Refractory Material Selection For Steelmaking (PDFDrive) [PDF]

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Refractory Material Selection for Steelmaking Thomas Vert, P.Eng., M.B.A. Foreword by Dr. Jeff Smith



Copyright © 2016 The American Ceramic Society and John Wiley & Sons, Inc. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at http://www.wiley.com/go/permission. Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) 762-2974, outside the United States at (317) 572-3993 or fax (317) 572-4002. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic formats. For more information about Wiley products, visit our web site at www.wiley.com. Library of Congress Cataloging-in-Publication Data: Names: Vert, Thomas, 1964- author. Title: Refractory material selection for steelmaking / Thomas Vert. Description: Hoboken, New Jersey : John Wiley & Sons, 2016. Includes bibliographical references and index. Identifiers: LCCN 2016003691| ISBN 978-1-119-21986-6 (cloth) | ISBN 978-1-119-21988-0 (epub) Subjects: LCSH: Refractory materials. | Metallurgical plants--Equipment and supplies. | Steel--Metallurgy. Classification: LCC TN677.5 .V47 2016 | DDC 669/.82--dc23 LC record available at http://lccn.loc.gov/2016003691 Printed in the United States of America. 10 9 8 7 6 5 4 3 2 1



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Introduction



Introduction



9*7



Chapter 1



1. Safety















































1. Goal of Availability











1. Total Cost of Ownership (TCO)



























1. Energy and Heat Flow Overview























1. Quality - Inert to the Steel Process































1. Environment











Chapter 2



2. TMC Analysis Overview











2. Thermal – High 5emperature 0verview































































































2. Thermal Shock























Ex of brittle = 90% Al2O3 Purity = weakness i.e. coffee cup



Ex of “Pillow” or ductile material = 65% Al2O3 Impurities soften































2. Mechanical Impact



3



4



5



6



2. Mechanical Abrasion



7



8



2. Wear of Refractories – Dissolution



9



























2. Wear of Refractories – Penetration















2. Interactions of TMC / SatVSEBZ /ight %esign / Rubble Pile Analysis



















Chapter 3



3.0 Selection - Raw .aterials Overview



















3.1 Magnesia Overview (MgO)







































3.2 Alumino-Silicate Overview (Al2O3 – SiO2)



























3.3 Carbon – Graphite Overview (C)























3.4 Antioxidants (Aka Preferential Oxide Formers)























3.5 Resins, Pitches and Binders Overview















3.6 4QFDJBM 3aw .aterials



















3.7 Dolomite











Chapter 4



4.0 Refractory Dryout and Anchoring Overview



























4.1 Bricks















4.2 Castables, Gunning and Shotcreting Overview



































4.3 Plastics, Rams
BOE Mortars Overview















4.4 Refractory Dryout and Anchoring Overview



























4.5 Selection – Insulation Board and Blanket Overview















Chapter 5



5.0 Refractory texture, Testing
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Chapter 6



6.0 Hot Metal Ladle Overview











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Chapter 7



7.0 Basic Oxygen Furnace (BOF) Refractory Overview















7.1 BOF Safety Bottom/Wall















7.2 BOF Top Cone Overview



















7.3 BOF Tapping Pad Overview















- The brick above the taphole are normally the same as the tap pad brick as the slag and liquid steel also rest in this area.











7.4 BOF Charge Pad Overview































7.5 BOF Trunnions Overview























7.6 BOF Stadium Overview























7.7 BOF Bottoms – #ricks, "rgon 4tirring 4ystems and +oints







































7.8 BOF Refractory Tapholes



























Chapter 8



8. Electric Arc Furnace (EAF) Overview











8. Safety Bottom/Wall



















8. Working Bottom - Hearth / Fettling



































8. Working Walls



































8. Argon Stirring 4ystems for EAFs



























8. EAF Refractory Delta



















8. EAF Refractory Tapholes























Chapter 9



9.0 Steel Ladle Refractory Overview















9.1 Steel Ladle Safety Bottom/Wall



















9.2 Steel Ladle Working Bottom



























9.3 Steel Ladle Stir Systems







































9.4 Steel Ladle Flow Control Systems































9.5 Steel Ladle Working Sidewall (Barrel)



1650 C



















9.6 Steel Ladle Working Slagline























9.7 Steel Ladle Lip Ring















9.8 RH Degasser Refractory Overview















Chapter 10



10.0 Caster / Tundish Refractory Overview











10.1 Caster Tundish Safety Lining



















10.2 Caster Tundish Working Lining



















10.3 Caster Tundish Flow Control



















10.4 Caster Flow Control Systems















Oxygen lancing of the top of the shroud creates high wear mechanism











Tundish Slag: - Al2O3: 3 -35% - CaO: 1 -40% - SiO2: 3-90% - MgO: 1-20% - FeO: 1-3%











































