Modelling of freeze layers and refractory wear in direct smelting processes

This work concerns the development of a new modelling technique for the simulation of refractory wear in smelting processes. In particular the model is concerned with the HIsmelt direct smelting process for iron production. The mechanisms of slag penetration, subsequent chemical corrosion and erosion by shear of the refractory material are examined. They are applied concurrently to an illustrative example case. Although work is at an early stage of development, results are very encouraging and wear patterns reflect those observed in practice. Further development work is in progress together with experimental validation.