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.     

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.     

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.     

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.     

Optimizing the Conditions for Pre-Start Heating of the Refractory Lining of Steel-Teeming Ladles

An energy-saving dry-out technology for the refractory lining of steel-teeming ladles with a thermal efficiency of 45 – 50% is developed. This technology provides high heat resistance of the lining to meet stringent requirements placed on the dry-out, preheating, and temperature regime of lined vessels. Positive results for the technology tested under industrial conditions are reported.     

State-of-the-art plants for drying and high-temperature heating of ladles

The Stal’proekt Institute has developed state-of-the-art plants for drying and high-temperature heating of steel-teeming ladles. Two new plants for drying tundish ladle lining have been designed for machine No. 6 for continuous billet casting at the Oskol’skii Electrometallurgical Works. Plants for drying and heating 30-ton teeming ladles to a temperature of 800°C and for high-temperature heating of ladle lining (1200°C) have been designed for a currently constructed metallurgical works. All these plants recover flue gas heat and use it for heating air supplied for combustion, thus decreasing the consumption of fuel. The process of drying and heating of lining is analyzed using a mathematical model developed at the institute. The plants are equipped with automatic control systems controlling the temperature schedule of drying and heating the lining. The specified plants ensure cost-effective operation in an automatic mode __________ Translated from Novye Ogneupory, No. 10, pp. 21–25, October, 2006.     

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.     

Development of a Technology for Manufacture of Periclase-Carbon Refractories

A technology for manufacture of periclase-carbon refractories for the lining of steel-teeming ladles of oxygen-blowing converter is developed.     

Guniting the lining of heating furnaces of rolling mills

Conclusions Guniting mass compositions and a procedure for guniting worn brickwork of continuous heating furnaces of rolling mills have been developed. At a number of metallurgical factories the worn brickwork of eight continuous heating furnaces of rolling mills have been repaired by guniting. The use of guniting enables the period between furnace lining repairs to be doubled (from 1 to 2 years), the volume of brickwork repair and the length of the repair work to be reduced, and a saving of 5000 rubles per annum per furnace to be obtained (merely by reducing the amount of repair work).Using IR spectroscopy the authors have investigated hydration and dehydration in alumina and high-alumina cements and aluminosilicate guniting masses with additives of these cements. They have shown that during guniting by the semidry method, hydration of the cements included in the composition of the gunite coatings does not go to completion and ends in the stage of formation of CaO·Al₂O₃·10H₂O; dehydration of the gunite coatings is completed below 300°C.Translated from Ogneupory, No. 5, pp. 30–35, May, 1980.     

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.     

Production and use of periclase-chromite concrete parts for the linings of high temperature ladles

Conclusions A method has been developed for production of standard periclase-chromite concrete parts for the linings of high temperature ladles for teeming steel and ferroalloys. The parts have high strength and low porosity and are practically shrinkage-free.The life of periclase-chromite concrete parts in the steel teeming ladles of Chelyabinsk Metallurgical Plant is about four times greater than that of fireclay parts, in Red October Plant practically the same as that observed with the use of high alumina parts, and at Chelyabinsk Electrometallurgical Plant it was higher only in the upper portion of ladles in comparison with that obtained with the normally used fired periclase parts.During service in ladles the parts do not spall, become encrusted at a metal temperature of 1620 °C, do not become encrusted at 1790°C, and at 2200°C are eroded by slag.Translated from Ogneupory, No. 7, pp. 16–20, July, 1982.     

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.     

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 linings of oxygen converters in the course of melting without stopping the blow

Problems arising in guniting converter linings in the course of melting without stopping the oxygen blow are considered. Deposition of a mixture based on magnesite is conducted in an oxygen jet. As the powder particles move in the vessel, they are heated due to the heat of the converter and afterburning of carbon monoxide, which ensures their strong cohesion with the surface of the lining. The velocity and diameter of the gas-powder jet are calculated as a function of the concentration of the periclase powder, the distance from the tuyere nozzle, and the temperature of the magnesite particles heated in the vessel. An experimental installation is developed and experiments on guniting in the course of melting without interrupting the blow are conducted. It is established that the gunited coating is deposited on the lining only at the end of melting. The endurance of the coating is 1–4 heats. In guniting, the temperature of the metal increases by 20–70°C. The experiments showed the possibility in principle of guniting a converter lining in the course of melting without interrupting the blow. Translated from Ogneupory, No. 3, pp. 27–31, March, 1996.     

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.     

Siliceous refractories for iron ladles of the mixer type

Conclusions For the first time in the linings of iron-carrying ladles of the mixer type we have tested siliceous refractory products. They showed satisfactory resistance in all zones of the ladle in contact with metal, and especially in the zone where the iron jet hits the lining, which means that in contrast to ladles with mullite-silica linings we can carry out the complete campaign for the ladle without repairing this section.In the zones not contacting the iron, and in the central parts of the lining made of siliceous articles, they are less resistant than those made of mullite-silica.On the basis of these tests in mixer-type ladles we recommend the use of combined linings from siliceous and high-alumina articles.The annual savings from the use of siliceous linings is 67,000 rubles.Translated from Ogneupory, No. 2, pp. 21–24, February, 1982.     

High-alumina mortar from scrap of refractory articles after use in metallurgical units

Scrap of refractory articles of grades MKS-72, MLKh-65, and ShKh-42 after use in steel-teeming and intermediate ladles of the OMK is studied. The possibility of using after-use scrap in the production of mortar is investigated. Experimental batches of high-alumina mortar have been produced and tested with positive results in linings of steel-teeming and intermediate ladles.Translated from Ogneupory, No. 5, pp. 28 – 31, May, 1995.     

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.     

Thermal stability of articles for lining steel-teeming ladles

A technology for refractories for lining steel-teeming ladles is considered from the standpoint of the requisite thermal stability of the articles. It is established that the present level of the production technology makes the tests of the thermal stability of ladle brick inexpedient. Translated from Ogneupory, No. 3, pp. 25–26, March, 1996.