Improving Lining Resistance Using High-Magnesia Fluxes in the Converter Steelmaking Process

Tests carried out at the Severstal Joint-Stock Co. and Magnitogorskii Iron-and-Steel Works JSC showed that a lime-magnesia flux containing 30 – 35% MgO used in the converter steelmaking process produced a favorable effect on the refractory lining resistance. Compositions for high-magnesia granules (50 – 65% MgO) were developed, their properties characterized, and the rate of solution in the slag melt was determined. Using these granules in the converter process makes it possible to increase the service life of periclase-carbon refractories for converter linings.     

Monolithic protective coatings for billet continuous casting machine tundishes

Conclusions Magnesia-spinellide refractory coatings for protection of tundish linings of brick refractory parts have been developed.The use of protective coatings makes it possible to increase the lining life by five heats, to decrease the refractory consumption by 1.6 kg per ton of steel, and to increase the productivity of billet continuous casting machines.Translated from Ogneupory, No. 7, pp. 49–52, July, 1984.     

Engineering in Action

Improvements in operational performance of the refractory lining of a direct-current electric furnace for cobalt smelting achieved at the Ufaleinikel Joint-Stock Co. in collaboration with the Kombinat Magnezit Joint-Stock Co. are reported.     

Optimizing the Plastic Properties of Binding Clays with Use of a Simplex-Lattice Method of Experimental Design

The effect of plasticizers on the plastic properties of refractory clay mixtures is studied. Optimal concentrations for additions are specified. Applications to the serial production of aluminosilicate materials at the Borovichskii Refractory Kombinat Joint-Stock Co. are reported.     

Expanding the product range to meet metallurgists’ growing demands

A brief overview of carbon-containing refractory products available from the Semiluki Refractory Plant Joint-Stock Co and areas of their application is given. __________ Translated from Novye Ogneupory, No. 1, pp. 27–30, January, 2006.     

The Use of Refractory Castables in the Ferrous Metallurgy

Products commercially available from the Ogneupornye Tekhnologii Joint-Stock Co. are described and their physicochemical characteristics presented. Results for refractory castables tested under industrial conditions are presented and compared with those of foreign analogs. Routes toward further improving convention castables and developing new materials are outlined.     

Increasing the resistance of oxygen converter linings

Conclusions We developed a. differentiated construction for converter linings using tarred dolomite and periclase — spinel refractories in sites most prone to erosion: the throat, the neck, and the upper cylindrical parts on the pivot sides. Taking into account the topography of the wear we selected a rational profile for the working layer of the lining with which we obtained a higher and more uniform resistance.We developed and introduced a production technology for tarred dolomite refractories by pressingbodies cooled to 35–45°C, using tar with an increased coke residue and a viscosity of C¹⁰ ₄₀=40-50 sec as the bond.We also improved the order of feeding in the batch materials, introduced slag and blow cycles for converter melting, ensuring rapid finishing of the high-basic slag in the blow process, reducing the melting time and the number of heats produced with the blow, etc.As a result of improving the quality of the tarred dolomite refractories, the introduction of the differentiated (with respect to thickness and types of refractories used) constructions for the linings, the use of rational firing cycles for the linings, improvements and stabilization in the quality of the batch materials, and improvements in the converter melting technology, the average life of the converter linings increased to 612 heats and the total consumption of refractories dropped to 2.95 kg/ton of steel; the maximum resistance reached 646 heats.The increase in the life of the linings ensured regular operation of the converter shop and provided a substantial increase in steel output.Translated from Ogneupory, No. 1, pp. 5–11, January, 1970.     

Refractories for the Taphole of Converters

A range of refractory materials for the converter's taphole lining commercially available from the Kombinat Magnezit Joint-Stock Co. and major aspects of the processing technology are considered. The effective use of antioxidant additions is confirmed by thermal analysis. Results of operational tests of refractory materials are discussed. The advantages of an innovative design of the taphole unit composed of blocks of variable diameter and assembled on a metal template are emphasized. An economic feasibility analysis of the use of periclase-carbon taphole blocks is given. The newly designed refractory material are shown to conform with the requirements of modern converter technology.     

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.     

Oxide-carbon refractories produced by OOO Gruppa Magnezit in lining steel-pouring ladles

The activity of OOO Gruppa Magnezit is described, concerning production of oxide-carbon refractories, and methods of preparing refractory linings from them for steel-pouring ladles with the aim of obtaining the minimum specific consumption of refractory materials and achieving a prescribed life.     

Advanced Refractory Products and Materials Developed at the A. S. Berezhnoi Ukrainian Research Institute for Refractories Joint-Stock Co.

A brief survey of R&D activities carried out at the A. S. Berezhnoi Ukrainian Research Institute for Refractories (UkrRIR) Joint-Stock Co. is presented aimed at the output of unique high-tech refractory products for metallurgical, machine building, glass-making, petrochemical, and other branches of industry. A wide range of products recently developed and/or commercially available is considered: refractory components of different size and shape — mullite-corundum, corundum with zircon added, chromium oxide, periclase-lime-carbon, silicon carbide, zirconia, high-efficient lightweight calcium hexaaluminate and anorthite-based composites, concrete and ramming mixes of corundum zirconia, mullite-corundum, mullite-silica, chamotte and silicon carbide composition (low-cement included).     

