Thermodynamic Stability of Spinel Phase at the Interface Between Alumina Refractory and CaO–CaF2–SiO2–Al2O3–MgO–MnO Slags

The interfacial reaction between alumina refractory and CaO–CaF₂–SiO₂–Al₂O₃–MgO–MnO slag was observed at 1873 K to estimate the stability of the spinel phase using computational thermodynamics under refining conditions of Mn‐containing steels. The concentration of MnO formed by the slag–steel reaction in the CaO–CaF₂–SiO₂–Al₂O₃–MgO melts generally increased by decreasing the CaO/SiO₂ ratio of the initial melts. No intermediate compounds were formed at the refractory–slag interface when the initial CaO/SiO₂ ratio was 0.5, whereas CaAl₁₂O₁₉ (CA6) and Mg(Mn)Al₂O₄ (spinel), identified from TEM analysis using EDS mapping and SAED patterns, were observed at the refractory–slag interface when the CaO/SiO₂ ratio was 1.0 or greater. The (at.%Mg)/(at.%Mn) ratio in the spinel solution increased by increasing the CaO/SiO₂ ratio, which originated from the fact that MgO activity continuously increased as the CaO/SiO₂ ratio increased. From thermodynamic analysis considering the equilibrium constant (K_SP) and activity quotient (Q_SP) of the spinel formation reaction at the slag–refractory interface and the bulk slag phase, the precipitation–dissolution behavior of the spinel phase was predicted, which exhibited good consistency with the experimental results. Hence, the dissolutive corrosion mechanism of alumina refractory into the CaO–CaF₂–SiO₂–Al₂O₃–MgO–MnO slag was proposed.     

Effect of substituting CaO with BaO on the viscosity and structure of CaO‐BaO‐SiO2‐MgO‐Al2O3 slags

In this study, the effect of CaO and BaO substitution on the viscosity and structure of CaO‐BaO‐SiO₂‐MgO‐Al₂O₃ slags was investigated. The results showed that the viscosity increased with an increase in the BaO substitution concentration, which was correlated to an increase in the degree of polymerization (DOP) of the slag structural units as the activation energy increased from 207.9 to 263.8 kJ/mol for viscous flow. Deconvolution and area integration of the Raman spectrum of the slag revealed that the ratio of Q³/Q² (Qⁱ, i is the number of O⁰ in a [SiO₄]‐tetrahedral unit) increased and NBO/Si (nonbridging oxygen per unit silicon atom) decreased with higher BaO content. It was also observed from the ²⁷Al magic angles pinning nuclear magnetic resonance (²⁷Al MAS‐NMR) spectrum that the relative proportion of Al^IV increased, while that of Al^V decreased because of the decrease in the percentage of nonbridging oxygen (O^?), indicating the polymerization of the slag. O_1s X‐ray photoelectron spectroscopy (XPS) was also carried out to semi‐quantitatively analyze the various types of oxygen anions present in the slag. The XPS results correlated well with the results obtained from the analysis of the Raman and ²⁷Al MAS‐NMR spectra of the slags and its viscous behavior.     

1250°C liquidus for the CaO–MgO–SiO2–Al2O3–TiO2 system in air

Ti-bearing blast furnace slags have been regarded as an important secondary material in modern society, and the efficient recycling of Ti oxides from it is of key interest. For this reason, more thermodynamic data is needed regarding the phase relations in different composition ranges and sections. Therefore, the equilibrium phase relations of CaO–MgO–SiO₂–Al₂O₃–TiO₂ system in a low w(CaO)/w(SiO₂) ratio of 0.6–0.8 at 1250 °C in air and fixed concentrations of MgO and Al₂O₃, were investigated experimentally using a high temperature equilibration and quenching method followed by SEM-EDS (Scanning Electron Microscope and Energy Dispersive X-ray Spectrometer) analyses. The equilibrium solid phases of perovskite (CaO·TiO₂), a pseudo-brookite solid solution (MgO·2TiO₂, Al₂O₃·TiO₂)_ss, and anorthite (CaO·Al₂O₃·2SiO₂) were found to coexist with the liquid phase at 1250 °C. The calculated results of Factsage and MTDATA were used for comparisons, and significant discrepancies were found between predictions and the experimental results. The 1250 °C isotherm has been constructed and projected on the CaO–SiO₂–TiO₂-8 wt.% MgO-14 wt% Al₂O₃ quasi-ternary plane of the phase diagram. The obtained results provide new fundamental data for Ti-bearing slag recycling processes, and they add new experimental features for thermodynamic modeling of the high-order titanium oxide-containing systems.     

