The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia...

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The Overview of the Refractory Technology from the Mini-Mill Application Perspective Tomas Richter General Manager Europe HarbisonWalker International

Transcript of The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia...

Page 1: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

The Overview of the Refractory Technology from

the Mini-Mill Application Perspective

Tomas Richter

General Manager Europe

HarbisonWalker International

Page 2: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Content

1. Type of Refractories

2. Raw Materials

3. Bonding Systems

4. Manufacturing Process

5. Wear Mechanisms

6. Standard Brick Shapes and Anchors

7. EAF Refractory Lining Considerations

8. Ladle Refractory Lining Considerations

9. Tundish Refractory Lining Considerations

Page 3: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Type of Refractories

Shaped

Products

Unshaped

Products

Hydraulic

Press

Fused

Cast

Isostatic

Press

Assem.

w/cast.

Gunning

Mixes Vibratables

Cast-

ables Mortars

Page 4: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Type of Refractories

Shaped

Products

Hydraulic

Press

Fused

Cast

Isostatic

Press

Prefab

Shapes

Page 5: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Type of Refractories

Unshaped

Products

Monolithics

Gunning

Mixes

Dry

Vibratables Castables Mortars

Page 6: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Manufacturing Process - Refractories

MUCH KNOW-HOW RAW MATERIALS

Equipment

Machinery MIXING

Kilns

etc. SHAPING

TEMP. TREATMENT

Final Product B R I C K

KNOW-HOW Installation

P R O D U C T I O N

B R I C K S

At Customer Site

M I X E S

P R O D U C T I O N

RAW MATERIALS KNOW-HOW

Equipment

MIXING

Semi-finished Product

M I X

At Customer Site

MIXING MUCH KNOW-HOW

Equipment

SHAPING Machinery

Service

TEMP. TREAT. etc.

Page 7: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Acid Neutral Basic

Silica Alumina

Chromic Oxide

Magnesia

Lime

Alumino-Silicate Magnesia-Chrome

Refractory Classifications

Page 8: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Refractory Classification for Steelmaking

Refractory

TypeSilica Fireclay Mullite High Alumina

Main Raw

MaterialQuartz Flint Clay KaoliniticClay

Bauxite and

Corundum

Dominant

Application

Coke Ovens

Blast Furnace

Coke Ovens

Blast Furnace

Blast Furnace

Reheat Furnace

Ladles

EAF

Refractory

Type

Magnesia

Chrome

Zirconia

ZirconDoloma Magnesia

Main Raw

Material

Magnesite

Chrome Ore

Zircon and

Zirconium OxideDolomite Magnesite

Dominant

Application

Secondary

Steelmaking

Ladles, EAF

Flow ControlLadles

AOD

Ladles

BOF

EAF

Mini-mill applications in red

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1500

1600

1700

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

SiO2 Al2O3 Cr2O3 CaO ZrO2 MgO

Te

mp

era

ture

[°C

]

Silica

1702 C

3128 ºF

Alumina

2050 C

3722 ºF

Chromia

2275 C

4127 ºF

Calcia

2600 C

4712 ºF

Zirconia

2700 C

4892 ºF

Magnesia

2800 C

5072 ºF

Melting points of pure refractory oxides

1530 C

2786 ºF

Steel

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Melting points of mixed oxides

Page 11: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Ternary Diagram

Page 12: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Magnesia

Sintered and Fused Magnesia

MgO between 90 to 99%

Purity (impurities)

B2O3

SiO2

Al2O3

Fe2O3

(CaO)

Crystal Size between 10 to 1000 microns

Density (porosity of grain) 3.10 to 3.45 g/cc

Page 13: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Microstructure Magnesia

Sintered Magnesia Fused Magnesia

Page 14: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon
Page 15: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Bonding System Classification

Class Characteristics Result Of:

Ceramic Strong to high temps, brittle, High Temp Firing

low porosity

Chemical Strong to intermediate temps, flexible Acid/Alkali Reaction

continuous matrix

Hydraulic Strong to intermediate temps, Cement/water Reaction

low permeability, high porosity

Carbon Strong to very high temps, oxidation Resin decomposition

continuous matrix, low porosity Carbide development

Page 16: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Bonding Systems

CERAMIC BOND CARBON

BOND

SINTERING

NO

STRENGTH

CARBONISATION

CHEMICAL

BOND PYROLYSIS PYROLYSIS

MESO-

HYDRAU- PHASE

HYDRAULIC RESIN

BOND LIQUEFACTION NETWORK 100°C

500°C

1000°C

1500°C

CACement

Reactive Alumina

-Sodium Silicates

- Phosphates

- Sulphates

- Chromates

Petroleum Pitch Resin

Page 17: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Ceramic bond

Theory: Reality:

unsintered sintered unsintered sintered

Sintering will develop at

presence of:

- additions (binder/sinter aid)

- high temperature

- impurities

- pressure (e.g..: ferrostatic

pressure of steel bath)

- small crystals and grains

Page 18: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Carbon Bonding Resin

45%

Pitch

55 – 70% Carbon yield

- Environment

+ + Matrix strength + Structure

- + Oxydation resistance

Behaviour at process + +

-

-

Page 19: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

0

100

200

300

400

212 444 525 1022

Temperature, °F

Wate

r V

apor,

cm

3/g

Casting Water

C3AH6 C3AH6

C3AH1.5

Source: DL Hipps and JJ Brown, Jr.

