріал є одним із основних технічних засобів, що впливає на показники витрат ново-
го підприємства феронікелю у Косово. Більш висока продуктивність вогнетривкої футеровки позитивно вплине на довговічність
печі та якість кінцевого продукту.
Ключові слова: феронікель, вогнетривкі матеріали, шлак, оптимізація, графітові блоки

Обоснование огнеупорной футеровки, которая влияет на эффективность

использования электропечей для производства ферроникеля
Н. Дева, И. Ибрагими
Цель. Обоснование возможности замены существующего кирпича MgO кирпичом MgO-C из-за его устойчивости к жесткому
воздействию шлаков электрической печи и содержания Si в полученном металле, что может положительно повлиять на уменьше-
ние затрат огнеупорных материалов.
Методика. Исследование показывает результаты теоретических и экспериментальных данных, определяющих зависимость электри-
ческой печи от типа огнеупорного материала, конструкции стен, эксплуатационных параметров и футеровки электропечи, которые, как
ожидается, будут иметь значительное влияние на стоимость производственного процесса. Для определения срока службы/долговечности
огнеупорного покрытия были изучены рабочие параметры (химические, термические и технологические), а также качество/свойства и
содержание огнеупорных материалов на заводах. Лабораторные анализы проводились в специализированных лабораториях.
Результаты. Выявлено на основе проведенных исследований, что кирпич MgO-C более эффективный с точки зрения предотвра-
щения повреждения печи. Рекомендовано для оптимизации производственного процесса улучшить состав расплавленного металла и
шлака, и усилить контроль над основными параметрами процесса. Предложен регулярный осмотр огнеупора печи, который дает ин-
формацию о текущей ситуации и, кроме того, показывает степень износа и критические точки износа поврежденной футеровки печи.
Научная новизна. Впервые установлено, что FeNi-электрическая печь работает под влиянием шлака с высоким содержанием
SiO2, металла с низким содержанием C и высоким содержанием Si, высоких температур и очень высокой окислительной атмосферы.
Практическая значимость. Огнеупорный материал является одним из основных технических средств, который влияет на по-
казатели расходов нового предприятия ферроникеля в Косово. Высокая производительность огнеупорной футеровки положительно
повлияет на долговечность печи и качество конечного продукта.
Ключевые слова: ферроникель, огнеупорные материалы, шлак, оптимизация, графитовые блоки
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