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2020 | Book

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Introduction to Refractories for Iron- and Steelmaking

Authors: Subir Biswas, Prof. Debasish Sarkar

Publisher: Springer International Publishing

Part of: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik" , Springer Professional "Wirtschaft"

Table of Contents
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About this book

This book promotes understanding of the raw material selection, refractory design, tailor-made refractory developments, refractory properties, and methods of application. It provides a complete analysis of modern iron and steel refractories. It describes the daily demands on modern refractories and describes how these needs can be addressed or improved upon to help achieve the cleanest and largest yields of iron and steel. The text contains end-of-chapter summaries to help reinforce difficult concepts. It also includes problems at the end of chapters to confirm the reader's understanding of topics such as hoop stress modeling in steel ladle and vessels, establishment of thermal gradient modeling , refractory corrosion dynamics, calculation of Blast furnace trough dimension based on thermal modeling, to name a few. Led by editors with backgrounds in both academia and industry, this book can be used in college courses, as a reference for industry professionals, and as an introduction to the technology for those making the transition to industry.Stands as a comprehensive introduction to the science and technology of modern steel and iron-making refractories that examines the processes, construction, and potential improvement of refractory performance and sustainability;Serves as a versatile resource appropriate for all levels, from the student to industry novices to professionals;Reinforces difficult-to-grasp concepts with end-of-chapter summaries;Maximizes reader understanding of key topics, such as refractory selection for steel ladle and vessels, and their corrosion dynamics, with real life problems.

