Interactions of refractory materials with molten gasifier slags

The current study focuses on the analysis of sessile-drop interfacial reactions between two synthetic slags (based on average ash chemistries of coal and petcoke feedstock) and two refractory materials (90 wt% Cr2O3–10 wt% Al2O3 and 100 wt% Al2O3), using a Confocal Scanning Laser Microscope (CSLM). Ground slag samples (less than 325 mesh) were placed at specific microstructure locations on refractory substrates and heated to 1500 °C in an atmosphere of CO/CO2 gas mixture (volume ratio = 1.8), using a gold-image heating chamber. Cross-sections of the slag/refractory interface indicated unique slag penetration into preferred areas of the refractory and grain dissolution into the slag which promoted spalling of the refractory. Initially, the slag attacked both grain boundaries and fine microstructure areas, freeing alumina grains into the slag. The formation of VOx-based crystalline material in the petcoke slag was found to alter the liquid composition. Chemical spalling of Cr-containing crystal layer also facilitated degradation of the refractory.