Dissolution behavior of silica in molten CaO–SiO2–Fe2O3–MgO–MnO slag

The modification of basic oxygen furnace (BOF) slag by adding silica can improve the properties of BOF slag for applications in the cement industry. The rapid dissolution of silica is essential to hot slag modification. In this work, the dissolution behavior of silica in the molten CaO–SiO₂–Fe₂O₃–MgO–MnO system as synthetic BOF slag was investigated by using the traditional rotating cylinder technique. Effects of rotation speed, temperature, immersion time, and slag basicity on the silica dissolution were studied. Scanning electron microscopy equipped with energy dispersive spectrometer (SEM-EDS) and FactSage simulations were employed to reveal the dissolution mechanism. It was found that the dissolution of the silica rod was affected by both the thermodynamic driving force and the slag viscosity. The silica dissolution rate in molten CaO–SiO₂–Fe₂O₃–MgO–MnO slag increased with increasing the rotation speed and temperature, but first increased and then decreased when decreasing the slag basicity from 2.5 to 1.5. A linear correlation between the logarithm of the dissolution rate and the logarithm of cylinder periphery velocity with a slope of 0.44 was observed, indicating the mass transfer within the boundary layer as the dissolution rate determining step. A direct dissolution way was found during the dissolution of silica in molten CaO–SiO₂–Fe₂O₃–MgO–MnO slag.     

Effects of promoters on catalytic activity and carbon deposition of Ni/γ‐Al2O3 catalysts in CO2 reforming of CH4

Catalytic reforming of methane with carbon dioxide was studied in a fixed‐bed reactor using unpromoted and promoted Ni/γ‐Al₂O₃ catalysts. The effects of promoters, such as alkali metal oxide (Na₂O), alkaline‐earth metal oxides (MgO, CaO) and rare‐earth metal oxides (La₂O₃, CeO₂), on the catalytic activity and stability in terms of coking resistance and coke reactivity were systematically examined. CaO‐, La₂O₃‐ and CeO₂‐promoted Ni/γ‐Al₂O₃ catalysts exhibited higher stability whereas MgO‐ and Na₂O‐promoted catalysts demonstrated lower activity and significant deactivation. Metal‐oxide promoters (Na₂O, MgO, La₂O₃, and CeO₂) suppressed the carbon deposition, primarily due to the enhanced basicities of the supports and highly reactive carbon species formed during the reaction. In contrast, CaO increased the carbon deposition; however, it promoted the carbon reactivity. © 2000 Society of Chemical Industry     

High‐Selectivity Y2O3‐Doped SiO2 Nanocomposite Membranes for Gas Separation in Steam at High Temperatures

Asymmetric structures were fabricated by depositing Y₂O₃‐doped SiO₂ (Si/Y) membranes onto γ‐Al₂O₃ supported by tubular α‐Al₂O₃. The thickness of the Y₂O₃‐doped SiO₂ deposits was approximately 100 nm. The deposits/membranes have micropores with a pore diameter ~ <0.40–0.55 nm. Pore size distribution measurements were conducted directly on the membranes before and after hydrothermal treatment with a nano‐permporometer. The gas permeance properties of the membranes were measured in the temperature range 100°C–500°C. The Y‐doped SiO₂ membrane (Si/Y = 3/1) was found to exhibit asymptotically stable permeances of 2.39 × 10^?7 mol/m²/s/Pa for He and 6.19 × 10^?10 mol/m²/s/Pa for CO₂, with a high selectivity of 386 (He/CO₂) at 500°C for 20 h in the presence of steam. The Y‐doped silica membranes exhibit very high gas permeances for molecules with smaller kinetic diameters. The apparent activation energies of the H₂ permeance at 400°C were 24.2 ± 0.2 and 21.3 ± 0.7 kJ/mol for SiO₂ and Si/Y, respectively.     