Table of Contents

Frontmatter
Chapter 1. Refractories for Iron and Steel Plant
Abstract
Refractories are the essential lining materials for working interfaces and backup zone of furnaces during manufacturing of iron and steel, in specific sequential and consecutive operation of forming, holding, mixing and transporting hot metal, liquid steel and slag. Despite refractory-metal direct interactions, refractory has to successively experience high temperature and corrosive environment through flues, stack or shaft and ducts. In this context, this chapter deals with the classification and description of acidic, neutral and basic refractories for different environment and application zones for iron- and steel-making processes. Prior to considering the refractories, recent market trend, designing parameters including predominant mechanical and thermal behaviour are explicitly discussed to provide a better insight of the subject. Modern class of both shaped and unshaped refractories is highlighted starting from raw materials to installation practice. Refractory corrosion mechanism influenced by blast furnace slag, and primary and secondary steel-making slag, is analysed in order to understand and develop next-generation refractories.
Subir Biswas, Debasish Sarkar
Chapter 2. Iron- and Steel-Making Process
Abstract
With extensive changing in the operating practice due to stringent control in product quality, introduction of new product mix and demand for high productivity, it is indeed to upgrade the refractory quality to cope up with the changed environment and refractory life improvement. Hence, starting with the master plan, it was decided to provide a brief introduction on modern iron- and steel-making practice along with background of refractory choice in Chap. 2, to amalgam the relation of refractory performance with changed escalating demand on safe performance. As small blast furnaces have been closed and replaced by large-size furnaces, open-hearth steel making has been replaced by high-productive basic oxygen furnaces (BOF), RH (Ruhrstahl Heraeus)—degasser is the most popular for making ultra-low carbon steel. Additional Composition Adjustment by Sealed argon bubbling with Oxygen Blowing (CAS-OB) is started to operate in many integrated and large-size steel plant to produce high-quality alloy steel; the operating processes of those equipment has been discussed in detail.
Subir Biswas, Debasish Sarkar
Chapter 3. Blast Furnace Refractory
Abstract
Blast furnace is like to continue as the most efficient route to produce pig iron for its high productivity and cost optimization, for many years to come. Although a small part of iron making has been supplemented by alternate iron-making process such as direct reduced iron (DRI) and smelting reduction, however, the replacement of blast furnace for steel making is a distant dream. Thus, the refractory for modern blast furnace including cast house refractories is a critical issue and discussed in Chap. 3. Different refractory maintenances practices prolong campaign of blast furnace life with improved productivity, and thus their key features are enrolled. Starting from the reduction of coke rate to effective hot metal through runner is a challenging task to the operator in the mind of production cost reduction and in turn, efficiency of blast furnace is analysed.
Subir Biswas, Debasish Sarkar
Chapter 4. Hot Stove and Hot Air Carrying System
Abstract
Hot stove is a thermal heat regenerator to produce and supply constant hot air to blast furnace. The present demand of increased hot metal productivity through blast furnace route requires high hot blast temperature, more than 1200 °C, and it requires to optimize and upgrade the quality and design of refractory. Thus, design of stove and their checkers have undergone a major change and demand installation of superior-quality refractories. Advantages in changed design and upgrade refractory quality from alumina dome to silica, installation of ceramic burners are extravagantly explained in this chapter. Latest development in stove design is top combustion stove that can deliver hot air more than 1300 °C; in obvious this operational feature has economic benefit over conventional one. Detailed discussion has been done on critical refractory application in those type of stoves that eventually help to generate knowledge on how one can use effectively hot blast more than 1300 °C for as large as 5000 m3 blast furnace.
Subir Biswas, Debasish Sarkar
Chapter 5. Refractory Practice in Electric Arc Furnace
Abstract
Owing to several advantages including flexibility to produce several grades of steel, precise control, cleaner environment and minimum installation space, many mini steel plants are producing steel through electric arc furnace (EAF) route. This protocol is benefited to use sponge iron and higher share of scrap utilization. EAF supports 35% high alloy steel production around the globe. Different constructional and operational features, side wall and bottom/hearth refractory properties, and refractory design for bottom tapping are discussed in the perspective of effective steel processing. Despite the use of three carbon electrodes in EAF, only one electrode-based direct current (DC) arc furnace is highlighted. Refractory corrosion mechanism in the presence of different impurities and subsequent slag interaction are discussed through relevant phase diagrams in order to select the refractory depending on steel compositions. Eventually, the state-of-the-art operating practice and refractory performances are summarized.
Subir Biswas, Debasish Sarkar
Chapter 6. Refractory for Hot Metal Transport and Desulfurization
Abstract
Continuous steel production demands uninterrupted iron supply for steel vessels. Limited 60- to 80-ton hot metal ladle has several disadvantages and thus high capacity up to 300-ton torpedo ladle is being introduced to overcome the hot metal ladle limitations. Herein, explicitly focused on the design aspects, competitive early days and recent refractory lining, plausible refractory deterioration factors and operational influence on the refractory performance to operate the torpedo ladle effectively. Torpedo ladle refractory development and lining modules for higher campaign, effect of insulation refractories, refractory maintenance protocols and future challenges are encountered to improve the working environment. Despite torpedo ladle, desulfurization in hot metal ladle and in situ process reactions with refractories and wear mechanisms are discussed to fulfil the knowledge gap.
Subir Biswas, Debasish Sarkar
Chapter 7. BOF Refractory
Abstract
