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Corrosion Study and Thermodynamic Calculations for MgO-C Refractories Containing CMA Additive

M. Ludwig, M. Sułkowski, M. Klewski, E. Wojtaszek-Jajków, D. Madej

Journal of Ceramic Science and Technology, Vol. 16, No. 3 (2025), pp. 125-134

DOI: 10.4416/JCST0024_00016

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Abstract

MgO-C refractories are extensively utilized in the steel industry, particularly in steel ladles, basic oxygen furnaces, and electric arc furnaces. These materials are subjected to intense mechanical and thermal stresses, as well as aggressive interactions with corrosive agents. The most severe wear typically occurs upon contact with slag or molten metal; therefore, the use of high-purity raw materials is essential to ensure durability under such conditions. To enhance the thermomechanical performance of MgO-C refractories, antioxidants are commonly incorporated, leading to the formation of high-temperature ceramic phases (e.g. MgAl2O4, AlN, SiC) that reinforce the material's structure. However, alternative additives may also be considered to further improve their performance in demanding environments. Raw materials containing CaO and MgO-bearing aluminates not only enhance slag resistance but are also considered among the most promising solutions for stabilizing steel ladle linings. Laboratory tests involving the addition of various grain sizes of CMA additives to MgO-C refractories demonstrated improved slag resistance through the formation of a protective contact layer. Furthermore, these modifications enabled better control over dimensional changes after heating, as well as thermal expansion behavior. The study also investigated the feasibility of incorporating recycled raw materials in combination with aluminates. The obtained results enabled the design of a complete ladle lining system optimized for use in silicon-killed steel processes and environments subjected to high thermomechanical stress in secondary metallurgy. Microstructural analysis of post-mortem samples using SEM/EDS methods provided insight into the influence of aluminates on slag attack resistance and thermal stress behavior, particularly through reinforcement of joint areas. The corrosion study was further supported by thermodynamic calculations.

Keywords

MgO-C refractories, CMA, SEM/EDS, corrosion, post-mortem.

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