Cement is a HYDRAULIC BONDING agent for castables, gunning mixes and some mortars which develops hydrates in contact with water.

The type and quantity of hydrates determine the properties of the final refractory concrete.

Page 20: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Classification of Castables (ASTM C401-91)

CaO Level Cement Level

Conventional

Castables

Low Cement

Castables

Ultra-Low Cement

Castables

Cement-Free

Castables

>2.5%

1.0-2.5%

<1.0%

<0.2%

15-30%

4-8%

<4%

No Cement

Category

Page 21: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

2. Moisture Loss of Castables with Different

Cement Contents

0

20

40

60

80

100

0 200 400 600 800 1000 1200

Temperature, °F

Mois

ture

Loss,

%

ULC CAST LC CAST CON CAST HC CAST

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3. Curing Temperature vs. Strength Castable with 15% Cement Dried 24 hrs. @ 220°F

0

200

400

600

800

1000

1200

1400

40 60 70 90

Curing Temperature, °F

Str

ength

, psi

Page 23: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Permeability of Bricks vs. Castables

0

1

2

3

4

5

6

7

0 250 500 750 1000 1250 1500 1750

Firing Temperature, °C

Rela

tive P

erm

eabili

ty

BRICK

CASTABLES

Page 24: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

4. Curing Temperature vs. Permeability Castable with 15% Cement Dried 24 hrs. @ 220°F

0

10

20

30

40

50

60

70

80

40 60 70 90

Curing Temperature, °F

Perm

eabili

ty C

onsta

nt,

Englis

h u

nits x

10

6

Page 25: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Manufacturing Process - Refractories

MUCH KNOW-HOW RAW MATERIALS

Equipment

Machinery MIXING

Kilns

etc. SHAPING

TEMP. TREATMENT

Final Product B R I C K

KNOW-HOW Installation

P R O D U C T I O N

B R I C K S

At Customer Site

M I X E S

P R O D U C T I O N

RAW MATERIALS KNOW-HOW

Equipment

MIXING

Semi-finished Product

M I X

At Customer Site

MIXING MUCH KNOW-HOW

Equipment

SHAPING Machinery

Service

TEMP. TREAT. etc.

Page 26: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Refractory Manufacture - Brick

Page 27: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Standard Refractory Shapes

Page 28: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Standard Refractory Shapes

Page 29: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Standard Refractory Shapes

Page 30: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Standard Refractory Anchors

Page 31: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Standard Refractory Anchors

Page 32: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Wear Mechanisms

Corrosion by Slag

Chemical

Page 33: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Temperature Wear

Page 34: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Wear Mechanisms

Corrosion by Slag

Chemical

Page 35: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Thermal Expansion of Refractories

0

0.3

0.6

0.9

1.2

1.5

1.8

2.1

0 500 1000 1500

Temperature [C]

Th

erm

al E

xp

an

sio

n [

%]

M agnesia

Dolomite

Chromite

90% Corundum

80% Bauxite

M ullite

SiC

Graphite

Mechanical Wear

Page 36: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Thermal Conductivity of Refractory Bricks

0.0

20.0

40.0

60.0

80.0

100.0

120.0

900 1,400 1,900 2,400

Temperature, [o F]

Th

erm

al

Co

nd

ucti

vit

y,

BT

U.i

n/(

hr.

ft2.oF

)

Mag Carbon 20% C

Mag Carbon 15% C

Mag Carbon 10% C

Mag Carbon 5% C

Dolomite or MgO - Fired

Dolomite C - Bonded

Alumina Magnesia

Carbon

Mag-Chrome Fired

80% Alumina - Fired

Mechanical Wear

Page 37: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

One-sided heating

One-sided expansion

tensile + compression stresses

cracks

One-sided cooling down

One-sided shrinking

compression + tensile stresses

cracks

Reasons for thermal stresses

Page 38: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Wear Mechanisms

Corrosion by Slag

Chemical

Page 39: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Solutions consisting primarily of molten metal oxides

Float on top of the steel because of specific gravity

lower than that of molten steel

Primarily liquid at steel making temperatures

Play an essential role in the steel making process

2C + O2 2CO

2Fe + O2 2FeO

4Al + 3O2 2Al2O3

Si + O2 SiO2

4P + 5O2 2P2O5

2Mn + O2 2MnO

Slags

Page 40: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Larry Wolfe, Carmeuse Lime & Stone– AIST Practical Seminar

Charleston, S.C., 2/2012

Slag Formers – Lime and Dolo-lime

Page 41: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

PRIMARY SOURCES OF SLAGS

Oxidation of metallic elements from scrap

Non metallics- Sulfur & Phosphorus

Flux Additions – Dolo & hi calcium lime, spar

Dissolved refractory – Hearth material, gun

material, brick

Page 42: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

0

5

10

15

20

1 2 3 4 5

Lime-Silica Ratio of the Liquid Slag (CaO/SiO2)

