Copper concentrate ore smelting reverberator is rectangular, chamber type flame furnace, which adopts coal or heavy oil as fuel. The heat exchange of reverberator not only relies on flame reverberation, but also the radioactive heat transmission of furnace top, furnace wall and high temperature gases. The production process of reverberator is continuous, the smelting process takes place under oxidizing atmosphere and 1500~1550℃ temperature. Furnace slag is composed of iron, silicon, calcium and aluminum oxides. When the molten slag splashes on furnace wall and furnace top refractory masonry, the refractory materials will suffer corrosion and damage. The highest temperature in the reverberator is at furnace top, can reach to 1800℃. Refractory materials for this place should have high refractoriness under load temperature, good thermal shock resistance, high bulk density, small linear change rate and good slag corrosion resistance.
Copper Smelting Reverberator Refractories
The reverberator bottom mainly adopts sintered integral bottom, magnesia iron ramming mix are usually used as sintering layer material. Magnesia iron ramming mix are made from magnesia sand, iron oxide powder and brine.
Magnesia Iron Ramming Mass Index
Item
Component
Ratio
Granularity/mm
Note
Magnesia sand
MgO
78 %
Coarse sand:3~6mm; Middle sand: 1~3mm; fine sand 0~1mm
Should be dried ath 120℃~150℃ before using.
CaO
<3.5%
SiO2
<5%
H2O
<0.5%
Iron oxide
FeO+Fe2O3
>95%
0.147~0.104
Melting point lower than 1400℃, dried at 120~150℃
SiO2
<4%
brine
Density between 1.3~1.4g/ml
The furnace wall of copper smelting reverberator are usually built by magnesia bricks, magnesia alumina bricks which have good corrosion resistance, thermal impact resistance. At some important parts such as powder coal combustor surrounding and converter slag entrance and so on, chrome magnesia bricks are used to prolong the service life. Large scale copper smelting reverberator usually adopts hanging type furnace top, made from magnesia alumina bricks.
Furnace top and vault are usually built by silica brick, magnesia alumina bricks, direct bonded magnesia chrome bricks, phosphate bonded magnesia chrome bricks. Furnace wall is built by sintered magnesia bricks, magnesia chrome bricks, chrome magnesia bricks, magnesia alumina bricks.
Furnace bed is usually constructed by lightweight clay bricks, sintered magnesia bricks, magnesia ramming mix.
