Microstructural characteristics of refractory magnesia produced from macrocrystalline magnesite in China

Sintered and fused magnesia (FM) produced from the macrocrystalline magnesite in China have attracted attention worldwide for the production of various refractories. Herein, dead burnt magnesia (DBM) with varying compositions was investigated. The results revealed that the periclase crystals of the DBM92 sample were sub rounded to rounded euhedral, whereas the periclase crystals of the DBM95 sample were subhedral and idiomorphic. In addition, a significant amount of periclase-periclase bonding with straight boundaries was observed in the DBM97 sample. The periclase crystals of the DBM98 sample with no clear boundaries exhibited the densest packing among the samples. The silicate matrix around the periclase grains of the DBM92 sample contained forsterite and monticellite, whereas that around the periclase grains of the DBM95 sample was mainly composed of monticellite and merwinite. Dicalcium silicate and merwinite were observed in small amounts as interstitial phases in the DBM97 sample. In contrast, only dicalcium silicate, which was concentrated in small triangular pockets, was observed in the densely packed periclase grains of the DBM98 sample. The hot modulus of rupture tests revealed that an alkali-resistant DBM95-based brick can be prepared at a lime-silica ratio of <0.5. The best quality DBM97-based brick can be prepared at a lime-silica ratio of approximately 2.2, which ensures that dicalcium silicate is the only interstitial phase. The periclase crystals of the two-step FM were significantly larger than those of the one-step FM and exhibited remarkably fewer silicate boundaries. The superior structure and large crystal size of the two-step FM can endow magnesia-carbon bricks with slag corrosion resistance.