Energetics of Silica‐Poor Glasses in the Systems MgO–SiO2 and Mg0.5Ca0.5O–SiO2

A series of alkaline‐earth silicate glasses, with compositions ranging from the metasilicate to the ortho‐ and suborthosilicate, have been synthesized by aerodynamic levitation and CO₂ laser melting. They have been studied by high‐temperature oxide melt solution calorimetry with 2PbO·B₂O₃ as solvent. The enthalpies of formation from the oxides at room temperature () have been calculated from the solution enthalpies. Glasses in the Ca_0.5Mg_0.5O–SiO₂ system show greater energetic stability than those in the MgO–SiO₂ system, with a more pronounced negative enthalpy of mixing near the orthosilicate composition. This stabilization may explain why it is possible to prepare glasses poorer in silica (suborthosilicate) in the Ca_0.5Mg_0.5O–SiO₂ system but not in the MgO–SiO₂ system. The thermodynamic observations support earlier structural studies in these systems.     

Influence of FeO/SiO2 and CaO/SiO2 Ratios in Iron‐Saturated ZnO‐Rich Fayalite Slags on the Corrosion of MgO

The corrosion behavior of MgO in iron‐saturated ZnO‐rich fayalite (ZFS) slags having various FeO/SiO₂ ratio and CaO/SiO₂ ratio was investigated using MgO crucible tests for 12 h at 1200°C. The FeO/SiO₂ and CaO/SiO₂ ratios in the ZFS slags were varied from 1.0 to 2.2, and from 0.04 to 0.32, respectively. In all of the tests, it was observed that MgO dissolves into ZFS slags and that (Zn,Fe,Mg)₂SiO₄ olivine and (Zn,Fe,Mg)O solid solution are formed at the crucible/slag interface. The MgO dissolution decreased with the FeO/SiO₂ ratio up to a value of 1.7 and then slightly increased, whereas it continuously increased with the CaO/SiO₂ ratio. There is no obvious relationship between the amount of olivine and the FeO/SiO₂ ratio or CaO/SiO₂ ratio. In comparison, the formation of (Zn,Fe,Mg)O solid solution is enhanced by increasing the FeO/SiO₂ ratio or CaO/SiO₂ ratio in ZFS slags. The results suggest that MgO corrosion is the lowest for FeO/SiO₂ and CaO/SiO₂ ratios around 1.7 and 0, respectively.     

Experimental phase equilibria studies of the PbO–SiO2 system

Phase equilibria of the PbO–SiO₂ system have been established for a wide range of compositions: (i) liquid in equilibrium with silica polymorphs (quartz, tridymite, and cristobalite) between 740°C and 1580°C, at 60‐90 mol% SiO₂; (ii) with lead silicates (PbSiO₃, Pb₂SiO₄, and Pb₁₁Si₃O₁₇) and lead oxide (PbO) between 700°C and 810°C. A high‐temperature equilibration/quenching/electron probe X‐ray microanalysis (EPMA) technique has been used to accurately determine the compositions of the phases in equilibrium in the system. Significantly, no liquid immiscibility has been found in the high‐silica range, and the liquidus in this high‐silica region has been accurately measured. The phase equilibria information in the PbO–SiO₂ system is of practical importance for the improvement of the existing thermodynamic database of lead‐containing slag systems (Pb–Zn–Fe–Cu–Si–Ca–Al–Mg–O).     