Chapter 11



11.0 Purchasing 4trategies























Chapter 12



12.0 Final Summary







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*OEFY $ $$ per kg of refractory ...................................................................................................................................................................... 355 $$ per piece of refractory................................................................................................................................................................ 355 $$ per tonne of steel including gain sharing .......................................................................................................................... 355 $$ per tonne of steel produced..................................................................................................................................................... 355 % % B2 O3 ........ 2, 5, 6, 7, 22, 23, 26, 47, 48, 49, 52, 60, 64, 70, 75, 89, 97, 99, 101, 111, 113, 114, 121, 127, 151, 152, 157, 194, 196, 201, 206, 213, 223, 226, 231, 245, 252, 271, 274, 294 296, 300, 327 A brasion ...... 2, 36, 77, 78, 89, 90, 125, 196, 200, 204, 210, 216, 221, 230, 236, 237, 243, 250, 257, 267, 270, 276, 284, 287, 295, 304, 309, 314, 318, 327, 331, 336, 340, 342, 344, 346, 348 absorption .......................................................................................................................................27, 33, 66, 67, 71, 73, 113, 209 AC furnace .................................................................................................................................................................................... 241, 253 accelerant ...................................................................................................................................................... 135, 137, 142, 143, 145 dministration costs ............................................................................................................................................................................ 17 aggregates ................................................................................................................................... 83, 111, 135, 144, 150, 163, 164 air entrainment ..................................................................................................................................................................26, 324, 349 air ingress.................................................................................................................................................................................................. 31 ir set bonding .................................................................................................................................................................................... 151 air/ oxygen aspiration ....................................................................................................................................................................... 338 alkemade triangles .........................................................................................................................................................................54, 55 lumina ................................................................................................................. 11, 57, 72, 84, 109, 110, 111, 112, 149, 163 alumina graphite ................................................................................................................................................................................. 128 alumina-magnesia-carbon (AMC) ............................................................................................................................................... 310 aluminum carbide .............................................................................................................................................................................. 119 amorphous ................................................................................................................................................................................................ 12 nchoring....................................................................................................................................................................... 2, 133, 153, 154 andalusite ...........................................................................................................................................................................110, 111, 164 ngle of Impact ..............................................................................................................................................................74, 75, 77, 210 angle of wetting ...............................................................................................................................................................................86, 88 ntioxidants Al 2, 118 Al-Mg .................................................................................................................................................... 118 B4C........................................................................................................................................................ 118 Mg......................................................................................................................................................... 118 MgB2 .................................................................................................................................................... 118 pplied stress 36, 196, 200, 204, 211, 216, 221, 230, 236, 237, 243, 251, 257, 267, 270, 276, 284, 287, 295, 305, 310, 314, 318, 327, 331, 336, 340, 342, 345, 347, 348 rches ...................................................................................................................................................................................................... 139 rch-key-wedge .................................................................................................................................................................................. 139 argon flow system .............................................................................................................................................................................. 294 argon stir plug ....................................................................................................................................................... 265, 268, 295, 297 rgon Stirring........................................................................................................................................................ 263, 264, 268, 298 asbestos .........................................................................................................................................................................................................9 ASTM .......................................................................................................................................................................... 61, 65, 94, 95, 165 availability .....................................................................................................................................................13, 18, 73, 90, 137, 209 B baffle ............................................................................................................................................................................................... 334, 335 barrel ..........................2, 29, 37, 200, 203, 204, 205, 208, 211, 212, 215, 216, 217, 221, 308, 309, 310, 311, 317 asic xygen urnace (BOF) BOF bottom joint ...................................................................................................................................... 5 BOF charge pad impact ............................................................................................................................ 5 BOF furnace .............................................................................................................................................. 5 BOF inclined stadium................................................................................................................................ 5 BOF lining.................................................................................................................................................. 5 BOF mouths .............................................................................................................................................. 5 BOF safety lining....................................................................................................................................... 5







BOF stadiums ............................................................................................................................................ 5 BOF taphole .............................................................................................................................................. 5 BOF tapped steel chemistry ..................................................................................................................... 5 BOF trunnion ............................................................................................................................................ 5 bath stirring ......................................................................................................................................................................................80, 83 bauxite ..................................................................................................................................................110, 111, 144, 150, 163, 164 binders ............................................................................................................................................................ 113, 123, 130, 131, 163 bio-soluble .........................................................................................................................................................................................10, 12 lanket............................................................................................................................................. 2, 135, 137, 159, 161, 283, 326 oard ......................................................................................................................................2, 135, 137, 159, 161, 198, 283, 326 bore .....................................................................................................................................................................31, 304, 346, 348, 349 oron arbide (B4 C) ......................................................................................................................................................................... 120 bottleneck ..........................................................................................................................................................................................13, 18 bottom ........ 2 6, 13, 17, 18, 61, 68 70, 72 4, 90, 91, 100, 115, 116, 140, 148, 150, 151, 156, 172, 173, 185, 187, 191, 193, 196, 197, 209, 210, 224 228, 230 233, 241, 243, 244, 247, 250 254, 263, 265, 267, 268, 273, 276, 282, 284, 286 292, 295, 296, 298, 299, 301, 309, 310, 314, 322, 331, 338 breakouts ... 2 6, 14, 126, 183, 191, 194, 233, 241, 280, 282, 286, 291, 299, 300, 301, 307, 308, 311, 312, 316, 322, 324, 326, 338, 345 brick 6, 7, 8, 14, 17, 18, 21, 27, 29, 33, 34, 37, 38, 43, 44, 46, 47, 56, 60, 64, 65, 67, 68, 69, 70, 71, 72, 76, 79, 83, 84, 87, 92, 95, 100, 104, 111, 114 119, 122 123, 125 127, 130, 131, 135, 137, 139 141, 149, 150, 154, 164, 165, 166, 173, 180, 181, 190, 191, 196 206, 208, 211, 212, 213, 215 224, 228 231, 236, 237, 239, 243, 244, 247, 251 254, 256 259, 262, 267, 274, 275, 276, 277, 284, 288, 296, 309, 310, 314, 315, 322, 328, 332, 336, 341, 343, 355, 356, 357 brick coatings .............................................................................................................................................. 200, 204, 211, 216, 221 brick quality ................................................................................................................................................................................ 199, 357 Brine .....................................................................................................................................................................................................97, 99 brittle...................................................................................................................................................65, 66, 86, 112, 213, 239, 247 brown fused alumina ........................................................................................................................................ 110, 144, 150, 164 buildup ..................................................................................................................................................................... 199, 200, 348, 349 ulk patching .............................................................................................................................................................................. 207, 214 burners / injectors ...................................................................................................................................................................................6 C C/ S atio ................................................................................................................................................................................................. 104 Ca vapour attack ....................................................................................................................................................................... 305, 347 calcium aluminate .................................................................................................................................................................. 31, 43, 56 alcium chloride ................................................................................................................................................................................. 145 calcium magnesium carbonate CaMg(CO3 ) 2 ......................................................................................................................... 130 aptive source purchasing ............................................................................................................................................................. 356 .................................................................................2, 26, 27, 33, 57, 113, 114, 118, 123, 126, 135, 253, 277, 362 carbon black .......................................................................................................................................................................................... 125 carbon pickup................................................................................................................................................................................34, 127 carcinogens .............................................................................................................................................................................................. 11 cardboard expansion paper .................................................................................................................. 200, 204, 211, 216, 221 castable........38, 43, 65, 135, 142, 143, 144, 145, 154, 155, 156, 157, 163, 173, 233, 270, 309, 322, 325, 328, 332, 336, 341, 343, 345 caster refractories ............................................................................................................................................... 111, 129, 324, 338 eramic ibres ...................................................................................................................................................................................... 2, 9 charge pad............................................................................................................................73, 74, 208, 209, 210, 212, 213, 214 charging angle ...................................................................................................................................................................................... 230 hrome re .............................................................................................................................................................................................. 33 hromite ................................................................................................................................................................................................. 126 linoenstatite .......................................................................................................................................................................................... 48 clogging ....................................................................................................................31, 304, 325, 338, 342, 344, 346, 348, 349 losed porosity ............................................................................................................................................................................. 86, 167 cobblestoning .......................................................................................................................................................................................... 64 coked porosity .................................................................................................................................................................165, 167, 169 old rushing strength (CCS) ....................................................................................................................................................... 165 commodities ......................................................................................................................................................................................... 354 compression .....................................................................................................................61, 171, 236, 237, 276, 305, 317, 347 onduction................................................................................................................................................................................................ 21 conductor .................................................................................................................................................................................................. 69 consignment...................................................................................................................................................................................17, 354







