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Zinc-Lead ISP
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    Iron Making and Ferroalloy Metallurgy
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Zinc-lead blast furnace, also known as Imperial Smelting Process (ISP) blast furnace, is a smelting equipment to recover metal zinc from roasted zinc concentrate, especially when it contains relatively high lead in it, since the same process can yield also crude lead as by-product.
Though ISP blast furnace is developed based on lead blast furnace, it is completely sealed. The reason lies in the fact that metal zinc is recovered from zinc vapor, and that the presence of oxygen in off-gas would turn the zinc vapor into zinc oxide, if the furnace is not properly sealed. Another difference to lead blast furnace lies in that the roof & upper stack of ISP blast furnace need to be protected by refractory material since the working temperature there is around 1000°C.
The refractory lining protecting the roof, as mentioned above, consists usually of chamotte or high-alumina refractory castable (UR8257C), above which lies the insulating castable (UI8057C or UI8257C). In upper stack, the erosion of high-temperature burden including roasted zinc concentrate and coke is the main wearing factor. Therefore, refractory high-alumina brick (FB8257), which has good erosion resistance, is recommended as wearing lining, and high-alumina insulating castable (UI8257C) as insulation layer.
In order to protect the hot blast pipe from the high temperature (around 800°C), refractory chamotte brick (FB8057) is recommended as inner layer, whereas insulation chamotte brick (IB8057C) as outer layer. Meanwhile, a monolithic lining concept with sole refractory insulation castable (UI8057C or UI8257C) is also applicable in many cases.
Main slag components of ISP blast furnace, from high to low content, are FeO, CaO, SiO2, Al2O3 and so on. In this regard, magnesia brick (FB6057) or magnesia-chrome brick, which has good resistance to FeO and CaO, is recommended.
In sidewall of hearth, magnesia brick (FB6057) or magnesia-chrome brick should be applied as wearing lining. Outside the wearing lining is refractory chamotte brick (Fb8057). The outmost lining consists of chamotte insulation brick (IB8057C) or insulation refractory castable (UI8057C).
Bottom of hearth follows the similar refractory lining concept as sidewall, which is magnesia brick/magnesia-chrome brick, chamotte brick and insulation layer respectively from the inside out, whereas the bricks should be laid to shape a counter-arch.
Yanmu's recommended refractory usage in ISP blast furnace is summarized in the following table. For further products information please refer to previous chapter “Refractory Products Collection for Non-Ferrous Metallurgy”.