Non-isothermal crystallization kinetics of MgO–BaO–B2O3–Al2O3–SiO2 glass

5MgO–9BaO–33B₂O₃–33Al₂O₃–20SiO₂ (mol%) glass was prepared by the melt quenching method at 1823 K for 2 h. Dilatometry and differential scanning calorimetry (DSC) curves of the glass have been investigated. Fragility index F was used to estimate glass formability. The crystallization kinetics of the glass was described by the activation energy (E) for crystallization and numerical factors (n, m) depending on the nucleation process and growth morphology. XRD and SEM analysis were also used to describe the crystals’ types and morphology precipitated from the MgO–BaO–B₂O₃–Al₂O₃–SiO₂ glass. The results show that the effective activation energy of the crystallization process E was 45.19 kJ/mol, and n up to 4.05. Two crystals phases, i.e. Al₄B₂O₉ and Al₂₀B₄O₃₆ were observed in the crystallized samples. SEM results were consistent with crystallization kinetics.     

Radical reaction-induced Turing pattern corrosion of alumina refractory ceramics with CaO–Al2O3–SiO2–MgO slags

Quasi-volcanic corrosion occurs at the triple-phase interface of alumina refractory ceramics and MgO-containing CaO–Al₂O₃–SiO₂ slags in the air, causing severe damage to ceramics. To address this limitation, in this study, a slag corrosion experiment is performed on alumina refractory ceramics using CaO–Al₂O₃–SiO₂–MgO slags. Various spectroscopic techniques, including electron paramagnetic resonance spectroscopy, are used to investigate the influence of slag structures with varied MgO contents on the corrosion peaks and mechanism. The results show large quantities of reactive radicals, including superoxide radicals, in the slags. Free-radical reactions between refractory ceramics and slags lead to Turing pattern corrosion. An increase in the amount of non-bridged oxygen in the slag structure decreases the amount of original superoxide radicals. Consequently, the intensity of the free-radical reactions of alumina dissolution increases, thereby increasing the height of the corrosion peaks.     

Preparation of α-cordierite through mechanochemical activation of MgO–Al2O3–SiO2 ternary system

Samples of the ternary system MgO–Al₂O₃–SiO₂ with stoichiometric composition in relation to α-cordierite (Mg₂A_l4Si₅O₁₈), consisting of 22.2 mol% MgO, 22.2 mol% Al₂O₃, and 55.6 mol% SiO₂, were activated in a low energy mill with a constant speed of 100 rpm, in an aqueous medium. The precursors used were corundum (Al₂O₃), silica gel HF254 type 60 (SiO₂), and periclase (MgO). The objective of the present study was to evaluate the effect of mechanochemical activation on the solid-state synthesis of α-cordierite, using a low energy ball mill. Another objective was to shed light on the effect of mechanochemical activation on the steps of α-cordierite formation. For this end several grinding conditions were evaluated, varying the time and mass ratio of precursors/grinding elements, as well as calcination at different temperatures between 950 °C and 1350 °C for 2 h. The samples were analyzed for the determination of the formed phases by Infrared (IR) and X-ray Diffraction (XRD). The phases identified in uncalcined samples were brucite (Mg(OH)₂), forsterite (Mg₂SiO₄), enstatite (MgSiO₃), spinel (MgAl₂O₃), amorphous silica (SiO₂), corundum (α-Al₂O₃), and zirconia (monoclinic and tetragonal ZrO₂). The lowest temperature corresponding to the formation of α-cordierite (α-Mg₂Al₄Si₅O₁₈) was 1150 °C and a considerable amount of this phase (16.2%) was observed at this temperature, for the sample with the higher mechanochemical activation. In a solid-state reaction, α-cordierite is normally obtained at around 1400 °C, therefore, the formation of this phase at 1150 °C confirms that the mechanochemical activation method, using a low-cost ball mill, is efficient in reducing the solid-state reaction temperature.     

