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.     

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.     

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.     

Ladle brick from semiacid clays

Conclusions The main feature of the technology developed for the production of high-density ladle brick which expands in service, made from semiacid clay from Chasov Yar and Druzhkov sources, is the regular firing cycle for the chamotte and the finished products, namely completion of firing in the temperature range in which we can guarantee sintering of the material, but in which bloating has not yet begun.The life of the ladle brick in service made from semiacid clays is greater than that of high-chamotte ladle brick owing to the high density of the structural joints, governing the expansion of the working layer of the brick coming into contact with metal and slag.Mass production of semiacid ladle brick using the technology developed by VIO should be organized in refractory plants of the UkrSSR.Deceased.Translated from Ogneupory, No.2, pp.14–17, February, 1967.     

Making ladle products using North Onezhsk bauxites

Conclusions It was found that the North-Onezhsk bauxites are promising raw materials for the production of highly resistant ladle bricks.We developed and mastered a technology in the BKO conditions for making ladle brick using these bauxites containing up to 6% iron oxides.In the lining of the steel ladles made with the use of bauxite chamotte, the bricks wear out 30–40% less than with ordinary ladle brick produced by BKO and the Chasov Yarsk Combine.Translated from Ogneupory, No. 8, pp. 4–9, August, 1980.     

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.     

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.     

Refractory fiber from natural starting materials

Refractories and Industrial Ceramics - The feasibility was demonstrated of producing refractory fiber from high-alumina chamotte of calcined Arkalyk clay. The fiber properties conform to the...     

Making refractory products from Arkalyksk clays

Conclusions With the use of Arkalyksk clay in existing conditions of refractories production at the ChMZ plant for obtaining grog with a water absorption of up to 5–6% it is necessary to add 25% plastic clay of the Buskul'sk type.The introduction into use of a rotary furnace will permit the firing of refractory Arkalyksk high-grade clays without additions, which should increase the life of the ladle and stopper refractories.     

Results of a competition for the most resistant ladle brick

Conclusions The wear of the Chasov-Yar ladle brick was less than that of bricks made by the other factories; its average resistance for the five ladles was 13.3 melts.The average wear of the ladle brick made by the Zaporozh Plant exceeded the wear of the Chasov-Yar brick. The average resistance of this brick for the five ladles was 13.2 melts.The wear of the ladle brick made at the Belokamen Firebrick Plant is uniform, with only slight washing-out of the joints. The surface of the ladle after service was smooth and glazed.Examining all the materials tested during the competition the award panel awarded: first place in the compeitition to the Chasov-Yar Combine; second place to the Zaporozh Plant; third place to the Belokamen Plant.On the basis of material on the technology for the manufacture of ladle bricks used in the plants taking part in the competition, and also the service factors of the products during competitive testing, and on the basis of proposals from the All-Union, Ukraine and Vostok Institutes of Refractories for improving the quality of ladle brick, the award panel of the competition made the following recommendations for further improving the quality of ladle bricks:scientific-research institutes for refractories in collaboration with factory producers should carry out tests of fired ladle bricks made from chamotte and semiacid bodies, kaolinized and high-alumina raw materials and unfired products, and also should test linings made from rammed bodies in ladles of different capacities in different conditions of service;concerns should specialize in the manufacture of ladle bricks and install modern grinding, blending and pressing equipment;the assortment of bricks should be reexamined and the sizes of ladle bricks should be increased with the aim of reducing the number of joints in the structure;output of adequate supplies of high-grade special packaged mortars should be ensured.     

Production of dense refractories for blast furnace shafts

Conclusions The Zaporozhe Refractories Plant with the help of the Ukraine Refractories Research Institute has produced a batch (1100 tons) of kaolin brick with a porosity of not more than 12% for a 2700 m³ blast furnace at the Krivoi Rog Steel Factory. The brick made on toggle presses from Noveselits chamotte using Chl clay as the bond had outstanding quality factors which were obtained by stabilizing the industrial production parameters, increasing the firing temperature, and carefully controlling the grain-size composition.Translated from Ogneupory, No. 7, pp. 7–11, July, 1968.     

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.     

Aluminosilicate refractories based on high-alumina HCBS. Part 1. Refractories based on mixed HCBS in the system bauxite — silica

Comparative studies are provided for the properties of compacted and cast specimens of fine-grained ceramic concrete prepared on the basis of a mixed HCBS and two varieties of refractory filler with different Al₂O₃content from bauxite and chamotte based on Arkalyk clay. For specimens containing a chamotte filler, after firing at above 1250°C there is typically significant linear growth (up to 2.5%), connected with secondary mullite formation and caused by interphase reaction of SiO₂ from filler grains and very fine Al₂O₃ of the matrix system. The correlation of matrix system properties and materials with a refractory filler is analyzed     

Improving the strength of chamotte-kaolin refractories

Conclusions In the production of chamotte products including standard sizes, on the basis of Vladimirovsk kaolin without the use of plastic clays, it is necessary to introduce finely milled chamotte into the bond part of the batch due to the sandiness and low plasticity of the kaolin; the chamotte content must be increased to 70–80%, and small additions of sodium tripolyphosphate made to the moistening slip.The increase in the strength of the chamotte-kaolin articles with the use of sodium tripolyphosphate is attained on account of the plasticizing and sintering action of this additive. The action of the additive is manifest with any concentration of chamotte in the compound including the case when clay is added to the bond part of the batch. Adding small amounts of sodium tripolyphosphate does not increase the cost of the goods.Translated from Ogneupory, No. 4, pp. 16–20, April, 1981.     

