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Corrosion of Cement-Bonded Refractory Castables due to Hydrogen-Containing Atmosphere

T. Tillmann, T. Leber, T. Tonnesen

Journal of Ceramic Science and Technology, Vol. 16, No. 3 (2025), pp. 161-172

DOI: 10.4416/JCST2024-00022

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Abstract

This study examined the influence of a hydrogen-containing atmosphere on cement-bonded refractory castables. Two series of tests were conducted using different materials, a fireclay and a high-alumina castable with SiC. Each test series consisted of three samples exposed in a tube furnace at temperatures of 1 100 °C and 1 500 °C for 24 and 72 hours. The temperature of 1 100 °C represents the upper temperature limit of a direct reduction plant, while 1 500 °C should provoke corrosion. An optical examination revealed a change in colour, due to the formation of oxygen vacancies. At 1 100 °C, there were only minor changes, with no significant loss of mass or change in porosity. At 1 500 °C a greater loss of mass was observed, particularly at the gas inlet, and an increase in porosity was determined. The chemical composition of the high-alumina material undergoes a transformation, with the loss of SiO2, SiC, and alkalis. Depending on the temperature and holding time, non-oxide agglomerates of iron and phosphorus, form on the surface. Similarly, agglomeration occurs in the castable with a high alumina content and SiC. In contrast to the other test series these agglomerates do not consist of iron and phosphorus, but of iron and silicon.

Keywords

Hydrogen, refractories, corrosion, high temperature.

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