Solid Solution Effects on the Thermal Properties in the MgAl2O4–MgGa2O4 System

Solid solution effects on thermal conductivity within the MgO–Al₂O₃–Ga₂O₃ system were studied. Samples with systematically varied additions of MgGa₂O₄–MgAl₂O₄ were prepared and the laser flash technique was used to determine thermal diffusivity at temperatures between 200°C and 1300°C. Heat capacity as a function of temperature from room temperature to 800°C was also determined using differential scanning calorimetry (DSC). Solid solution in the MgAl₂O₄–MgGa₂O₄ system decreases the thermal conductivity up to 1000°C. At 200°C thermal conductivity decreased 24% with a 5 mol% addition of MgGa₂O₄ to the system. At 1000°C, the thermal conductivity decreased 13% with a 5 mol% addition. Steady‐state calculations showed a 12.5% decrease in heat flux with 5 mol% MgGa₂O₄ considered across a 12 inch thickness.     

In Situ Observation of the Dissolution of SiO2 Particles in CaO–Al2O3–SiO2 Slags and Mathematical Analysis of its Dissolution Pattern

The dissolution of amorphous SiO₂ particles in CaO–Al₂O₃–SiO₂ slags was investigated at 1450°C by high‐temperature confocal scanning laser microscopy (HT‐CSLM) and thermodynamic/kinetic analyses. The SiO₂ particles used in this experimental study had a spherical form so that any rotation of the particle did not cause errors in the determination of the particle size during the dissolution. Moreover, a wide composition range of the slag could be chosen without forming any solid reaction layer which could distort the evaluation of the dissolution mechanism. The evolution of the diameter of the spherical SiO₂ particle was measured by image analysis of pictures obtained from the HT‐CSLM. It was found that the dissolution curve of the SiO₂ particle (size as a function of time) exhibited either a parabolic‐like curve or an S‐shaped curve depending on the slag composition. The patterns were compared with a well‐known shrinking core model (SCM), and it was shown that the SCM could not represent the dissolution behavior of the SiO₂ particle observed in this study. It was experimentally found that the shape of the dissolution curves varies as a function of the slag composition. The curve exhibited a parabolic‐like shape for low SiO₂‐containing slags and changed to an S‐type shape with increasing SiO₂ concentration in the slag. To elucidate the dissolution mechanism, a model based on approximations for the diffusion near the particle was proposed by modifying the previously available model [M. J. Whelan, Met. Sci. J., 3, 95–97 (1969)]. From the experimental data and the model calculations, the viscosity of the slag was shown to be the major factor affecting both dissolution rate and mechanism. Effective binary diffusion coefficients were estimated using the model and experimental data. Those were shown to be in the range of literature data.     

Corrosion of spinel clinker by CaO–Al2O3–SiO2 ladle slag

Three different grades of sintered spinel clinker were used containing 47, 69 and 94 wt.% Al₂O₃, respectively, i.e. MgO-rich, stoichiometric and Al₂O₃-rich. Based on these clinkers, the corrosion mechanism of each spinel clinker by CaO–Al₂O₃–SiO₂ slag was investigated and the corrosion and penetration behavior of castables containing powdered spinel clinker examined. A layer of MgO·(Al, Fe)₂O₃ complex spinel formed at the slag-refractory interface was proportional to the MgO content of the spinel clinkers, and it depressed the slag corrosion. The free MgO and spinel minerals in each spinel clinker mainly trapped Fe₂O₃ from the slag. CaO–Al₂O₃ compounds were formed at the slag-clinker interface by the reaction between free Al₂O₃ in the Al₂O₃-spinel clinker and CaO from slag. Slag penetration into the spinel clinkers was retarded by these compounds. As a result of adding fine spinel powder to the matrix of Al₂O₃-based castables, it was observed that higher content of MgO in spinel clinker showed better resistance to slag corrosion but lower resistance to slag penetration.     

