Improvement in The Steel-Pouring Ladle Lining Life in Open-Hearth Production of Zao Metallurgical Plant Petrostal'

Refractories and Industrial Ceramics Vol. 50, No.
2, 2009
IMPROVEMENT IN THE STEEL-POURING LADLE LINING LIFE

IN OPEN-HEARTH PRODUCTION OF ZAO METALLURGICAL PLANT
PETROSTAL’
V. A. Kononov,1 N. V. Kononov,1 S. N. Skrobov,2 and O. A. Salomakhin2
Translated from Novye Ogneupory, No. 4, pp. 66 – 72, April 2009.
Original article submitted September 22, 2008.
Basic principles are considered for the development of refractory linings for steel-pouring ladles operating un-
der severe conditions using a furnace-ladle unit. Joint action of personnel of the metallurgical enterprise and
refractory supplier makes it possible to determine the local area of lining wear and to adopt timely measures
for improving life. The effect of the main factors governing wear is determined. The order of selecting the re-
quired standard sizes and quality indices for objects taking account of the type of metal smelted is determined.
Keywords: refractory lining, slag belt, local wear.
As a result of technical progress in the field of refractory 800°C. With presence in some cycles of cooling below
production the possibility has developed not only of improv- 800°C there may be some reduction in lining life.
ing metal quality, but also reducing expenditure connected The life of refractory linings used in furnace-ladle de-
with steel-pouring ladle lining operation, in particular those vices is determined by a group of factors, each of which
operating under conditions of furnace-ladle installations and should be considered in lining operation. These are factors
metal evacuation. connected with refractory properties, lining construction, and
Refractory consumption for lining ladles in metallurgical pouring technology.
enterprises with a complete cycle is about one quarter of all In the presence of high quality refractories it is not al-
refractory consumption (in absolute value and cost) [1]. The ways possible to achieve maximum lining life. Even insignif-
overall expenditure for traditional ladle refractories in the icant changes in metal smelting technology and pouring may
cots of Russian metal was previously 1.5 – 2.0%, and there- lead to a reduction in refractory life.
fore a insufficient attention has been devoted used to saving
refractories. A long life for a lining has a marked effect the
non-metallic inclusion content in metal. EFFECT OF REFRACTORY QUALITY
Currently the expenditure on acquiring contemporary ON LINING LIFE
refractories is 4 – 7% of metal cost. An increase in metal cost
may be balanced by a reduction in specific refractory con- Refractories used
sumption due to the use of modern methods for lining opera-
tion and new standard sizes for refractory objects.
In contemporary linings there is mainly use of car-
For effective operation of carbon-containing refractories
bon-containing refractories based on periclase-carbon or
it is necessary to have a high-temperature unit for warming
up refractories. A lining warm-up unit may be horizontal or aluminopericlase-carbon composition. Some Russian enter-
vertical. Expenditure in installing a high-temperature unit is prises manufacture these refractories based on imported Chi-
repaid in 6 – 8 months. Each uint is equipped with a heat-pro- nese raw material. In principle the production technology for
tective cover in order to avoid heat loss during pouring. domestic refractories provides the required specifications.
The carbon-containing composition refractories used in There are small deviations with respect to ecology, con-
contemporary linings do not exhibit high heat resistance and nected with the release of free phenol from the binder.
during operation they should not be cooled to lower than Studies performed by the enterprises make it possible to hope
for a reduction of harmful discharges into the atmosphere [2].
1 Russian metallurgists mainly use imported refractories.
Company Shiber, Moscow, Russia.
2
ZAO MZ Petrostal’, St. Petersburg, Russia. In the first stage supplies were produced by European firms
89
1083-4877/09/5002-0089 © 2009 Springer Science+Business Media, Inc.
90 V. A. Kononov et al.
(RHI, etc.). European refractories, in spite of comparatively EFFECT OF REFRACTORY LINING