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.     

Semiacid ladle brick based on low-fired chamotte,quartz sand,and Ch1PK clay

Conclusions Dense semiacid products based on low-fired chamotte can be obtained by adding 15–30% quartz sand to the batch. The articles need to be fired at 1260±30–40°C. Firing at temperatures above 1300° and below 1230 even by 20–40° reduces the apparent density and after-expansion of the products.Preliminary testing in service showed that the wear of the semiacid ladle brick is 10% less than that of dense kaolinized brick.Using the proposed technology it is necessary to produce large batches of semiacid refractories, observing the optimum parameters of their manufacture in order to establish the economic effectiveness and advantages of organizing the industrial production of such articles.Translated from Ogneupory, No. 8, pp. 9–15, August, 1969.     

CORRECTION OF AN EXTREME CASE OF CRACKING IN THE DRYING OF BRICK1

I. In the manufacture of stiff-mud brick from a highly colloidal clay of low permeability to water, drying breakage was extremely high even though the drying was conducted at a very slow rate under high humidity conditions. Laboratory investigation yielded two methods of correcting the faults: (1) Preheating the clay for half an hour at a temperature between 400 °C and 500 °C increased the permeability to such an extent that brick made from the preheated clay could be dried rapidly without cracking. (2) Coagulating chemicals, such as aluminium chloride, ferric chloride, sodium chloride, and hydrochloric acid, in conjunction with moderate additions of grog, increased the permeability and thus improved the drying properties of the clay. II. Plant scale tests using ferric chloride, sodium chloride, and grog resulted in the production of brick which could be dried safely in a reasonable time. The fired brick were improved in quality as to strength and color. III. The chemical treatment of the clay using 1% ferric chloride and 0.5% sodium chloride with 10 to 15% grog was adopted for plant operation and resulted in increased production, lower cost of manufacture, and improved quality of product.     

Treatment of the production waste water of Konstantinovka Refractory Plant

Conclusions The coagulating action of aluminum sulfate and of the combination of it with polyacrylamide on a suspension of chamotte and clay, leading to a significant increase in particle size of the dispersed phase, was investigated.The presence of a threshold value of the addition of coagulant as an important production parameter determining the unstable suspension type sedimentation of particles was shown.To disturb the stability of the systems and to accelerate the clarification process of waste waters contaminated with chamotte and clay the necessary additions of reagents are 25–50 mg/liter of aluminum sulfate and 5 mg/liter of polyacrylamide.Translated from Ogneupory, No. 6, pp. 42–44, June, 1985.     

Kaolin refractories with a minimum amount of clay bond

Conclusions When dry bond clay and some of the normal fine-ground chamotte are replaced by chamotte which has been finely ground with the addition of 0.1% C₇-C₉ acid for the same amount of grinding time, and when clay is added solely in the form of dross, it is possible to obtain dry specimens with a porosity of only 2% more and fired specimens in no way inferior in density to the control specimens, but even with less porosity after firing, though the shrink-age is slightly increased.Hydrophobization of the chamotte fractions 2–0.5 mm without the addition of dried clay makes it possible to obtain fired specimens showing the same properties as the control ones, and less porous ones, though there is slightly increased shrinkage.The replacement of the clay bond added to the mixture in dry form by fine-ground hydrophobized chamotte sharply reduces the after-effect in these mixtures during pressing.The possibility has been established, in principle, of obtaining multichamotte parts from kaolinite raw materials by the addition of bond clay to the mixtures in the proportion of 2–4% in the form of dross alone.The industrial production of these parts should be of practical interest since an increase in the alumina content and a reduction in the flux content in parts is thereby achieved; an increase in the efficiency of tube mills and the degree of dispersion of the fine-ground chamotte on account of being ground without clay and the addition of a dehardener, and a simplification of the production process by eliminating the preparation of the clay for the bond are also made possible.The results and the behavior of parts during service should be tested under semi-plant and plant conditions. Here tests should be made on replacing all the ordinary fine-ground chamotte by chamotte ground with a hydro-phobizer, since this will simplify the production process still more.The manufacture and testing of experimental-industrial batches of parts by the proposed method should be organized together with the UNIIO.     

Producing dense ladle brick with a kaolin bond

Conclusions The use of finely milled chamotte, triethanolamine, and bentonite in chamotte-kaolin batches considerably improves their moldability and sintering capacity, which enables us to obtain dense ladle brick with a porosity of 11–12% with a kaolin bond.Translated from Ogneupory, No. 4, pp. 10–13, April, 1972.