What do you think are the effects of gases on the corrosion of refractories? How refractories corroded by HCl gas?

The corrosion of refractories by gases is a complex process that depends on the type of refractory material and the specific gas involved. Generally, refractories are designed to withstand high temperatures and harsh environments, but exposure to certain corrosive gases can lead to deterioration over time. Here are some general considerations for the effects of gases on the corrosion of refractories:

Effects of Gases on Refractories:

Chemical Attack:Gases can chemically react with the refractory material, leading to the formation of compounds that are less stable or more soluble. This chemical attack can weaken the refractory structure.

Erosion and Abrasion:Particulate matter carried by gases can cause erosion and abrasion of refractory surfaces, especially at high flow velocities.

Temperature Effects:Elevated temperatures can enhance the reactivity of gases with refractories. High temperatures may promote more aggressive chemical reactions.

Formation of Volatile Compounds:Some gases can react with refractories to form volatile compounds, leading to material loss and degradation.

Thermal Cycling:Alternating cycles of heating and cooling can exacerbate the effects of gas corrosion on refractories, as the expansion and contraction may contribute to the mechanical breakdown of the material.

Corrosion by HCl Gas:

Hydrochloric acid (HCl) is a highly corrosive gas, and its effects on refractories depend on factors such as concentration, temperature, and exposure time. When refractories are exposed to HCl gas, several mechanisms can contribute to corrosion:

Acidic Corrosion:HCl is acidic and can react with the basic components of refractories, such as oxides, to form soluble chloride compounds. This can lead to the leaching of refractory material.

Hydration and Dehydration:HCl can promote hydration and dehydration reactions within the refractory structure, causing physical changes that weaken the material.

Formation of Volatile Chlorides:The reaction of HCl with certain refractory components may result in the formation of volatile chlorides, leading to material loss.

Cracking and Spalling:Intense corrosion by HCl can cause cracking and spalling of the refractory surface, compromising its integrity.

Prevention and Mitigation:

Material Selection:Choose refractory materials that are resistant to the specific corrosive gases present in the environment.
Protective Coatings:Apply protective coatings to refractories to create a barrier against corrosive gases.
Temperature Control:Control and monitor temperatures to minimize the severity of chemical reactions between gases and refractories.

Understanding the specific conditions of the application and the properties of both the refractory material and the corrosive gas is crucial for designing refractory systems that resist degradation over time.

Nesli Yürük

Thank you for your comment

Firoz Ahmed Makrani

Reaction with Silica (SiO2) Refractories: Silica refractory react with HCl gas ‎to form silicon tetrachloride (SiCl4) and water (H2O).‎

SiO2 + 4HCl -> SiCl4 + 2H2O

‎Reaction with Alumina (Al2O3) Refractories: Alumina refractories react with ‎HCl gas to form aluminium chloride (AlCl3) and water.‎

Al2O3 + 6HCl -> 2AlCl3 + 3H2O

‎Reaction with Magnesia (MgO) Refractories: Magnesia refractories react with ‎HCl gas to form magnesium chloride (MgCl2) and water.‎

MgO + 2HCl -> MgCl2 + H2O

Mehdi Noori

Carbonaceous Atmosphere and Water Vapor are Detrimental for the Oxide Refractories. Interaction with Water Vapor Leads to Formation of the Volatile Species and Subsequent Recession of the Refractories. Carbonaceous Atmosphere Leads to the Decomposition of Even Mullite, Which is Categorized as Neutral Refractory Due to its Excellent Thermochemical Stability. Oxidizing Atmosphere with Water Vapor Dominates the Corrosion of Non-Oxide Refractories (Such as silicon carbide). Presence of Impurities in the Gas Stream such as Alkali Vapor and Halogens can Alter the Corrosion Mechanisms and Favor “Hot Corrosion.”

Armin Niehaus

To protect refractory against corrosion by acidic gases (typically desulphurization units to purify flue gas) rubber linings are applied. Traditionally CR (Chloroprene Rubber), more widely Halobutyl linings are used.

Alejandro Martinez Gordon

Mainly, loss of mass and efficiency.

The gases will form byproducts on the surface of these refractory bricks.

Basic refractories (CaO or MgO) should be avoided if HCl is present.

The concentration, duration and even the type of gas will have an impact on how these refractories will be damaged.

Armin Niehaus

Temperature is the main question. Ideally a PTFE coating could solve the problem. For a more professional information I recommend

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