long life properties, have a high cost and therefore the major- CONSTRUCTION ON ITS LIFE
ity of refractory users have transferred purchasing to China.
Some Russian refractory enterprises have created in-house Lining construction features
production in China (OOO Gruppa Magnezit, OAO Boro-
vich Refractory Combine, etc.). In service there is wear of the refractories in the lining of
a steel-pouring ladle, connected with the specific nature of
ladle operation by the user. In the slag belt zone there is in-
Accuracy of refractory object preparation tense breakdown of the lining as a result of chemical reaction
of slag with refractory. Therefore in the slag belt zone use of
The life of refractories is determined to a considerable basic composition refractories is recommended based on
extent by the thickness of vertical and horizontal joints. The fuzed or sintered periclase. Objects made from fuzed materi-
als have the best have the best structure and exhibit the lon-
size of a joint mainly depends on deviations with respect to
gest life. In order to reduce the wettability of refractory with
object thickness. In a lining made from refractory objects,
slag high purity graphite is added to its composition. The
having the minimum deviations in thickness, joint-free lining amount of graphite in the refractory is determined from pour-
assembly is provided. The accuracy of manufacture with re- ing conditions. The content of impurities (SiO2, Fe2O3, etc.)
spect to thickness is at the level of ±0.5 mm. This index is in refractory objects should be at a minimum.
determined by modern press equipment. Currently in the ma- In the area of impact of the metal stream in a ladle there
jority of Russian enterprises there is imported press equip- is erosion breakdown of refractory. Depending on pouring
ment that makes it possible to provide the required tolerance conditions the stream of molten metal may hit the side of the
with respect to object dimensions. ladle or a specific area of the bottom. In order to overcome
this effect it is necessary to reinforce the ladle lining in the
area of molten metal impact. Reinforcement of the so-called
Standard sizes of objects used striking zone is performed as a result of both improving ma-
terial composition, and also increasing the refractory contact
In Russia many metallurgical enterprises provide tech- area. With metal blowing through channel blowing tuyeres
nology of ageing helical laying of a lining in 2 – 3 standard there is erosive wear of the lining in the zone where bubbles
sizes of objects. In world practice there is mainly use of cir- pass, and therefore it is also desirable to strengthen this area.
cular laying of a ring of lining of made of objects of one stan-
dard size. In order to provide joint reliability in a ring no Types of lining
fewer than two key bricks are used, that are cut from a nor-
mal object by means of a diamond tool. The key bricks pro- Several types of modern lining are widespread: from
vide wedging of the lining and guarantee exclusion of metal piecewise objects, poured, rammed, vibration based on
low-cement mixes, etc. Sometimes different combinations
penetration over a vertical joint of a lining.
are used: poured at the bottom and piecewise in the walls, vi-
The leading producers for laying objects use bricks of
bration mixes in the bottom and walls and piecewise in the
trapezoidal shape. Some firms make linings with objects slag belt. The method of an “infinite lining” has been intro-
150 – 200 mm thick having the shape of a trapezoidal duced where as the lining elements wear there is restoration
wedge. This makes it possible to reduce the number of hori- by a special template that is installed within the ladle. A
zontal joints that has a favorable effect on lining life. How- low-cement thixotropic mix is poured between the wall and
ever, object of considerable thickness have different density template. The life of linings of this type exceed 1000 melts.
during manufacture. Their central part has a lower density According to experience in the OAO O. A. Serov Metallurgi-
than the periphery, and this has a deleterious effect on the life cal Plant it is not profitable to use a lining of this type up to a
of the whole lining. life of 500 melts, but after a life of 1000 melts production ef-
Recently in world practice of laying a lining there has ficiency increases. The refractory mix used is raw material
been use of trapezoidal objects of smaller thickness (up to components based on special grades of tabular and reactive
100 mm). These objects are manufactured in presses with a alumina, that are only produced abroad, and the cots of the
mix is considerably higher than for piecewise objects. Effi-
lower force, the objects have a more uniform density
cient use of these mixes is only possible with special equip-
throughout the whole cross section and this promotes uni-
ment produced mainly by European firms.
form wear. There is a tendency to use ladle objects of small
dimensions, so-called mini-keys [3].
Lining laying technology
The small size of objects and their high quality makes it
possible to increase lining life by 15 – 20% in spite of an in- Assembly of a lining without mortar requires highly
crease in the number of horizontal joints. The uniform den- qualified layers and special attachments and equipment.
sity of each object and their high strength properties also There is considerable importance in laying technology for
makes it possible to increase lining life. heat insulation, reinforcing and the working layers of walls.

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Refractories and Industrial Ceramics Vol. 50, No.

IMPROVEMENT IN THE STEEL-POURING LADLE LINING LIFE

V. A. Kononov,1 N. V. Kononov,1 S. N. Skrobov,2 and O. A. Salomakhin2

Translated from Novye Ogneupory, No. 4, pp. 66 – 72, April 2009.

Original article submitted September 22, 2008.

(RHI, etc.). European refractories, in spite of comparatively EFFECT OF REFRACTORY LINING

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