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Synthesis process and production properties of forsterite-based refractory from iron ore tailings

Abstract Forsterite-based refractories were prepared using iron ore tailings as some of its starting raw materials in the study. Forsterite's synthesis process was also examined at the same time. The crystallization behaviour of synthesised fosterite samples was investigated using differential scanning calorimetry (DSC), X-ray diffraction (XRD) and Scanning Electronic Microscopy (SEM). According to the DSC analysis, the forsterite synthesis experiments were carried out at different temperature of 1423, 1473, 1593, 1673 and 1723 K. The formation temperature of forsterite was determined. A forsterite-based light insulate brick preparation experiment was carried out at 1723 K for 6 hours. The XRD analysis results show that the major phase of the synthesised forsterite-based refractory was primarily forsterite along with Mg-Ferro spinal, and smaller amounts of MgO (periclase). The properties of the synthesised forsterite-based refractory compared well with the value of the industrial forsterite-based refractory. The result indicated interesting potential for iron ore tailings to produce useful materials.