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.     

High-alumina refractories for lining steel ladles (discussion)

Conclusions We developed and evaluated, in industrial conditions, a technology for the production of unfired, mullite-corundum refractories, and also fired, mullite-siliceous refractories with additons of chrome ore for lining steel ladles.The life of the 150-tonne steel ladles, with steel processing outside the furnace, when the ladles were lined with the experimental unfired mullite-corundum refractories, equals the life of the ladles lined with similar, industrial fired bricks. The same resistance (on average 20 pourings) was possessed by the ladles lined with the experimental mullite brick of improved quality. The resistance of the ladles lined with the experimental, fired mullitesiliceous refractory with the chrome additive was 26–27 pourings.To explain the effectiveness of using the newly developed refractories in the linings of steelcasting ladles, it is necessary to continue testing them in different metallurgical enterprises.The first part of the discussion was published in No. 8, 1988, and it was continued in Nos. 9–12, 1988, and Nos. 1–3 and 5, 1989.Translated from Ogneupory, No. 7, pp. 4–8, July, 1989.     

Use of unfired periclase-carbon refractories in parts of linings of 350-ton steel-teeming ladles

Workers of the Azovstal’Company have established the causes of the decrease in the endurance of slag-line areas of linings of 350-ton steel-teeming ladles. In 1995–1996 they conducted industrial tests and introduced a process for lining the slag areas of 350-ton teeming ladles with unfired periclase-carbon refractories. The mean service life of a lining of a 350-ton teeming ladle with a slag line made of periclase-carbon refractories amounts to 23 heats on the average without hot repairs of the slag line during the campaign. The wear of the periclase-carbon lining in the slag line is 3.6–4.3 mm per heat. The specific consumption of refractories and materials for a lining has been decreased by 0.6–0.8 kg per ton of converter steel. Such an operating capacity for the periclase-carbon refractories in slag lines is provided by the composition and structure of the refractories, which possess a high heat resistance and resist the effect of the molten metal and slag. Translated from Ogneupory i Tekhnicheskaya Keramika, No. 2, pp. 37–39, February, 1998.     

Guniting the lining of 300-ton steelcasting ladles

Conclusions The practice of guniting the lining of steelcasting ladles has been introduced for the 300-ton ladles of the open-hearth division of the Cherepovetsk Metallurgical Plant. The guniting parameters are as follows: the temperature of the lining of the ladle wall should be 60–120°C; the amount of wetting agent (sodium silicate solution) for the optimal adhesion of the G unite layer to the brick masonry should give the G unite mix a moisture content of 8–15%, and the density of the aqueous sodium silicate solution should be 1.15–1.30 g/cm³.The guniting operation is carried out with a remote-controlled centrifugal-action machine which permits the operation to be carried out at a temperature in the ladle of 200°C. The durability of the ladle lining increases significantly when the lining is gunited regularly up to five times per campaign. The estimated economic benefit from the practice of guniting the 300-ton steelcasting ladles is 85,000 rubles/yr.Deceased.Translated from Ogneupory, No. 2, pp. 29–32, February, 1978.     

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.     

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.     

Refractories for powerful blast furnaces abroad

Conclusions Abroad, the linings of the shafts of powerful blast furnaces are made from dense chamotte brick of high purity with the minimum content of iron oxides and other contaminating impurities. Impregnation of the fired chamotte brick with phosphates substantially increases the alkali resistance, and consequently the resistance of the blast furnace lining. The bosh and well are lined with carbon refractories. Speedy mechanized laying of the wells is done with large blocks up to 6.4 m long, and with cross sectional measurements of up to 0.8-0.6 m. In particularly severe service conditions in the absence of a protective skin layer in the lower part of the shaft and shoulders successful use is being made of carbon linings using electrographitic and semigraphitic products.Effective cooling systems with high thermal conductivity carbon refractories reduces the temperature, which substantially retards the wear of the working layers in the lining.Translated from Ogneupory, No. 7, pp. 56–59, July, 1973.     

Guniting the necks of hot-metal transfer ladles

The components of a guniting mixture (clay and chamotte) and their optimum proportion have been determined in working out the process of guniting necks of hot-metal transfer ladles. The use of guniting increases the service life of the linings of the ladles, decreases the specific consumption of refractories, and reduces the frequency of maintenance of the top layers. Translated from Ogneupory i Tekhnicheskaya Keramika, No. 7, pp. 35–36, July, 1997.     

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.     

