Fundamental Design of Steelmaking Refractories

Fundamental Design of Steelmaking Refractories
Contents
Preface
Acknowledgment
About Author
1 Heat and Mass Transfer
1.1 Introduction
1.2 Energy Conservation
1.3 Conduction
1.3.1 Basic Concept and Properties
1.3.2 One-Dimensional Steady-state Conduction
1.3.3 Two-Dimensional Steady-state Conduction
1.4 Convection
1.4.1 Boundary Layers
1.4.2 Laminar and Turbulent Flow
1.4.3 Free and Forced Convection
1.4.4 Flow in Confined Region
1.5 Radiation
1.5.1 Basic Concepts
1.5.2 Emission from Real Surfaces
1.5.3 Absorption, Reflection, and Transmission by Real Surfaces
1.5.4 Exchange Radiation
1.6 Mass Transfer
1.6.1 Convection Mass Transfer
1.6.2 Multiphase Mass Transfer
1.6.3 Analogy—Heat, Mass, and Momentum Transfer
1.7 Heat Transfer in Refractory Lining
1.7.1 Tunnel Kiln
1.7.2 Ladle Lining
References
2 Equilibrium and Nonequilibrium Phases
2.1 Introduction
2.2 Basics of Phase Diagram
2.2.1 Gibb’s Phase Rule
2.2.2 Binary Phase Diagram and Crystallization
2.2.3 Ternary Phase Diagram and Crystallization
2.2.4 Alkemade Lines
2.3 One-Component Phase Diagrams
2.3.1 Water
2.3.2 Quartz
2.4 Two-Component Phase Diagrams
2.4.1 Fe–C
2.4.2 Two Oxides Phase Diagrams
2.5 Three-Component Phase Diagrams
2.5.1 Three Oxides Phase Diagrams
2.5.2 FeO–SiO2–C
2.6 Nucleation and Crystal Growth
2.6.1 Homogenous and Heterogeneous Nucleation
2.6.2 Crystal Growth Process
2.7 Nonequilibrium Phases
References
3 Packing, Stress, and Defects in Compaction
3.1 Introduction
3.2 Refractory Grading and Packing
3.2.1 Binary and Ternary System
3.2.2 Particle Morphology and Mechanical Response
3.2.3 Nanoscale Particles and Mechanical Response
3.2.4 Binder and Mixing on Packing
3.3 Stress–Strain during Compaction
3.4 Agglomeration and Compaction
3.5 Uniaxial Pressing
3.6 Cold Isostatic Pressing
3.7 Defects in Shaped Refractories
References
4 Degree of Ceramic Bonding
4.1 Introduction
4.2 Importance of Heating Compartment
4.2.1 Loading and Heating
4.2.2 Heat Distribution
4.2.3 Temperature Conformity
4.3 Initial Stage Sintering
4.3.1 Sintering Mechanisms of Two-particle Model
4.3.2 Atomic Diffusion
4.3.3 Sintering Kinetics
4.3.4 Sintering Variables
4.3.5 Limitations of Initial Stage of Sintering
4.4 Intermediate and Final Stage Sintering
4.4.1 Intermediate Stage Model
4.4.2 Final Stage Model
4.4.3 Influence of Entrapped Gases
4.5 Microstructure Alteration
4.5.1 Recrystallization and Grain Growth
4.5.2 Grain Growth: Normal and Abnormal
4.5.3 Pores and Secondary Crystallization
4.6 Sintering with Low Melting Constituents
4.7 Bonding Below 1000 °C
4.7.1 Organic Binder
4.7.2 Inorganic Binder
4.7.3 Carbonaceous Binder
References
5 Thermal and Mechanical Behavior
5.1 Introduction
5.2 Mechanical Properties
5.2.1 Elastic Modulus
5.2.2 Hardness
5.2.3 Fracture Toughness
5.2.4 Strength
5.2.5 Fatigue
5.3 Cracking
5.3.1 Theory of Brittle Fracture
5.3.2 Physics of Fracture
5.3.3 Spontaneous Microcracking
5.4 Thermal Properties
5.4.1 Stress Anisotropy and Magnitude
5.4.2 Thermal Conductivity
5.4.3 Thermal Expansion
5.4.4 Thermal Shock
5.4.5 Thermal Stress Distribution
5.5 Thermomechanical Response
5.5.1 Refractoriness under Load
5.5.2 Creep in Compression (CIC)
5.5.3 Hot Modulus of Rupture
5.6 Wear
5.6.1 System-dependent Phenomena
5.6.2 Adhesive
5.6.3 Abrasive
5.6.4 Erosive
5.6.5 Oxidative
References
6 High Temperature Refractory Corrosion
6.1 Introduction
6.2 Thermodynamic Perceptions
6.3 Effect of Temperature and Water Vapor
6.4 Slag–Refractory Interactions
6.4.1 Diffusion in Solids
6.4.2 Oxidation
6.4.3 Infiltration
6.4.4 Dissolution
6.4.5 Crystallite Alteration
6.4.6 Endell, Fehling, and Kley Model
6.5 Phenomenological Approach and Slag Design
6.5.1 Refractory Solubility
6.5.2 Slag Composition and Volume Optimization
References
7 Operation and Refractories for Primary Steel
7.1 Introduction
7.2 Operational Features in BOF
7.2.1 Charging and Blowing
7.2.2 Mode of Blowing
