Degradation mechanisms of magnesia-carbon refractories by high-alumina stainless steel slags under vacuum

The corrosion behaviour of a pitch-bonded magnesia-carbon refractory by an Al2O3 rich (∼15 wt.%) stainless steelmaking slag was investigated by rotating finger tests in a vacuum induction furnace at high temperature (>1650 °C) and low oxygen partial pressure (1.5–4.3 × 10−10 atm). This study confirms the poor slagline behaviour of MgO-C bricks industrially observed in VOD ladles. Higher temperatures and longer exposure times lead to more severe slag infiltration and direct MgO dissolution. The intrinsic MgO-C reaction is the major decarburisation mechanism, while extrinsic decarburisation by oxygen from the atmosphere and/or reducible slag components (CrOx, FeOx) was limited. Three kinds of metallic particles with different size, shape, location, composition and origin were observed in the refractory specimens. Concurrently, the thermodynamic conditions for the formation of a protective Mg(Al,Cr)2O4 spinel layer at the slag/refractory interface are investigated. The industrial relevance of this spinel layer formation is discussed with respect to the chosen Al2O3 level. Guidelines are proposed to minimise MgO refractory dissolution in VOD slaglines.