Microstructural characterization of alkali metal mediated high temperature reactions in mullite based refractories

Two types of refractory bricks were used in reaction tests with slag from a production kiln for iron ore pellet production. Electron microscopy was used to characterize morphological changes at the slag/brick interface and active chemical reactions. Phases such as kalsilite, nepheline and potassium β-alumina form, in a layered structure, as a consequence of alkali metals migration in the brick. Larger hematite grains (50-100 μm) in the slag remain at the original slag/brick interface, while smaller grains dissolve and move through the partly dissolved brick bulk, and forms micrometer sized needle shaped crystals deeper in the lining material. Thermodynamic simulations predict the formation of a solid solution between hematite and corundum which is also observed in the reaction zone after extended time periods.