7.2.3 Physicochemical Change in BOF
7.2.4 Tapping
7.2.5 Slag Formation
7.3 Operational Features in EAF
7.4 Refractory Designing and Lining
7.4.1 Steel Chemistry and Slag Composition
7.4.2 Thermal and Mechanical Stress
7.4.3 Refractory Lining and Corrosive Wear
7.4.4 Refractory Composition and Properties
7.5 Refractory Maintenance Practice
7.6 Philosophy to Consider Raw Materials
7.7 Microstructure-dependent Properties of Refractories
7.7.1 Microstructure Deterioration Inhibition to Improve Slag Corrosion Resistance
7.7.2 Slag Coating to Protect the Working Surface
7.7.3 Microstructure Reinforcement by Evaporation-Condensation of Pitch
7.7.4 Whisker Insertion to Reinforce Microstructure
7.7.5 Fracture Toughness Enhancement and Crack Propagation Inhibition
References
8 Operation and Refractories for Secondary Steelmaking
8.1 Introduction
8.2 Steel Diversity, Nomenclature, and Use
8.3 Vessels for Different Grades of Steel
8.4 Operational Features of Vessels
8.4.1 Ladle Furnace (LF)
8.4.2 Argon Oxygen Decarburization (AOD)
8.4.3 Vacuum Ladle Degassing Process
8.4.4 Stirring and Refining Process in Degassing
8.4.5 Composition Adjustment by Sealed Ar Bubbling with Oxygen Blowing (CAS–OB)
8.4.6 RH Snorkel
8.5 Designing Aspects of Refractories
8.6 Refractories for Working Lining
8.6.1 Magnesia–Carbon Refractories
8.6.2 Alumina–Magnesia–Carbon Refractories
8.6.3 Dolo–Carbon Refractories
8.6.4 Magnesia–chrome (MgO-Cr2O3)
8.6.5 Spinel Bricks
References
9 Precast and Purging System
9.1 Introduction
9.2 Composition Design of Castables
9.2.1 Choice of Raw Materials and Properties
9.2.2 Choice of Binders
9.2.3 Aggregates Grading
9.2.4 On-site Castable Casting
9.3 Precast-Shape Design and Manufacturing
9.4 Precast Shapes and Casting
9.5 Purging Plugs
9.5.1 Plug Design and Refractory
9.5.2 Gas Purging
9.5.3 Installation and Maintenance
9.5.4 Clogging and Corrosion
References
10 Refractories for Flow Control
10.1 Introduction
10.2 First–Second–Third Generation Slide Gate
10.3 New Generation Ladle Slide Gate System
10.4 Ladle Slide Gate Plate
10.4.1 Critical Design Parameters
10.4.2 Selection of Slide Plate and Fixing
10.4.3 Materials and Fabrication of SGP
10.4.4 Mode of Failures
10.4.5 FEA for Stress and Cracking
10.5 Tundish Slide Gate and Plate
10.5.1 Modern Slide Gate and Refractory Assembly
10.5.2 Materials and Fabrication
10.5.3 Cracking and Corrosion Phenomena
10.6 Short Nozzles for Ladle and Tundish
10.7 Nozzle Diameter and Gate Opening in Flow
References
11 Refractories for Continuous Casting
11.1 Introduction
11.2 Importance of Long Nozzles in Steel Transfer
11.2.1 Furnace to Ladle Transfer
11.2.2 Ladle to Tundish Transfer
11.2.3 Tundish to Mold Transfer
11.3 Tundish Lining
11.3.1 Lining and Failure
11.3.2 Lining Improvement and Maintenance
11.4 Ladle Shroud (LS)
11.4.1 Design and Geometry
11.4.2 Failures, Materials and Processing
11.4.3 Operational Practice
11.4.4 Flow Pattern
11.5 Mono Block Stopper
11.5.1 Preheating Schedule
11.5.2 Installation
11.5.3 Failures
11.5.4 Glazing
11.6 Submerged-Entry Nozzle
11.6.1 Installation and Failures
11.6.2 SEN Fixing for Thin Slab Caster
11.6.3 SES Installation and Failures
11.6.4 Corrosion and Clogging
References
12 Premature Refractory Life by Other Parameters
12.1 Introduction
12.2 Refractory Manufacturing Defects
12.2.1 Consistence Raw Material
12.2.2 Processing Parameters
12.2.3 Pressing and Firing
12.3 Packing and Transport
12.3.1 Packaging and Packing Material
12.3.2 Vibration-free Packaging
12.3.3 Loading, Transporting, and Unloading
12.4 Procurement and Lining Failures
12.4.1 Total Cost of Ownership Concept
12.4.2 Preliminary Features of Lining
12.4.3 Workmanship
12.5 Preventive Maintenance in Operation
12.5.1 Professional Service
12.5.2 Slag Composition, Temperature, and Viscosity
12.5.3 Monitor and Maintenance of Lining
12.6 Consistent Supply and Time Management
12.6.1 Cycle Concept
12.6.2 Pull/Push Concept
References
Index
EULA