ontainment ........................................................................................................................................... 2, 183, 194, 241, 280, 324 ontinuous aster .............................................................................................................................................................................. 279 contractor.................................................................................................................................................................................................. 17 onvection ................................................................................................................................................................................................ 22 corrosion .. . 24, 25, 38, 39, 41, 47, 49, 51, 55, 71, 79, 80 84, 86, 89, 113, 116, 121, 123, 159, 161, 165, 167, 168, 173, 176, 177, 178, 179, 223, 229, 231, 237, 271, 276, 283, 306, 315, 319, 322, 326, 327, 330, 347, 349, 361 orrosion resistance ......................................................................................................................................................................... 165 corundum ...........................................................................................................................................................................................46, 47 crack bridgers ...............................................................................................................................................................................71, 229 crack initiation .............................................................................................................................................................................67, 175 crack propagation ............................................................................................................................................................... 67, 73, 175 creep ...................................................................................................................................................................................38, 65, 91, 289 cristobalite ............................................................................................................................................................................ 9, 12, 48, 60 rucible testing .................................................................................................................................................................................... 177 crust ......................................................................................................................................................................................113, 247, 248 crystal size ..................................................................................................................... 101, 102, 106, 164, 206, 213, 218, 239 crystalline ............................................................................................................................................................................................. 9, 12 customers .................................................................................................................................................................................................. 26 D dam.................................................................................................................................................................................................. 334, 335 DC furnace ..................................................................................................................................................... 241, 253, 262, 271, 277 ecarbonization .................................................................................................................................................................................. 320 deflocculent ........................................................................................................................................................................................... 145 degasser ................................................................................................................................................................... 126, 127, 320, 321 dehydrogenization ............................................................................................................................................................................. 320 demolition costs ..............................................................................................................................................................................15, 17 dense layer formation ....................................................................................................................................................................... 118 density ...... 27, 28, 61, 67, 86, 94, 142, 143, 144, 145, 146, 148, 150, 151, 165, 166, 169, 175, 176, 213, 248, 254, 330, 331, 332 de-oxidation ............................................................................................................................................................................................. 26 deskulling ...................................................................................................................................................... 204, 216, 322, 330, 331 iameter of impact ............................................................................................................................................................. 74, 75, 210 diaspore .................................................................................................................................................................................................. 110 dicalcium ferrite .................................................................................................................................................................................. 249 di-calium silicate ................................................................................................................................................................................. 131 ilatent .................................................................................................................................................................................................... 145 direct contact plugs ........................................................................................................................................................................... 267 disposal .................................................................................................................................................................................... 15, 18, 354 issolution 2, 36, 79, 89, 92, 125, 197, 201, 205, 211, 217, 222, 230, 236, 244, 251, 258, 267, 270, 276, 284, 296, 305, 310, 314, 318, 328, 332, 336, 341, 343, 345, 347, 349 olomite ............................................................................................................................................................... 2, 44, 130, 149, 313 down-leg ................................................................................................................................................................................................. 322 dry vibratable ........................................................................................................................................................ 244, 247, 275, 331 dryout ............................................................................................................................ 7, 91, 125, 153, 154, 158, 260, 289, 357 ductile ..................................................................................................................................................................................................65, 66 usting .................................................................................................................................................................................................... 146 E EBT ( ccentric ottom apping) ................................................................................................................................................ 273 Electric rc urnace (EAF) EAF delta ........................................................................................................................................... 6, 241 EAF hearth measuring device ................................................................................................................... 6 EAF injection ............................................................................................................................................. 6 EAF slag chemistry .................................................................................................................................... 6 EAF taphole .............................................................................................................................................. 6 EAF tapped steel chemistry ...................................................................................................................... 6 emissivity .................................................................................................................................................................................................. 23 energy ...................................................................................... 15, 19, 21, 23, 28, 29, 36, 75, 159, 183, 210, 241, 292, 313 eutectic temperature ....................................................................................................................................................................41, 43 eutectoid .............................................................................................................................................................................................42, 48 expansion allowance . 64, 65, 72, 141, 196, 197, 200, 204, 211, 221, 229, 230, 244, 251, 25 8, 259, 284, 310,