Experience gained in production and use of non-fired chamotte parts made of ural raw materials

Conclusions When used for the walls of pre-heating furnaces, steel-pouring spouts and vises for ingot molds, multi-filled non-fired chamotte parts are not inferior in strength to fired chamotte refractories.Non-fired chamotte and chamotte-quartz parts did not show sufficient strength when tested in the lining of steel-casting ladles. Chamotte-quartz brick was not inferior in durability to the multichamotte ladle parts made in the refractory shop of the NTMK.In order to introduce non-fired chamotte parts into industry, it is essential to improve their technology with a view to reducing shrinkage, increasing density and mechanical strength and selecting additives which will prevent them becoming soaked in water.It is also advisable to investigate other spheres of application of non-fired alumo-silicate refractories.     

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.     

Functional carbonized refractories

Functional carbonized refractories for the lining of steel ladles have been developed. Results of tests carried out on 400-ton steel ladles under industrial conditions are reported. The average durability of the refractory lining was 94.5 heats against rated value of 100 heats. __________ Translated from Novye Ogneupory, No. 7, pp. 34–38, July, 2005.     

Refractories for coke oven doors

Conclusions The main requirements of refractories for the doors of coke ovens are enhanced strength and thermal-shock resistance, and a reduced thermal conductivity. The use of chamotte articles due to lamination leads to scaling and spalling, and increases the gas permeability of the structure and causes rapid wearing. The resistance of the brick is reduced with an increase in the volume of the coking chamber, and this equals 1.5–2 years.In recent years a start has been made with the use of block concrete linings for the doors of coking ovens on the basis of concrete containing chamotte fillers and aluminous cements. The resistance of concrete blocks reaches 4–5 years or more. With block linings there is a reduction in the number of joints, ensuring mechanization of the installation and demolition of the lining, and a reduction in the time spent on lining operations.Two types of Soviet designs are used for the doors of coke ovens with block linings. The most promising is the nonreinforced lining with removable components, permitting independent changing of the blocks, and repeated use.Abroad, research is going on into reinforcement of blocks with metal fibers of special composition and the use of fused quartz for preparing the blocks.Translated from Ogneupory, No. 8, pp. 38–43, August, 1984.     

High-density ladle brick from Arkalyk clay

Conclusions The Bogdanovich Refractories Plant has developed a production technology for a high-quality high-density brick from clay from the Arkalyk deposits. Service tests with the brick showed that it increases the durability of the lining of steelcasting ladles of varied capacity by a factor of 1.6–2.0.To obtain the best results, the Arkalyk clays must be blended before being used.Deceased.Translated from Ogneupory, No. 3, pp. 28–31, March, 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.     

Increasing the life of steel ladle linings at the Cherepovets Metallurgical Factory

Conclusions A 4-stage lining was developed and introduced at the Cherepovets Metallurgical Factory for 300 ton steel ladles.As a result of introducing this lining and improving the quality of the brick the life of the ladle increased by 31% compared with that achieved in 1968.To ensure uniform resistance in the 4-stage lining over the height of the structure tests were made with a lining using semisilica brick based on Latnensk clay and Ovruch pyrophyllites in the upper and central belts of the structure. The use of the semisilica brick in place of the KShU-37 brick manufactured by the Borovich Refractories Combine increases the resistance of the lining in the ladles, and reduces the refractories consumption per ton of steel.Translated from Ogneupory, No. 4, pp. 22–25, April, 1971.     

Testing MKB-75 mullite-corundum articles in linings of casting ladles

The West Siberian Integrated Iron-and-Steel Works has tested in 350-ton casting ladles mullite-corundum refractories of grade MKB-75 (TU 14-8-633-95) produced by the Semiluki Refractory Plant. The use of these refractories in the ladles for casting steel into molds provides an endurance of 40 heats without replacing the slag zone or the bottom, which is 1.5 times higher than the endurance of ladles lined with conventional KVKB refractories. The use of MKB-75 refractories for continuous casting is inexpedient because of the elevated specific consumption and low endurance of the refractories.     

Chamotte and semiacid ladle brick from Barzassk clays

Conclusions The Barzassk (basic O1 and O2, and semiacid PK1) clays are suitable for making chamotte and semiacid ladle brick. The production of refractories from these clays can be organized using the technological production scheme for chamotte articles made by semidry pressing. In order to increase the strength of the green products made from semiacid clays it is necessary to reprocess the bodies with an addition of sulfite lye on runner mixers with rollers.The resistance of the experimental chamotte and semiacid brick in a 300-ton ladle was practically the same as that of ladle brick made from Buskul'sk clay produced by the Magnitogorsk Metallurgical Combine.Translated from Ogneupory, No. 5, pp. 1–5, May, 1969.     

Berlin clay as binder for chamotte products

Conclusions A. technology was developed and introduced for the production of ladle and steelcasting refractories bonded with a mixture of 75% Berlin clay and 25% Arkalyk clay.The durability of the ladle lining was 1.5 melts higher when constructed of this brick.Translated from Ogneupory, No. 7, pp. 4–6, July, 1977.     

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.