Interfacial reactions between magnesia refractory and electric arc furnace (EAF) slag with use of direct reduced iron (DRI) as raw material

Interfacial reactions between the electric arc furnace (EAF) slag, i.e., CaO–SiO₂–FeO–MgO–Al₂O₃–MnO system, and the magnesia refractory as a function of direct reduced iron (DRI) addition (0, 10, 20, 30 wt%) were investigated at 1550 °C under an Ar atmosphere. MgO solubility increases with increasing DRI content by decreasing basicity (i.e., CaO/SiO₂ ratio), which is due to an increase in SiO₂ supplied from DRI. The measured MgO content was always lower than the theoretical MgO saturation level irrespective of DRI content because the magnesiowüstite (MW) intermediate layer, which formed at the slag/refractory interface, retarded the direct dissolution of the refractory by acting as a self-protective layer. The thickness of the MW intermediate layer and dissolution depth were proportional to DRI content. However, the penetrativity decreased with increasing DRI content by decreasing the fluidity of the slag. Several kinetic parameters were estimated, including the dissolution rate constant of the MW intermediate layer, the dissolution rate of the MgO refractory, and the rate constant of MW growth. Dissolution of MgO refractory is controlled by the dissolution of the MW intermediate layer. Increasing the growth rate is very important for protecting refractory after the formation of a MW intermediate layer. In addition, we provided a schematic diagram of the slag/refractory interfacial reaction phenomena that compares situations of low and high DRI content. The results of the present study show that it is necessary to control DRI content to minimize refractory degradation during the EAF process. If a large amount of DRI must be used in the EAF process, then MgO content in the slag should be at the saturation limit at first, which accelerates growth of the MW intermediate layer.