314, 315, 318, 319 expansion/ contraction .............................................................................................................................................................59, 173 xposure imits ..................................................................................................................................................................................... 10 F anning.................................................................................................................................................................................................... 148 feed rate .................................................................................................................................................................................................. 146 ettling fettling machines .......................................................................................................................... 247, 252 fettling materials .................................................................................................................................. 247 field conditions .................................................................................................................................................................................... 179 filaments .......................................................................................................................................................................................................9 iller ......................................................................................................................................................................................235, 274, 277 inger testing........................................................................................................................................................................................ 178 fireclay ..................................................................................................................................................................................................... 109 lake size ............................................................................................................................................................................114, 115, 116 flakes ................................................................................................................................ 113, 114, 115, 116, 164, 166, 213, 239 lat ............................................................................................................................................................................................................. 140 locculant ............................................................................................................................................................................................... 145 flow control hardware ............................................................................................................................ 330, 332, 335, 336, 337 flow dynamics ...................................................................................................................................................................................... 324 fluorspar ................................................................................................................................................................................................. 314 orced convection ................................................................................................................................................................................. 22 formaldehyde ...................................................................................................................................................................................7, 125 orsterite ............................................................................................................................................................................................48, 72 full service package ........................................................................................................................................................................... 356 umes ........................................................................................................................................................................................................ 2, 7 urnace angle ................................................................................................................................................................................ 73, 209 furnace shells.................................................................................................................................................................................21, 282 fused grain ........................................................................................................................................16, 19, 71, 206, 213, 218, 239 fused silica .................................................................................................................................................. 60, 63, 67, 108, 144, 150 G gate system ................................................................... 31, 274, 276, 277, 301, 303, 304, 305, 306, 338, 346, 347, 348 grain boundaries ...........................................................................................................................................58, 101, 102, 103, 164 grain size....................................................................................................................................101, 130, 131, 134, 164, 175, 252 graphite ....... 16, 17, 69, 104, 113 117, 120, 123, 124, 164, 206, 213, 218, 223, 231, 239, 259, gunning gunning machine .................................................................................................................................. 135 gunning nozzle ...................................................................................................................................... 135 H hazardous waste .................................................................................................................................................................................... 18 hearth ................. .. 6, 243, 245, 247 254, 256, 257, 263, 264, 268, 274, 275, 277 eat apacity ....................................................................................................................................................................................21, 69 heat flow .............................................................................................................................................. 21, 23, 24, 37, 159, 283, 326 eat set bonding ................................................................................................................................................................................. 151 heat up ...............................................................................................21, 60, 67, 69, 108, 139, 154, 158, 169, 173, 348, 357 heating ...................................................59, 83, 99, 123, 128, 154, 166, 176, 177, 181, 292, 298, 313, 315, 318, 322 heel size ......................................................................................................................................................................................... 250, 266 hercynite ................................................................................................................................................................................................. 126 erringbone .......................................................................................................................................................................................... 140 ex mesh ................................................................................................................................................................................................ 157 ........................................................................................................................................................................... 157 hexavalent chrome............................................................................................................................................................................. 126 high alumina .......................................................................................................110, 288, 296, 310, 328, 332, 336, 341, 343 high temperature .... 4, 11, 34, 37, 38, 46, 56, 57, 108, 111, 128, 135, 139, 142, 203, 206, 215, 218, 220, 228, 235, 236, 250, 256, 258, 266, 269, 270, 271, 275, 286, 295, 303, 306, 308, 313, 318, 331, 335, 339, 341, 342, 343, 346, 347 hot metal charging ................................................................................................................................................................... 208, 209 hot metal chemistry .......................................................................................................................................................................... 184 ot metal impact ......................................................................................................................................................................... 74, 210







