Mechanized guniting of the lining of steelcasting ladles

Conclusions A method has been developed and equipment constructed for guniting steelcasting ladles without any manual labor. Experiments and tests were carried out with compositions based on quartzite, Chasov-Yar semiloamy sand, and fine-ground chamotte. The industrial-scale guniting tests showed that the durability of the lining of 130-ton steelcasting ladles increases by 30% (4.7 melts) on average with one guniting per ladle campaign.Translated from Ogneupory, No. 5, pp. 32–36, May, 1977.     

Drying the monolithic lining of 300-ton steelcasting ladles

Conclusions The optimal drying temperature for the monolithic silica lining of 300-ton steelcasting ladles is 500°C for a drying time of 18 h, provided the ladle casing contains an adequate number of ventilation holes.Translated from Ogneupory, No. 3, pp. 31–34, March, 1977.     

Quartz-clay ramming compounds with quartz sand from the Latnensk deposits

Conclusions Ramming compounds based on Latnensk clay-containing quartz sand and intended for the monolithic lining of steelcasting ladles were developed and tested and are now in production.The average durability of the lining of the 180-ton steelcasting ladles of converter section No. 1 of the Novolipetsk Metallurgical Plant is 9–10 melts when it consists of a ramming compound produced from Latnensk quartz sand. The lining becomes unserviceable owing to the low durability of the working layer of the bottom. When using a ramming compound based on Chasov-Yar semifatty sand, the lining of the lateral parts of the ladle bottom and that of the slag zone are severely eroded after 7–8 melts.Deceased.Translated from Ogneupory, No. 1, pp. 14–17, January, 1978.     

Cast magnesia-spinel concrete linings for steelcasting ladles

Conclusions The magnesia-spinel concretes developed by the writers possess good mobility, thermal-shock resistance, volumetric stability, and low porosity. The concretes settle without additional compaction.A simple technology was developed for the production of cast concrete linings in steelcasting ladles. In transformer steel production the lining of 25-ton recasting ladles lasted six times longer than a chamotte brick lining and the specific consumption of refractories was four times lower; in 35-ton steelcasting ladles a lining of concrete MShG-15 lasted twice as long as a chamotte brick lining and the specific consumption of refractories was 1.3 times lower.An installation was devised for the production of cast concrete linings in steelcasting ladles.Translated from Ogneupory, No. 5, pp. 9–15, May, 1977.     

Guniting of the monolithic lining of steel-teeming ladles

Conclusions The authors have developed the principles of guniting the monolithic lining of steel-teeming ladles with semidry masses. Determination of the wetting of a vitrified siliceous monolithic lining with aqueous solutions of additives and suspensions of these solutions, plasticizing additives, and refractory filler has shown that a coating can be deposited onto the surface of a monolithic lining. Formation of a ceramic bond between the coating and the vitrified surface of a monolithic lining takes place at high temperatures (900°C or above). Masses of siliceous, aluminosilicate, and periclase-chromite compositions have been developed for guniting the monolithic lining of steel-teeming ladles.A procedure for guniting the monolithic lining of 180- and 350-ton steel-teeming ladles has been developed and tested. The best results have been obtained with use of gunite masses of periclase-chromite composition.Translated from Ogneupory, No. 6, pp. 25–30, June, 1981.     

Guniting the lining of steel-casting ladles

Conclusions In a joint investigation by the Serp i Molot Metallurgical Plant in Moscow and the All-Union Institute of Refractories the advantages were demonstrated of guniting the lining of steel-casting ladles. The first industrial-scale trials showed that guniting results in a significant increase in the durability of the lining and in a decrease in the consumption of ladle brick. In order to extend the practice of guniting steel-casting ladles it will be necessary to organize the production of gunite at specializing establishments of the refractories industry.Translated from Ogneupory, No. 8, pp. 37–39, August, 1975.     

Durability of the lining of mixer-type transfer ladles

Conclusions A method has been developed and tested for increasing the durability of the lining of 420-ton mixer type transfer ladles for cast iron by the impregnation of the active layer with tar. At a tar temperature of 100°C the active layer is fully impregnated in 65 h. The result is a decrease in the porosity and increase in the coldcrushing strength of the chamotte brick. For a good-quality impregnation use must be made of a steam coil which will heat the tar evenly throughout the ladle volume to 100–120°C.The impregnation increased the durability of the ladle lining from 316 to 400 transfers.Translated from Ogneupory, Vol. 18, No. 8, pp. 29–31, August, 1977.     

A monolithic lining for 100-ton steelcasting ladles

Conclusions A technology for producing a monolithic lining in 100-ton steelcasting ladles was developed at the Dneprovsk Metallurgical Plant. The lining is rammed with a sand slinger and consists of a quartz—clay composition produced by the Krasnogorovsk Refractories Plant. It was found that the grain-size distribution of the composition is optimal when it contains 15% clay. The trials showed that the rib and buckets of the sand slinger head should be fabricated from materials with a higher resistance to abrasion.Translated from Ogneupory, No. 1, pp. 26–27, January, 1978.     