Is it BOF a “heart” of any steel sector? If yes, it is mandate to take extra care to keep it healthy through refractory management, lining practice and effective operational protocols. In this backdrop, this chapter concentrates on the refractory designing for the vessel and tap hole sleeve, and analyses probable wear mechanism through ternary phase diagram. Influence of gas purging and slag splashing on the refractory life of different zones, followed by zonal lining concept, is also being discussed systematically. MgO-C refractory lining wear is an inevitable circumstance, and discussed in consideration of refractory–slag interaction, reduction of MgO, metal infiltration with respect to critical pore diameter, thermal stress and spalling phenomena, impact caused by charging, and mechanical erosion and abrasion. Basic philosophy has been highlighted to improve the MgO-C refractory for BOF lining. Herringbone vessel relining and maintenance practice by gunning and patching are emphasized to improve the BOF lining life.
Subir Biswas, Debasish Sarkar
Chapter 8. Refractory for Secondary Refining of Steel
Abstract
Modern steel ladle is used not merely to transport liquid steel from BOF to caster, but also to act as a reactor vessel where refining of steel takes place to reduce impurities, carbon, alloy addition and killing (Al, Si, bi-metal) of steel to reduce oxygen and other gasses; these comprehend the necessity and critical role of refractories. Substantial modification and development have been brought into the refractory quality to eliminate carbon (C) and oxygen pick up into steel from refractory lining for ladle furnace (LF) and CAS–OB processes. Thus, refractory design in steel ladles, energy saving issues, variation of thermal conductivity with respect to conventional graphite and nanocarbon, thermal stress assisted cracks and refractory failure are discussed. RH degasser is in limelight to produce ultra-low C and high-alloyed steel with an efficient productivity. Most suitable refractory practice has been suggested in consideration of slag–refractory interaction that eventually facilitate prolong ladle life and high-quality steel.
Subir Biswas, Debasish Sarkar
Chapter 9. Refractory in Ladle Flow Control and Purging System
Abstract
Continuous strive towards new technology introduced reliable flow control systems that enable safe and prolong tapping liquid steel from ladle to tundish with consistent and high casting rate. Thus, synchronization of operational parameters, appropriate refractory and analysis of probable failure are essential and encountered. Erosion of bore and corrosion of sliding surface of the slide plates, radial cracking of plates and metal leakage are the most critical issues as addressed with mention of optimize refractory quality of plates and nozzles to prolong casting time. In order to homogenous the molten steel gas purging is an important aspect and thus different types of purging plugs, their design, refractory quality and the effect of casting sequences had also been discussed. Thermal stressed failure and premature wear may reduce the operational safety and promote shop floor safety hazards are also highlighted.
Subir Biswas, Debasish Sarkar
Chapter 10. Refractory for Casting
Abstract
Continuous casting (con-cast) demands uninterrupted product length whereas ingot process is popular for batch process. In modern production protocol, ingot casting process is limited and more than 90% of global steel production follows continuous casting of slab, bloom, billet, thin slab, etc. A brief understanding including mould, pouring, choice of refractory and their failure, advantages and disadvantages for ingot casting are discussed. In spite of batch process, exhaustive con-cast in specific operational features, and refractory design and failures are delivered in the perspective of minimizing casting defects and higher yield of finished steel. Tundish is the indispensable component in the con-cast process and it is the refractory lined last vessel before solidification of molten steel in the mould, in which different refractories in hot face and in back up for easy de-skulling are described. Causes of clogging, usage of anti-clogging refractory materials in subentry nozzle and other “black refractories” with latest design of inert gas purging in SEN had been mentioned.
Subir Biswas, Debasish Sarkar
Chapter 11. Modern Refractory Practice for Clean Steel
Abstract
Ductility facilitates reforming but elastic modulus provides the strength of steel. It all depends on constituents and phases in steel. The previous discussion emphasizes steel production is a multi-step process that has to pass through the exhaustive environment and thus possibilities of inclusions despite targeted compositions. This drawback reduces the steel performance and therefore modern amenities demand clean steel for an extensive range of applications. An excellent choice of new class of modern refractory is required to avoid contamination and maintain desired properties of steel. Detailed discussion concentrated on probable inclusions by refractories, the stability of refractory oxides to produce clean steel, low carbon-containing refractories through the adoption of nanotechnology like using nano-carbon and graphene. Magnesia–alumina–graphite refractories and spinel refractory are highlighted in view of the carbon reduction in a ladle and continuous casting refractories to make clean steel. Several operational features and refractory choice of large tundish including hydrogen pickup reduction in steel through non-aqueous resin-bonded dry-vibrating mass (DVM) is discussed.
Subir Biswas, Debasish Sarkar
Chapter 12. Advance Material Design and Installation Practices
Abstract
Design terminology is not only confined in a particular shape, rather performance of applied components depends on the geometry and material design, together. In early days, industrial furnaces and vessels were made of brickwork, but clean steel asks for total package including refractory composition, shape and installation practice for continuous and long period operation without interruptions for repairs. In order to accomplish steel sector demand, latest jointless monolithic especially colloidal silica-bonded cement-free castable, alumina-oxi-carbide-bonded castable, magnesia-containing castable and chrome-free castable are encountered and analysed. Despite different classic endless lining protocols, installation and repair methodologies are systematically discussed. Uniform microwave-assisted heating and drying opens up a new installation practice for endless working lining that is capable to replace partial damage zone without major replacement of original lining. Advantages of flame gunning over conventional wet gunning differentiate the performance of refractory lining. Ceramic welding process is emphasized in which base refractory hot surface is being repaired through metal powder at elevated temperature as high as 1200 °C, and exothermic reaction facilitates permanent bond and repairs the defective refractory zones.
Subir Biswas, Debasish Sarkar
Backmatter
Metadata
Title
Introduction to Refractories for Iron- and Steelmaking
Authors
Subir Biswas
Prof. Debasish Sarkar
Copyright Year
2020
Electronic ISBN
978-3-030-43807-4
Print ISBN
978-3-030-43806-7
DOI
https://doi.org/10.1007/978-3-030-43807-4

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