hot metal ladle......................................................................2, 5, 183, 184, 185, 186, 187, 188, 189, 190, 191, 243, 360 hot metal slag ....................................................................................................................................................................................... 184 ot odules of upture (HMOR) ................................................................................................................................................... 65 hot spots .......................................................................................................................................................................................................6 ydrated lime....................................................................................................................................................................................... 145 hydration ...........................................................................................................................44, 130, 131, 135, 197, 244, 252, 259 I mpact ..... 2, 20, 36, 73, 76, 77, 89, 90, 125, 151, 152, 196, 200, 204, 209, 210, 216, 221, 230, 236, 237, 243, 250, 257, 267, 270, 276, 284, 287, 289, 290, 295, 304, 309, 313, 318, 327, 331, 336, 340, 342, 344, 346, 348 impact pad ..................................................................................................................................... 90, 91, 287, 289, 334, 335, 336 impact zone ........................................................................................................................................................................................... 325 impurities ............................................................... 19, 26, 48, 58, 67, 99, 102, 103, 106, 111, 114, 135, 308, 312, 320 incinerator .............................................................................................................................................................................................. 7, 8 inclined brick .............................................................................................................................................................................. 202, 224 inclusion ..................................................................................................................................................................................... 26, 27, 31 nstallation costs .................................................................................................................................................................................... 17 nstallation packages ........................................................................................................................................................................ 356 insulating layer .................................................................................................................................................................................... 197 insulation . 9, 11, 23, 24, 25, 109, 135, 137, 159, 160, 161, 167, 170, 176, 197, 198, 245, 246, 283, 285, 326, 327, 328 nsulation lanket .............................................................................................................................................................................. 137 nsulation oard ................................................................................................................................................................................. 137 insulator ..............................................................................................................................................................................................21, 69 intermediate vessel ................................................................................................................................................................. 324, 338 internal loading .................................................................................................................................................................... 62, 65, 173 isostatic press ....................................................................................................................................................................................... 325 J joints ........31, 46, 64, 72, 92, 135, 137, 140, 141, 150, 151, 161, 191, 225, 229, 230, 235, 258, 274, 283, 284, 296, 322, 325, 326, 327, 328 K keys ............................................................................................................................................................................... 92, 139, 149, 298 kyanite ..................................................................................................................................................................................................... 110 L ladle barrel ............................................................................................................................................................................................ 310 ladle bottom .......................................................................................................................................................................................... 140 ladle metallurgy ..................................................................................................................................47, 126, 279, 292, 313, 318 ladle sand ...........................................................................................................................................................................128, 304, 305 ladle stirring ...................................................................................................................................................................................77, 292 ........................................................................................................................................................................................... 155 ever ule ................................................................................................................................................................................................. 42 lime....................................... 13, 14, 30, 31, 41, 42, 43, 44, 45, 51, 53, 55, 56, 58, 59, 102, 104, 130, 131, 252, 322 linear change ................................................................................................................................................62, 63, 64, 91, 174, 289 ................................................................................................................................................................................................ . 317 lip skull removal........................................................................................................................................................................ 313, 318 liquid iron........................................................................................................................................2, 5, 6, 129, 183, 191, 193, 195 liquidus line .......................................................................................................................................................................................41, 47 liquidus surfaces .................................................................................................................................................................................... 55 ogistical costs .................................................................................................................................................................................15, 17 ow alumina ............................................................................................................................................................................... 107, 109 ow cost country (LCC) purchasing ........................................................................................................................................... 356 lower cones ........................................................................................................................................................................................... 221 ower sidewalls .................................................................................................................................................................................. 256 M magnesia ..... ..18, 44, 46, 48, 49, 56 58, 67, 79, 80, 84, 89, 91, 99, 107, 125, 126, 130, 131, 163, 164, 180, 181, 197, 200, 201, 204, 205, 211, 213, 216, 217, 221 223, 230, 237, 244, 251, 252, 258 260, 267, 276, 277, 284, 289, 310, 322, 333, 344, 345, 356 agnesite .................................................................................................................................................................................................. 72







agnesium .................................................................................................................................................................................. 119, 120 magnesium ferrite .............................................................................................................................................................................. 249 maintenance ....................................................................................................................................... 7, 9, 13, 14, 15, 18, 247, 356 matrix ......................................................................................... 36, 71, 78, 83, 92, 123, 142, 144, 150, 163, 164, 172, 229 echanical impact .........................................................................................................................................................................37, 73 mechanical impact resistance .......................................................................................................................................................... 76 elting properties .........................................................................................................................................................................38, 95 MgO-C. 18, 22, 27, 33, 56, 57, 71, 104, 116, 117, 118, 139, 166, 180, 181, 207, 213, 214, 229, 239, 305, 313, 314, 315, 347 Micro-board ......................................................................................................................................................................161, 283, 326 microcracks ........................................................................................................................................................................................... 164 micro-defects .................................................................................................................................................................................71, 229 micrographs .........................................................................................................................................................................84, 164, 176 mineralogy ..................................................................................................................................... 39, 91, 169, 247, 249, 289, 354 mini-keys ................................................................................................................................................................................................ 139 modulus of elasticity ....................................................................................................................................65, 67, 68, 70, 91, 289 moisture .................................................................................................19, 44, 119, 130, 143, 144, 145, 150, 154, 330, 331 monolithic ...... 95, 135, 136, 139, 140, 143, 150, 153, 191, 196, 197, 201, 233, 244, 247, 251, 252, 253, 284, 285, 287, 288, 310, 318, 319, 327, 328, 357 mortar ................................................................................ 31, 72, 135, 141, 150, 151, 152, 229, 298, 299, 300, 305, 354 mould powder .....................................................................................................................................................................31, 176, 349 mouth cleaning .................................................................................................................................................................................... 200 mullite ............................................................................................................................ 12, 47, 55, 107, 109, 110, 111, 144, 150 ultiple ins ......................................................................................................................................................................................... 253 N natural convection ................................................................................................................................................................................ 22 natural mineral fibres .............................................................................................................................................................................9 nitrogen pickup ...................................................................................................................................................................................... 26 non metallic inclusions .......................................................................................................................................................... 301, 338 nozzles ............................................................. 30, 31, 34, 116, 128, 176, 306, 307, 325, 343, 344, 345, 349, 352, 354 O livine ...................................................................................................................................................................................................... 332 open porosity ......................................................................................................................................................................86, 169, 170 perational impact ............................................................................................................................................................................... 15 rganic polymers ............................................................................................................................................................................... 145 oxidation resistance ..........................................................................................................................99, 113, 114, 116, 120, 125 oxygen blowing processes .............................................................................................................................................................. 193 oxygen lancing ............................................................................................................................................ 200, 296, 306, 341, 347 oxygen pickup ............................................................................................................................................................................ 330, 334 oxygen stirring .................................................................................................................................................................225, 228, 231 P panel spalling test .................................................................................................................................................................... 176, 181 article hardness ................................................................................................................................................................................... 77 particle packing theory .................................................................................................................................................................... 166 article shape .......................................................................................................................................................................................... 77 particle size .....................................................................................................................................................................37, 77, 95, 145 particle size distribution .................................................................................................................................................................... 95 passivation layer .................................................................................................................................................................................... 80 patching .............................................................................................................................................................7, 18, 19, 74, 148, 213 eak temperature ..36, 125, 196, 199, 203, 208, 215, 220, 228, 235, 236, 243, 250, 256, 266, 269, 275, 284, 286, 295, 303, 308, 313, 318, 327, 331, 335, 339, 342, 343, 346, 347 enetration ........2, 36, 86, 88, 89, 106, 125, 197, 201, 205, 212, 217, 222, 230, 236, 237, 244, 251, 258, 267, 270, 276, 284, 288, 296, 306, 310, 315, 318, 328, 332, 336, 341, 343, 345, 347, 349 Penn State University .............................................................................................................................................................................8 permeability ....................................................................................................................................................86, 134, 167, 168, 169 phase changes ...................................................................................................................................................................................... 108 phase diagram Al2O3 - SiO2.......................................................................................................................................... 109 Al2O3-ZrO2 ........................................................................................................................................... 109 CaO-Al2O3 ............................................................................................................................................ 109