Improving the efficiency of guniting steel-pouring ladles

Conclusions Hot guniting of steel-pouring ladles without cooling the lining enables us to reduce the time taken to prepare them for pouring, and creates conditions for repeated hot guniting within a ladle campaign. This will make it possible to increase the stability of the lining and to reduce the energy expended on drying the gunite layer.The efficiency of mechanized guniting can also be improved by differential use of gunites with rational compositions.Translated from Ogneupory, No. 7, pp. 38–41, July, 1981.     

Temperature field of the quartz-graphite lining of steelcasting ladles

Conclusions The temperature field of the rammed quartz-graphite lining of a 34-ton steelcasting ladle was analyzed by electrical simulation.The addition of 10% graphite to the silica ramming compound does not result in a lower melt temperature during pouring.Translated from Ogneupory, No. 6, pp. 12–15, June, 1977.     

Gas-flame guniting of the lining of intermediate continuous steel-casting ladles

Conclusions As a result of laboratory investigations and rig testing of the flame guniting of intermediate ladles for continuous steel-casting plant we recommend the following bodies: 90% corundum, 10% sodium tripolyphosphate; 80–90% corundum, 20–10% chamotte; 80–90% high-alumina chamotte, 20–10% chamotte. The particle size of the corundum body is <0.088 mm, high-alumina <0.25 mm.The optimum guniting cycle is: consumption of natural gas 60 m³/h, oxygen 100 m³/h, gunite body 150–200 kg/h, guniting distance 450–550 mm, rate of moving the burner 1.0 m/min.In the case of chamotte, the coefficient of gunite body utilization equals 0.75, for high-alumina 0.70, and for corundum 0.40, with an open porosity in the gunite coating of 10–15, 8–10,and 4–6%, respectively.Using the experimental equipment the body made from 90% corundum and 10% sodium tripolyphosphate was used to gunite the side surface of the lining of an intermediate ladle. The wear of the gunite section of the lining was 1.3–2.5 mm per heat.Translated from Ogneupory, No. 4, pp. 37–42, April, 1973.     

Introducing “Orion” equipment for mechanized guncreting of steel ladles

Conclusions Industrial operation in steel factories of the Orion complex has shown the effectiveness of the plant and of mechanizing the guncreting of steel ladles. The average life of the lining in ladles was increased by 25–50%, the maximum life of 200-ton ladles at the Rustav factory having been brought to 52 heats. A reduction has been achieved in the specific consumption of ladle refractories equal to 1.7–3 kg/ton of steel. At Magnitogorsk they have increased the throughput capacity of steel melting bays by 3% with a reduction in the ladle stock of 11%.Translated from Ogneupory, No. 6, pp. 19–22, June, 1981.     

Mixtures of a base composition: Consumable lining of tundish ladles of continuous casting machines

Work on creating a refractory mixture of a base composition for consumable linings of tundish ladles of continuous casting machines is described. Various binders for mixtures deposited on the working lining of the tundish ladle by guniting have been tested. The endurance of a consumable lining based on periclase with an elevated content of CaO was 5 heats on a CCM of an electric steelmaking shop.Translated from Ogneupory, No. 4, pp. 28 – 30, April, 1996.     

Introduction of rammed linings for 250-ton steel-teeming ladles at Makeevka Metallurgical Combine

Conclusions In the open hearth shop of the Makeevka Metallurgical Combine the 250-ton steel-teeming ladles have been converted from a brick lining to a monolithic quartzite-clay rammed lining prepared with the use of a sand slinger using MKG-1 mixture according to Technical Specification 14-8-252-77 produced by the Krasnogorovka Refractory Plant. The use of monolithic linings of the ladle walls provided an increase in their average life from 9.06 to 15.6 heats.During service of the quartzite-clay rammed linings in teeming ladles partial degeneration of the quartz into cristobalite and full transformation of the fine crystalline binder into glassy occurs.The annual saving from the introduction of monolithic rammed linings of the 250-ton steel-teeming ladles of the Makeevka Metallurgical Combine was 2000,000 rubles.Translated from Ogneupory, No. 1, pp. 47–49, January, 1985.     

Guniting of the lining of furnaces for heating of steel billets

Conclusions A method of guniting of the rolling mill heating furnaces during shutdown for cold repairs and with a lining surface temperature of 900–1200°C was developed with the use of guniting powders produced by industry of aluminosilicate and basic compositions with hydraulic and silicate binders. The introduction of composite guniting of the lining in the cold and hot conditions makes it possible to reduce the volume of lining repair work by 10–15 m³ per furnace and the consumption of brick refractories by 0.1 kg per ton of steel rolled and to increase the life of the lining by 1.5–2.0 times.Translated from Ogneupory, No. 4, pp. 48–51, April, 1988.     