Basic-Composition Mixture for the Consumable Lining of Intermediate Ladles

Thermomechanical and chemical-ceramic properties of the PTMS basic-composition mixture for the consumable refractory lining of intermediate ladles in service at the Kombinat Magnezit Joint-Stock Co. are considered and some details of the fabrication technique are discussed. Results for the mixture tested for performance at various metallurgical plants are given. Advantages of the mixture for practical application, its microstructural characteristics in pre- and post-service conditions, and the wear behavior are discussed.     

Periclase-Carbon Refractories from the Kombinat Magnezit JSC for Use in Converter Steelmaking Technology at the Magnitogorskii Metal-and-Steel Works JSC

Cooperation between the Kombinat Magnezit Joint-Stock Co. and Magnitogorskii Metal-and-Steel Works Joint-Stock Co. in the area of exploitation of converter refractories is briefly outlined. Prospects for further improvement of the performance characteristics of refractories and converter design are discussed.     

Tarred magnesite refractories for oxygen converters

Conclusions A technology was developed for producing tarred magnesite refractories for lining steel converters. The average monthly life of the lining of the converters at the ZSMZ was increased to 624 heats (August 1970) with a maximum life of 662 heats.The tarred magnesite refractories based on MDPK-75 powder possess excellent resistance to hydration and have a high strength. Considering these facts and also in view of the high capacity of the refractories division of ZSMZ it is possible to transport tarred magnesite products over appreciable distances and to deliver them to converters in newly constructed factories.The outstanding feature of tarred magnesite refractories is their slight tendency to slagging, in connection with which the life of the tarred magnesite linings largely depends on the daily output of the converters. To reduce the consumption of refractories in each converter at the ZSMZ it is necessary to arrange more than 30 heats per day during the entire campaign period.Translated from Ogneupory, No. 1, pp. 4–9, January, 1971.     

Impregnation of a periclase-chromite lining with nickel matte

Results of an investigation of periclase-chromite linings in contact with matte (sulfide-metallic melt) in shaft melting of oxidized nickel ores are presented. It is shown that the sulfide components of matte, preferentially iron sulfide, impregnate the refractory, whereas the metal (21.9–23.1% Ni, 1.38–1.45% Co, 73.3–76.1% Fe, and 0.8–1.0% S) remains in the gaps between bricks. Chemical analysis data show that the sulfide-impregnated refractory contains 5.1–9.5% S, 9.8–27.9% Fe, 1.8–7.5% Ni, 0.09–0.15% Co, which markedly decreases the heat engineering parameters of the refractory and the entire lining. The results clarify the mechanism of failure of refractories and the formation of skull.Translated from Ogneupory, No. 6, pp. 28–29, June, 1995.     

Use of refractory coatings on linings of electric resistance furnaces

Results of experimental and theoretical studies of the reduction of power consumption in furnaces with a lining covered by IVAKS-2 and IVA-2 intensifying refractory coatings are presented. The heating curves of the metal confirm the conclusion that the consumption of electric power is reduced by up to 24%. IVAKS-2 and IVA-2 coatings developed by the workers of MGVMI provide maximum effect with minimum expenditure. The coatings can be recommended for heating and heat-treatment furnaces for forging and rolling production. The size coefficients for designing electric heaters in furnaces with coated linings are evaluated empirically.     

镁铝炭砖和铝镁炭砖在连铸包衬上的应用

用镁铝炭砖和铝镁炭砖综合砌筑连铸包衬，使用寿命由５３次（高铝砖衬）提高到１０１次，耐火材料单耗由４．３８ｋｇ／ｔ钢降低到２．３ｋｇ／ｔ钢。     

REFRACTORIES AND REFRACTORY CEMENTS FOR THE NONFERROUS FOUNDRY1

Development in refractory linings for the various furnaces encountered in the nonferrous foundry industry is outlined, and figures given showing the present trend. These include open-flame, crucible, and electric furnaces. The open-flame furnaces formerly used firebrick linings, but silicon-carbide and high alumina refractories are coming into use. The crucible furnace linings show a decided preference for silicon-carbide refractories, while the electric furnaces are partial to the alumina and mullite bearing types. Progress in the manufacture of refractory cements and their use in the various types of furnaces is discussed. Data are given which indicate that the use of the proper types of cements for maintaining furnace linings of similar composition is becoming more general.     

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.     

Carbon-based refractory lining components and materials available from the Chelyabinsk Electrode Plant

Carbon-based refractories for the lining of thermal power units for service in the ferrous and nonferrous metallurgy commercially available from the Chelyabinsk Electrode Plant Joint-Stock Co. (incorporated in the Énergoprom-Management Co.) are considered. Technologies for the manufacture of advanced carbon refractories are described. Routes towards further improvement of technologies for the manufacture of carbon-based lining materials and components of a third generation are discussed.__________Translated from Novye Ogneupory, No. 8, pp. 11 – 15, August, 2004.