Per

cent

of

MgO

Dis

solv

ed in

the

Liq

uid

3100ºF*

3000ºF**

2750ºF

2900ºF

Solubility of Magnesia in a

Steelmaking Slag

Page 43: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

• Four Variables:

– MgO content

– FeO content

– Temperature

– Basicity

• ISD’s show phase

relations of MgO

and FeO content at

fixed basicity and

temperature

Isothermal Stability Diagram

Page 44: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Solubility of Magnesia in Steelmaking Slag

Carmeuse Technical Training

Page 45: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

EAF Refractories

• Magnesia Carbon: fused / sintered

- Carbon content 10-15%

- Metal additions for oxidation and strength

• Burned Magnesite: impregnated with pitch

• Hearth / Anode: 70 - 80% Magnesia

• Gunning; 60 to 98% Magnesia

• Delta: 80-85% alumina

Page 46: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon
Page 47: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon
Page 48: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

EAF Bottom Designs

Page 49: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

EAF Bottom Designs

Page 50: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Hearth Installation

De-air using pitchforks, vibrators or

walking on until proper compaction is

attained

Repeat these steps several times until

desired depth is achieved

Final compaction should be very firm

Final grade may be finished off by

using vibrating sled if desired

Page 51: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon
Page 52: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Examples or Refractory Applications – Electric Arc Furnace at

Installation

Page 53: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Magnesia-Carbon Bricks

Carbon Levels (usually 5-20%)

Higher levels : more slag resistant

Higher levels : resist EAF and LMF arc flare

Higher levels : more thermal shock resistant

Higher levels : less oxidation resistant

Page 54: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Magnesia- Carbon Bricks

Metal Additions

Higher levels yield stronger bricks.

Higher levels yield more oxidation resistant bricks.

Higher levels cost much more.

Higher levels – Bricks more brittle

Page 55: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Welded Door Jambs

Page 56: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

NUCOR - NARCO

October 2009

One Piece Assembly

Page 57: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

February 16-17, 2010 ANH Refractories Company

Page 58: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

EAF Taphole Designs

Page 59: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

EAF Straight Bore Taphole

Page 60: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

EAF Conical Bore

Page 61: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon
Page 62: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

EAF Delta and Roof •Primary function of Delta is to protect the roof from the electrode arc generated

during the melting operation.

•It is exposed to arc flare, thermal shock, oxidation, chemical corrosion, post

combustion and high temperatures.

Page 63: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Furnace Mono Installation Equipment

Page 64: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Furnace Gunning

Page 65: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Steel Ladles

Page 66: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Steel Ladles Safety Lining

Brick Safety Lining Monolithic Safety Lining

Page 67: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Steel Ladles

Page 68: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

INSULATION

Insulation – Brings Freeze Plane into

Brick

Best Scenario - No Insulation

2nd Best - Minimize Insulation

Page 69: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Insulation versus no Insulation

Page 70: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Steel Ladles – Working Linings

US Steel Market

35%

50%

15%

Si-killed

Integrated

Al-killed

Page 71: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Steel Ladles

Page 72: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Lip Ring Constructions

Page 73: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon
Page 74: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Steel Ladles - Bottom

Page 75: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Precast and Composite Bottoms

Page 76: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Gas Purging Systems

Stir Plugs - Multiple Designs

and Compositions in Both Porous and Directional

Pocket Blocks – Multiple Compositions

Conventional Cast

Compression Cast

ISO Pressed

Plug Asssemblies – Could have some safety and life benefits

Plug Exchange Systems Multiple Systems ussually

supplied by the plug manufacturer

Page 77: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Well Blocks

Page 78: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Steel Ladles

Page 79: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Successful Monolithic Installations

Castables & Shotkast &Gunning Mixes

Material & Water Above 70 F

Cure at 70 to 90 F for High Strength

Use Recommended Amount of Clean,

Drinkable Water

Follow Recommended Heat-Ups

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Tundish Technologies

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Tundish Baffles

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Tundish Impact Pads

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Cast Tundish lining

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Dry Vibe vs. Spray Technology

Profile with dry vibe Profile with spray

2.0 inch

1.5 inch

0.5 inch

2.0 inch

1.25 inch

2.0 inch

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Tundish Spray Machines

What is important?

Reliable Control Equipment.

Easy operation.

Simple maintenance.

Recycle options.

Rapid, reliable spray application.

Auxiliary material handling systems.

Manual Spray systems.

Full Robotic systems for

high volume shops.

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Spraying Tundish

Page 90: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Sprayed Tundish w/Baffle

Page 91: The Overview of the Refractory Technology from the Mini ... AIS… · Refractory Type Magnesia Chrome Zirconia Zircon Doloma Magnesia Main Raw Material Magnesite Chrome Ore Zircon

Tundish Dryer

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Dry-Vibe Mandrel/Curing Unit

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Dry-Vibe Working Lining

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Thank You