Browsing by Author "Aneziris, Christos"

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GRK 2802: Characterization of a recyclate-based MgO-steel as-sintered inert anode candidate after exposure to cryolite electrolysis
(Technische Universität Bergakademie Freiberg, 2026-02-12) Yaroshevskyi, Serhii; Adamczyk, Alexander; Brachhold, Nora; Schmidt, Gert; Hubalkova, Jana; Gumeniuk, Roman; Charitos, Alexandros; Aneziris, Christos
The replacement of consumable carbon anodes with oxygen-evolving inert, carbon free anodes is a key technological challenge for decarbonizing primary aluminum production. While metallic, ceramic, and cermet anodes have been extensively studied, the use of recycled raw materials remains largely unexplored. In this work, composite cermet anodes consisting of 60 vol% AISI 316L stainless steel and 40 vol% recycled MgO from spent refractories were developed and tested under galvanostatic Hall-Héroult electrolysis conditions in cryolite at 1000 °C. The as-sintered composites exhibited stable cell voltage (3.2-3.3 V) over 2 h of operation. Post-mortem SEM/EDS/EBSD analyses revealed a multilayered structure with protective Fe-oxide, Al/Cr spinel formation, corroded Mg-F-rich phases, and cryolite infiltration extending beyond 2 mm depth. While the 316L steel matrix showed relative stability, the recycled MgO fraction proved chemically reactive, generating porosity and acting as the primary pathway for melt intrusion and secondary Al2O3 precipitation. Complementary static contact corrosion tests confirmed rapid fluoridation of MgO, whereas steel grains remained intact.
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GRK 2802: MgO-C REFRACTORIES BASED ON REFRACTORY RECYCLATES AND ENVIRONMENTALLY FRIENDLY BINDERS
(Technische Universität Bergakademie Freiberg, 2026-02-16) Stadtmüller, Till Manon Jannis; Storti, Enrico; Brachhold, Nora; Lauermannová, Anna-Marie; Jankovský, Ondřej; Schemmel, Thomas; Hubálková, Jana; Gehre, Patrick; Aneziris, Christos
This study focused on the development of an environmentally friendly binder system based on lignin and collagen for uniaxial pressed MgO-C refractories as an alternative to commonly used resin or pitch binders. Additionally, recycled MgO-C refractories from steel plants were partially utilized as raw material, investigating their influence on the resulting physical and mechanical properties. The binder system showed reliable binding properties, although the recyclate-containing MgO-C exhibited higher porosity, slightly lower density, and lower strength compared to the reference batches without recyclates. However, antioxidants significantly improved the properties of the recyclatecontaining MgO-C samples. Scanning electron microscopy analysis with energydispersive X-ray spectroscopy revealed the formation of whiskers, as well as oxidation and nitridation of aluminum particles. This research highlights the potential of environmentally friendly binders and the utilization of recycled materials in MgO-C refractories to mitigate their environmental impact and enhances the environmental performance of carbon containing refractory materials.
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GRK 2802: Pre‐oxidized Recycled MgO–Steel Composite Material for Possible Application in Cryolitic Melts
(Technische Universität Bergakademie Freiberg, 2026-02-16) Yaroshevskyi, Serhii; Brachhold, Nora; Malczyk, Piotr; Gehre, Patrick; Aneziris, Christos
Recycled MgO–C lining bricks and 316L stainless steel are used to manufacture composite material for inert anode samples for aluminum electrolysis cell. The microstructure of the composite material is characterized after preoxidation thermal treatments at 800, 900, and 1000 °C as well as in its sintered state. Preoxidation (PO) process is designed to enhance the material's corrosion resistance in molten cryolite environments by developing robust Fe–Mg–O, Fe–Cr–O- containing phases. Analytical techniques including scanning electron microscopy, electron backscatter diffraction, and energy dispersive X-ray spectrometry are applied to characterize the phase formation, revealing the potential of these composites for use as inert anodes in aluminum electrolysis cells. PO at 800 °C is not sufficient to form adequate protective oxide layers. Whereas, PO at 900 and 1000 °C leads to the formation of protective oxide layers containing Mg–O Fe–O halite-like solid solutions and (Cr,Fe)3O4 spinel phase. Sample, preoxidized at 1000 °C is sealed in Mg–Fe–O spinel phase.
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GRK 2802: Steel ceramic composite anodes based on recycled MgO–C lining bricks for applications in cryolite/aluminum melts
(Technische Universität Bergakademie Freiberg, 2026-02-16) Yaroshevskyi, Serhii; Weigelt, Christian; Malczyk, Piotr; Roungos, Vasileios; Hubalkova, Jana; Zienert, Tilo; Kraft, Bastian; Wagner, Stefan; Aneziris, Christos
Novel manufacturing route for composite inert anodes containing 60:40 of 316 L stainless steel and MgO powder obtained from recycled MgO-C brick material has been developed and evaluated. After burnout of residual carbon from the recycled MgO-C powder, MgO and steel were granulated and pre-sintered in order to generate agglomerates of composite material acting as coarse grains within the composite material, and thus lowering the sintering-related shrinkage. The pre-sintered granules were mixed with raw steel and MgO powder in order to achieve a high particle packing and subsequently cold isostatically pressed in the form of electrodes. All manufactured anode samples were subjected to sintering at 1350 ◦C and pre-oxidation at different temperatures – 800 °C, 900 °C, and 1000 °C. Afterwards, mechanical and electrical properties of the manufactured electrodes were characterized. The results show that upcycling of the MgO-C material enables manufacturing of sophisticated electrode products, which can be applied in the aluminum industry.