CaO-MgO .............................................................................................................................................. 109 CaO-MgO-Al2O3 ................................................................................................................................... 109 CaO-MgO-SiO2 ..................................................................................................................................... 109 CaO-SiO2............................................................................................................................................... 109 MgO-Al2O3 ........................................................................................................................................... 109 MgO-Al2O3-SiO2 .................................................................................................................................. 109 MgO-B2O3 ............................................................................................................................................ 109 Mgo-Cr2O3 ........................................................................................................................................... 109 MgO-SiO2 ............................................................................................................................................. 109 SiO2-ZrO2 ............................................................................................................................................. 109 phenols ..........................................................................................................................................................................................................7 pickup ..................................................................................................................................................................................................26, 27 picrochomite ......................................................................................................................................................................................... 126 itches ..................................................................................................................................................................................................2, 123 plastic ...........................................................................................................131, 135, 143, 150, 151, 152, 157, 158, 201, 244 pneumatic .................................................................................................................................................................................... 236, 237 polycrystalline ..............................................................................................................................................................................83, 163 pore diameter .......................................................................................................................................................................................... 86 porosity ..... 21, 71, 83, 84, 86, 94, 134, 142, 144, 145, 150, 164, 165, 166, 167, 168, 169, 170, 173, 181, 229 ports................................................................................................................................................................................................ 348, 349 post combustion ........................................................................................................................................................................................7 powders .......................................................................................................................................... 29, 71, 113, 123, 125, 229, 349 precast .......................................................................... 18, 37, 90, 91, 135, 137, 142, 144, 164, 190, 191, 270, 355, 356 referential xide ormers ........................................................................................................................................................2, 118 pre-formed or pre-fused spinel ...................................................................................................................................................... 46 preheaters ......................................................................................................................................................................................... 7, 90 rism spalling tests............................................................................................................................................................................ 175 P-series .................................................................................................................................................................................................... 139 pumpable...................................................................................................................................................................................... 143, 145 urchasing..................................................................................................................................................... 8, 13, 354, 355, 357, 358 pure alumina ...................................................................................................................................................................42, 47, 55, 112 purity ....... 16, 17, 19, 36, 43, 47, 58, 71, 99, 100, 101, 114, 115, 116, 125, 130, 146, 201, 203, 206, 208, 213, 215, 218, 220, 223, 229, 231, 239, 277 Q uality ssurance............................................................................................................................................................................... 171 uality ontrol..................................................................................................................................................................................... 171 quartz ..............................................................................................................................................................................................8, 12, 60 R radiation ..................................................................................................................................................................................... 22, 23, 34 adioactivity ............................................................................................................................................................................................ 34 amming material..........................................................................................................................................................135, 137, 150 raw materials . 2, 12, 38, 47, 48, 58, 62, 72, 78, 94, 95, 97, 109, 110, 111, 123, 125, 126, 130, 131, 133, 134, 135, 144, 150, 153, 163, 164, 173, 174, 180, 203, 208, 215, 220, 229, 356, 357, 360 reaction layer ...................................................................................................................................................................................80, 83 ectangular spalling tests............................................................................................................................................................... 175 refractory ceramic fibres .............................................................................................................................................................. 9, 10 refractory manufacturing ............................................................................................................................................................... 133 refractory suppliers .................................................................................................................................................. 8, 117, 355, 356 efractory texture ..........................................................................................................................................................................2, 163 removable bottoms........................................................................................................................................................................5, 224 re-oxidation ....................................................................................................................................................................................26, 118 residual carbon .................................................................................................................................................................................... 123 resin bonded ........................................................................................................................................................... 7, 8, 118, 123, 191 resins ..................................................................................................................................................................19, 113, 123, 125, 163 rheology ..............................................................................................................................................................................135, 143, 145 R-HOB .....................................................................................................................................................................................33, 126, 127 ing construction ............................................................................................................................................................................... 140 obotic installation............................................................................................................................................................................ 330 otary slag testing............................................................................................................................................................................. 178 owlock................................................................................................................................................................................................... 140 ubble ile nalysis ................................................................................................................................................................2, 89, 92







