THE CLOSED CIRCLE THE CLOSED CIRCLE REFRACTORIES REFRACTORIES - PDF document

R E – ADJUST STOCKHOLDING R E ADJUST STOCKHOLDING E QUIPMENT FOR INSTALLATION INSTALLATION F AILURE ANALYSIS R ESPONSIBLE MANAGEMENT A LTERATIONS TO STEELWORK C HECK INCOMING MATERIALS T OTAL COST STRUCTURE O PERATIONAL VARIABLES R E-EXAMINE INSTRUMENTATION CONSIDER THESE FACTORS

THE CLOSED CIRCLE THE CLOSED CIRCLE REFRACTORIES REFRACTORIES SUPPLIED D D I I E N M S NO NO O T PROGRESS L AL I I L L S H PRODUCTION VARIABLES

STEEL INDUSTRY REFRACTORIES $ $ % % PER OF TONNE OPERATIONAL OPERATIONAL of f COSTS STEEL INDIA 6,85 2,0 , CHINA 7,08 1,9 JAPAN JAPAN 7,30 7,30 1 8 1,8 S.AFRICA ? ?

BLAST FURNACE BOSH FIREBRICK LINING HEAVILY COOLED 1973 1973

SUPER DUTY FIREBRICK FIREBRICK STANDARD EXTRA SUPER A3 A4 A5 Al 2 O 3 42,5 Al O 42 5 43 0 43,0 43 3 43,3 SiO 2 53,6 53,0 52,8 Fe 2 O 3 Fe O 1 5 1,5 1,0 1 0 1 3 1,3 Na 2 O +K 2 O 0,4 0,5 , 0,5 , BULK DENSITY g/cm 2,16 g/cm³ 2,16 2,29 2,29 2,37 2,37 APPARENT POROSITY POROSITY % % 20,5 16,0 14,0

CARBON REFRACTORIES TYPICAL FAILURE ALKALI SPALLING ALKALIES IN VAPOUR FORM ALKALIES IN VAPOUR FORM PENETRATE INTO THE CARBON AND FORM LAMELLAR COMPOUNDS WHICH SWELL WITHIN THE CARBON CARBON

TAPHOLE MIXES TAPHOLE MIXES HISTORICALLY VERY SIMPLE MIXES VERY SIMPLE MIXES FILLER FILLER GRADED GRADED QUARTZITE SINTERING CLAY AND AIDS FELDSPAR POROSITY from LUMP COAL PLASTICITY f from HOT COAL TAR HOT COAL TAR MIXING CRITICAL-UP TO 30 minutes TO 30 minutes

CHEQUERS HOT CHEQUERS HOT LOAD FAILURE FAILURE ( CREEP ) TOFFEE BOND TOFFEE BOND • GLASSY • CRYSTALLINE • TRANSITION

PRECAST BLOCKS TORPEDO LADLE

CHEQUER BRICKS SILICA SILICA FIREBRICK

Magnesia-Carbon LABORATORY TESTS LABORATORY TESTS APPARENT POROSITY AND BULK APPARENT POROSITY AND BULK DENSITY APPARENT BULK DENSITY POROSITY Kg/cm 3 Kg/cm 3 % % JAPANESE E8 SLW330 2,8 , 2,91 , E8SLW270 1,3 2,97 EUROPEAN M9715ASS4 3,0 3,01 M9715S4 3,1 3,03

xxxxxx – CARBON BONDED BONDED REFRACTORIES WITH GRAPHITE WITH GRAPHITE ANOMALOUS THERMAL EXPANSION VALUES EXPANSION VALUES VERY HIGH THERMAL SHOCK RESISTANCE RESISTANCE REFRACTORIES WITH A DEGREE WITH A DEGREE OF PLASTICITY

STEEL PLANT LADLE STEEL PLANT LADLE JOINT ATTACK : JOINT ATTACK : MAG-CARBON BRICK

CASTABLES : SITE SENSITIVITY Castable A: 100MPa (low cement) water: 5,75% Castable B: 65 MPa water: 9,0% A % CCS B% CCS 5,75 120 9,0 70 6,00 90 6,25 60 9,5 66 6,50 40 10,0 60

ZONE EFFECT ZONE EFFECT TEMPERATURE ONLY ONLY SUSPENDED ROOFS PLASTIC PLASTIC – BRICK BRICK ANCHORS