Selected Phase Equilibria Studies in the Al2O3–CaO–SiO2 System

The Al₂O₃–CaO–SiO₂ system provides the basis for describing many important chemical processes. Although the system has previously been extensively studied, recent advances in experimental technique have provided the opportunity to obtain accurate liquidus measurements in the low‐silica region at fixed temperatures. The experimental procedures involve equilibration of high‐purity oxide powder mixtures at selected temperatures, rapid quenching, and accurate measurement of phase compositions using electron probe X‐ray microanalysis. The liquidus isotherms have been determined at selected temperatures between 1503 and 1873 K in the anorthite, gehlenite, pseudowollastonite, corundum, CaAl₁₂O₁₉, CaAl₂O₆, lime, Ca₃SiO₃, and Ca₂SiO₄ primary phase fields. The results are compared with currently available thermodynamic model predictions of the phase chemistry.     

Phase evolution mechanism of non‐oxide bonded Al–Al2O3–MgO–ZrO2 composites at 1873 K in flowing nitrogen

In flowing nitrogen, non‐oxides such as Al₄O₄C, Al₂OC, Zr₂Al₃C₄, and MgAlON bonded Al₂O₃‐based composites were successfully prepared by a gaseous phase mass transfer pathway using aluminum, zirconia, alumina, and magnesia as raw materials at 1873 K, after an Al–AlN core‐shell structure was formed at 853 K. Resin bonded Al–Al₂O₃–MgO–ZrO₂ composites after sintering were characterized and analyzed by X‐ray diffraction (XRD), scanning electron microscope (SEM) and, energy dispersive spectrometer (EDS), and the influence of the MgO content on the sintered composites was studied. The results show that after sintering, the phase composition of the Al–Al₂O₃–ZrO₂ composite is Al₂O₃, Al₄O₄C, Al₂OC, and Zr₂Al₃C₄, while the phase composition of the Al–Al₂O₃–ZrO₂ composite with the addition of MgO 6 wt% and MgO 12 wt% is Al₂O₃, MgAlON, Al₄O₄C, Al₂OC, and Zr₂Al₃C₄ as well as Al₂O₃, MgAlON, Al₂OC, and Zr₂Al₃C₄, respectively. The addition of MgO changed the phase composition and distribution for the resin bonded Al–Al₂O₃–MgO–ZrO₂ system composites after sintering. When the added MgO content is equal to or more than 12 wt%, the Al₄O₄C in the resin bonded Al–Al₂O₃–MgO–ZrO₂ system composites is unable to exist in a stable phase.     

INVESTIGATION OF REACTIONS OF SIMPLE MAGNESIA SPINELS WITH ALKALINE EARTH ORTHOSILICATES IN THE SOLID STATE *

The spinels MgO Al₂O₃, MgO Cr₂O₃., and MgO Fe₂O₃ and the orthosilicates 2MgO SiO₂, 2CaO SiO₂, 2SrO SiO₂, and 2BaO SiO₂ were synthesized by solid-state reaction of the component oxides or compounds yielding the oxides on ignition. Each of the spinels was tested at various temperatures with each orthosilicate in turn by placing a pellet of each in contact and also by intimately mixing the two. Petrographic microscopy and X-ray diffraction were employed in the identification of reaction products.     

Synthesis of Novel Solid Base of MgO Covered with Metal Oxides

The solid base catalysts of MgO covered with SiO₂, Al₂O₃, TiO₂, and ZrO₂ were prepared by decomposition of the corresponding alkoxide over an Mg(OH)₂ surface in ethyl acetate solution followed by thermal decomposition. The acid-base properties of the prepared catalysts were estimated using 2-propanol decomposition activity and selectivity. The stability of catalysts for the aldol reaction of acetone against H₂O was examined. The acid sites were generated on the MgO surface by covering with metal oxides. Base sites were formed when the MgO was covered with Al₂O₃. Catalysts made of MgO covered with more than 7 mol% Al₂O₃ showed sufficient stability against H₂O as well as reusability.