S safety .....13, 2, 7, 17, 18, 23, 123, 125, 145, 183, 185, 186, 191, 194, 196, 197, 202, 207, 214, 233, 241, 243, 244, 245, 251, 254, 262, 280, 282, 284, 285, 287, 288, 291, 301, 314, 324, 326, 327, 328, 329, 330, 354 afety ottom ....................................................................................................................................................2, 185, 196, 243, 282 safety lining ..............................................................................................................................196, 197, 244, 245, 284, 285, 328 aturday night designing ................................................................................................................................................................... 89 scrap charge .......................................................................................................................................................................................... 208 crap force ...................................................................................................................................................................................... 73, 209 scrap impact .......................................................................................................................................................................................... 210 .................................................................................................................................................................274, 275, 277 self flow .................................................................................................................................................................... 135, 137, 142, 144 emi-universal ..................................................................................................................................................................................... 139 shell protection ..............................................................................................................................................24, 159, 164, 283, 326 shell temperature ..........................................................................................................................22, 24, 25, 161, 245, 283, 327 helving ................................................................................................................................................................................................... 148 hotcrete (wet gunning) ................................................................................................................................................................. 143 hotcreting .............................................................................................................................................. 2, 142, 143, 145, 146, 190 sidewall ...................................................................6, 175, 176, 196, 197, 243, 257, 284, 308, 309, 310, 311, 327, 328 silica ... 9, 12, 26, 29, 34, 38, 45, 47, 48, 51, 53, 55, 57, 58, 60, 78, 84, 102, 104, 108, 109, 110, 111, 119, 129, 130, 131, 144, 150, 163 ilicon (Si) .............................................................................................................................................................................................. 119 ilicon arbide (SiC) .......................................................................................................................................................................... 120 silicosis ....................................................................................................................................................................................................... 12 sillimanite .............................................................................................................................................................................................. 110 single crystal ......................................................................................................................................................................................... 100 intered ......................................................................................................................... 71, 97, 99, 105, 106, 111, 229, 245, 248 sintered layer......................................................................................................................................................................................... 248 sintering ........................................................................................................ 39, 123, 131, 166, 173, 248, 249, 250, 251, 252 skull.........................................................................................................................................36, 73, 199, 209, 313, 318, 327, 333 labbing / palling / laking / eeling ........................................................................................................................................ 61 lag oating .............................................................................................................................................................................................. 84 slag stopper ................................................................................................................................................................................. 236, 237 slagline........ 2, 4, 5, 6, 17, 92, 100, 115, 117, 126, 176, 217, 256, 312, 313, 314, 315, 316, 317, 343, 349, 357 leeve ....................................................................................................................................................................... 274, 275, 277, 294 lide ate echanism lide gate plates ................................................................................................................................... 302 lide gate system .................................................................................................................................. 302 lidegates ............................................................................................................................................. 302 .......................................................................................................................................................................................... 30 slumping ................................................................................................................................................................................38, 135, 197 snorkels ......................................................................................................................................................................................... 176, 322 odium aluminate .............................................................................................................................................................................. 145 sodium silicate ..................................................................................................................................................................................... 151 softening .................................................................................................................................... 39, 65, 71, 95, 124, 125, 197, 229 soldier ...................................................................................................................................................................................................... 224 spinel .....................38, 46, 56, 57, 91, 95, 118, 119, 126, 181, 288, 289, 296, 310, 328, 332, 336, 341, 343, 349 spiral construction ............................................................................................................................................................................. 139 splitline ..........................................................................................................................................................................................................6 spoke area .............................................................................................................................................................................................. 271 spout .....................................................................................................................................................................................189, 190, 273 stabilized ................................................................................................................................................................................................... 59 stadium .....................................................................................................................73, 209, 220, 221, 222, 223, 224, 230, 233 tainless steel needles ............................................................................................................................................................... 71, 229 standard testing ................................................................................................................................................................... 94, 95, 165 steel cleanliness .................................................................................................................................................................29, 330, 334 steel defects ........................................................................................................................................................................................... 325 steel fins ..................................................................................................................................................................................................... 31 steel flow control system ................................................................................................................................................................ 325 steel ladle teel ladle argon system.. 2, 3, 4, 22, 43, 47, 83, 90, 92, 99, 110, 111, 114, 131, 139, 154, 160, 175, 176, 279 287, 290, 292, 301, 308 309, 311 313, 315, 317 319, 325, 356 teel ladle bottom ................................................................................................................................ 357