Production technology for ladle brick using semiacid clays

Conclusions A technology was developed for making ladle brick from Ch1PK semiacid clays mined in the Chasov Yar area.The biggest difference between semiacid ladle brick and firebrick is the after-expansion at service temperatures of 1500–1600° C which reaches about 3% and which densifies the structure of the ladle.The life of semiacid brick in 250-ton steel ladles on average is 11% higher than ordinary ladle brick.The production of ladle brick from semiacid raw materials is economic. The lower cost of the product is a result of using cheaper raw materials and firing the clay into chamotte and products at lower temperatures.Translated from Ogneupory, No. 5, pp. 3–7, May 1967.     

Composition and erosion of Gunite coatings and the technology of converter guniting

Conclusions Spalling and slag erosion are the principal forms of wear of the Gunite coating in converters. Spalling is caused mainly by the difference in the thermal conductivity of the magnesite coating and the tar-bonded dolomite-magnesite lining bricks. Spalling can be prevented without impairing the slag resistance of the coating by applying the Gunite mix in thin layers after every 2–4 melts. The coating was gradually dissolved in the slag before reaching the spalling stage.Tests were carried out with 130-ton converters at the Il'ich Metallurgical Plant in Zhdanov. Regular guniting increased the durability of one of the converters by 120 melts. On another converter a firm 70-mm-thick coating, which did not crumble even when the converter was cooled down for cold overhaul, was produced in the journal zones in 12 guniting operations after the lining had burnt through to the shell.Petrographic investigations showed that the principal phases of the Gunite coating after service in the converter are periclase, magnesiowuestite, calcium ferrite, dicalcium silicate, a vitreous silicate bond, and RO-phase; inclusions of metallic iron occur here and there.Translated from Ogneupory, No. 1, pp. 34–40, January, 1977.     

Masses based on Arkalyk clay for guniting steel-teeming ladles

Conclusions The authors investigate the properties of gunite masses based on Arkalyk clays with regard to service conditions in steel-teeming ladles used in open-hearth manufacture of steel. The optimal composition of the mass is as follows: 90% chamotte, 10% clay, and 10% binder (above 100%). Industrial tests have been performed on a mass for guniting 230-ton steel-teeming ladles of the MMC. The durability of a gunite layer 30–35 mm thick is about 6 pourings. The results confirm that Arkalyk clay is a promising material for making gunite masses.Translated from Ogneupory, No. 6, pp. 30–35, June, 1981.     

Guniting the roof of open-hearth furnaces at the Zaporozhstal' plant

Conclusions Laboratory analyses and industrial-scale tests resulted in the development of the technological parameters for guniting the lining of the main roof of 500-ton open-hearth furnaces operated at an accelerated melting cycle.The microstructure of chromite and chrome — magnesite coatings containing low-melting additives was analyzed and the chemical composition and structure of coatings which had served in the roof of an open-hearth furnace were determined.The work carried out at the Zaporozhstal' Steel Plant confirmed the effectiveness and advantages of guniting the roof of large-tonnage open-hearth furnaces.Translated from Ogneupory, No. 5, pp. 28–35, May, 1976.     

Refractory compounds of basic composition for the monolithin lining of steel-teeming ladles

Conclusions Questions of the method of production of basic ramming compounds at Panteleimonovka Refractory Plant and their use in the monolithic lining of the walls of 160-ton steel-teeming ladles of the No. 2 Converter Shop of Kirvoi Rog Steel Combine are considered.An analysis of the wear of the lining during service showed that it occurs as the result of spalling of the sintered zone and salamandering of the lining. The use of a movable thermally insulated lid made it possible to hold the temperature of the ladle lining within limits of 730–1120°C between heats and to obtain a basic rammed lining life of 21–39 heats as opposed to an average life for the shop of 14.8 heats.A reserve for increasing the ladle basic lining life is optimization of the thermal conditions of its service, including high-temperature heating of the lining before pouring of the metal, the use of thermally insulated lids with the minimum consumption of time for placing of them, an increase in the life of the well refractory to the life of the walls and bottom, and elimination of cooling of the lining between heats.A Discussion: Problems of the Production and Use of Refractories for the Lining of Steel-Teeming Ladles. [For the start of the discussion see No. 8 (1988) and for the continuation Nos. 9–12 (1988) and Nos. 1–3, 5, and 7 (1989).]Deceased.I. I. Glaka, N. F. Drobot, N. V. Kurmaz, B. P. Zinchenko, S. A. Poznyak, I. M. Ryaboshapkin, V. V. Slushko, A. A. Chulkov, Yu. Bormatov, S. I. Vanchyuk, V. I. Dobrovol'skii, B. G. Zhuravel', N. I. Kiyan, L. I. Nekrasov, N. M. Sokolov, P. V. Khomenko, G. A. Nikitenko, S. Dorgobuzov, P. I. Valiev, N. N. Gorbatko, V. I. Kovalenko, and M. I. Lyakhov of Krivoi Rog Steel participated in the preparation and tests of the basic monolithic linings.Translated from Ogneupory, No. 8, pp. 1–4, August, 1989.