teel ladle insulation ............................................................................................................................ 357 teel ladle processing routes ................................................................................................................ 357 teel/slag dumping process .................................................................................................................. 357 tiffness ...................................................................................................................................................................................................... 67 stir plug .................................................................................................................................................................... 232, 265, 267, 295 tokes law ..........................................................................................................................................................................................27, 31 stopper rod ......................................................................................................................................................31, 339, 342, 343, 344 torage costs ............................................................................................................................................................................................ 17 traights .................................................................................................................................................................................................. 139 train-controlled load ......................................................................................................................................................................... 61 trength and mechanical resistance .......................................................................................................................................... 119 tress / train .......................................................................................................................................................................................... 61 tress-controlled load ......................................................................................................................................................................... 61 submerged entry nozzle (SEN) .................................................................................................................................................... 325 urface ondition ..................................................................................................................................................................... 148, 149 surface tension.................................................................................................................................................................................86, 87 ynthetic itreous ibres...................................................................................................................................................................... 9 T tabular alumina ...............................................................................................................................................................110, 144, 150 amman temperature ......................................................................................................................................................................... 39 tap pad ............................................................................................................................................. 6, 203, 204, 205, 206, 207, 235 taphole .........................................6, 75, 206, 210, 213, 234, 235, 236, 237, 238, 239, 256, 273, 274, 275, 276, 277 aphole lock ....................................................................................................................................................................................... 235 aphole epairs ........................................................................................................................................................................ 238, 277 tapping force ............................................................................................................................................................. 90, 287, 288, 309 tapping height/ angle .................................................................................................................................................................90, 309 apping ad ......................................................................................................................................................................................2, 203 tapping rate ....................................................................................................................................................................................75, 210 tapping time ................................................................................................................................................................................ 234, 274 tearout profile ...................................................................................................................................................................................... 259 echnical ata heets ...................................................................................................................................................................2, 163 tension ......................................................................................................................................................................... 87, 171, 348, 357 ernary iagrams ................................................................................................................................................................................. 50 thermal conductivity ................................................................................................................................... 69, 114, 116, 125, 228 thermal cycling ....... 13, 66, 84, 86, 88, 112, 175, 176, 178, 179, 191, 205, 212, 217, 222, 235, 237, 258, 270, 276, 306, 310, 315, 331, 336, 347, 349 thermal diffusivity .......................................................................................................................................................................69, 228 thermal expansion ...... 37, 61, 62, 64, 65, 67, 69, 70, 72, 84, 90, 108, 110, 114, 125, 131, 141, 155, 166, 173, 174, 197, 201, 205, 212, 217, 222, 228 30, 235 7, 244, 251, 258, 267, 270, 274, 276, 284, 288, 296, 306, 310, 315, 319, 328, 332, 336, 341, 343, 345, 347, 349 hermal xpansion llowance........................................................................................................................................................ 64 hermal expansion curves ........................................................................................................................................................... 174 thermal gradient .................................................................................................................................................................. 65, 69, 173 thermal losses .......................................................................................................................................................... 24, 159, 283, 326 hermal modeling ................................................................................................................................................................................. 23 hermal shock 36, 61, 121, 125, 165, 175, 196, 199, 203, 208, 215, 220, 228, 235, 236, 243, 250, 257, 266, 270, 275, 284, 287, 295, 304, 309, 313, 318, 327, 331, 336, 340, 342, 343, 346, 348 thermal shock resistance ...... 46, 68, 69, 70, 113, 121, 123, 125, 131, 164, 165, 176, 198, 213, 228, 231, 239 thermal stress resistance .................................................................................................................................................... 67, 68, 70 thermal stresses.................................................................................................................................................................................. 175 hixotropic ............................................................................................................................................................................................ 145 TMC analysis .......37, 89, 90, 117, 124, 196, 199, 203, 208, 215, 220, 227, 235, 236, 243, 249, 250, 256, 266, 269, 274, 275, 284, 327, 331, 335 op one ..............................................................................................................................................................2, 194, 199, 200, 201 otal ost of wnership .................................................................................................................................................2, 15, 354 transfer ladle desulphurization ................................................................................................................................................... 183 transfer vessel .....................................................................................................................................................................55, 183, 279 ransport costs ....................................................................................................................................................................................... 17 tri-calcium silicate .............................................................................................................................................................................. 131 ridymite ............................................................................................................................................................................................12, 52 trivalent chromium ............................................................................................................................................................................... 33







trunnion refractory............................................................................................................................................................................ 215 tundish undish boards . . 2, 6, 12, 29, 30, 31, 32, 73, 209, 221, 230, 286, 324 undish gate ......................................................................................................................................... 286 undish lining ....................................................................................................................................... 286 undish nozzle ...................................................................................................................................... 286 undish powder .................................................................................................................................... 286 undish shroud ..................................................................................................................................... 286 undish spray ....................................................................................................................................... 286 undish stopper rod ............................................................................................................................. 286 tuyeres .......................................................................................................................................................... 5, 68, 225, 250, 268, 322 U unformed refractory ............................................................................................................................................................... 135, 150 V vacuum tank degasser ...................................................................................................................................................................... 293 V........................................................................................................................................................................................... 156 velocity of slag movement ..........................................................................................................................................................79, 83 vibrated .................................................................................................................................................................... 131, 135, 137, 142 vibration machines ............................................................................................................................................................................ 254 viscosity of slag ................................................................................................................................................................................79, 83 W ater cooled rods .............................................................................................................................................................................. 253 wear patterns ................................................................................................................................................................................18, 281 wedge brick ........................................................................................................................................................................................... 219 wedges ........................................................................................................................................................................................................ 31 wedge-splitting test .............................................................................................................................................................................. 68 weirs .....................................................................................................................................................................................334, 336, 337 welded wire mesh .............................................................................................................................................................................. 155 white fused alumina .......................................................................................................................................................................... 110 wools ...................................................................................................................................................................................................... 9, 10 work of fracture ............................................................................................. 36, 37, 68, 70, 71, 76, 91, 125, 228, 229, 289 ork of fracture tests....................................................................................................................................................................... 181 orking ottom................................................................................................................................................... 187, 247, 286, 290 orking ining ................................................................................................................................................................................6, 330 orking idewall ............................................................................................................................................................................... 308 Y Y.................................................................................................................................................. ......................................... 157 yttria ............................................................................................................................................................................................................ 59 Z zircon........................................................................................................................................................................................................... 34 zirconia (zirconium oxide) ................................................................................................................................................................ 34 zirconium silicate .................................................................................................................................................................................. 34







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