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    Technology for Recycling Unshaped Refractories

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    Technology for Recycling Unshaped Refractories

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    © All Rights Reserved
    Download as PDF or read online from Scribd
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    10 views5 pages

    Technology For Recycling Unshaped Refractories - Log

    Uploaded by

    Hilder Caldas
    Technology for Recycling Unshaped Refractories

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Journal ofthe Technical Association of Refractories, Japan, 25 (2) 123-127 (2005) Report Technology for Recycling Unshaped Refractories HISAHARU SASAKI, TOMOAKI WAKAE and MAKOTO NAMBA 1. Introduction ‘Unshaped refractories (also known as monolithics) have been ‘used in Japan for forty years. Although that history is relatively short, the technology of unshaped refractories has developed rapidly, and their use i increasing. with many applications in the steel and nonferrous industries. In Japan, approximately 65% of the annual refractory production was unshaped products in 2005, Recently, the refractories industry has demonstrated increasing {improvements that will benefit the earths environment. The improvements can be divided broadly into two groups: (1) {improvement of the working environment such as the installation and repairremoval of linings and the fumace operations. and (2) {improvement of the earth's environment which focuses on the conservation of resources and energy, and the reduction of pollution (solids, liquids, gases). This paper introduces some examples of the recent recycling technology for unshaped refractories, from the point of view of conserving energy and 2. Environmental Improvements with Unshaped Refractories Figure 1 shows a schemat improvements associated with unshaped refractories. The practices involving unshaped refractories are different than shaped outline of the environmental refractories. Unshaped refractories are shipped to the customers/ users as pre-cast shapes. and also as half-finished produets, in which case they become final products where they are installed, including installation in new linings and the maintenance and repair of furnace linings. The refractories industry has tried to {improve the working environment from the development stage 10 the industrial application. One reason for the widespread, increasing use of unshaped refractories isthe development of high Improvement ofthe ‘working environment FRoducing fator Conserving ‘energy eduction of ‘environment potting Reduced dust Conserving formation Environmental improvements associated with unshaped refractories. ‘Research Gene, Shinagawa Refacoies Co Lad 71 nk. Bera, Okay en 158577 ts | Veneering repair | i Lxeceeert |e z¢ Oo o GD Scrappeo Bs aa Ls Zo ia = SS Fig.2 Relationship between the tons of unshaped refractories used and scrapped at X steel works. performance castables with low content of cement. In addition, unshaped refractories can be installed by automated methods, “which expedites the installation process, and reduces the labor ‘costs, with no requirement for skilled workers. The lining materials in furnaces are renewed whenever the furnace is repaired. Until this time, most ofthe used refractories Ihave been treated as waste materials for disposal, However, the development of repair technology with castable refractories has resulted in a decreasing amount of waste materials, compared with the traditional brick lining technology. The technology of castables, which i called the “endless ining” technique, is used in blast furnaces and ste! ladles in steel works. Figure 2 shows a ‘comparison of the unshaped refractories installed and the amount ‘scrapped at steel works X. The data indicate thatthe amount of refractory serapped inthe endless lining method is small compared with the tundish process, without a castable ining. In addition to decreasing the amount of scrapped materials, the development of ‘improved recycling technology for waste materials will contribute to saving resources and reducing environmental pollution. The refractory industry needs to take prompt measures to reduce the pollution of the earth’s environment. Recycling of ‘unshaped refractories, which focuses on the savings of energy and resourees, will be very important and essential technology. 3. Recycling Technology for Unshaped Refractories 3.1 Status of Recycled Materials ‘The main purposes fr recycling materials can be considered as: (use of waste materials to save resources and to reduce the need for disposal of waste materials, and @ decreasing the 123 HISAHARU SASAKI et al. Joumel of the Technical Association of Refractories, Japan, Vol.25 No.2 production costs by reducing the amount of virgin materials used. ‘The reduction of production costs depends on the treatment thatthe ‘waste materials need, such as the cost of pulverizing and particle sizing, andthe life of recycled materials. ‘The recycling business is divided into two main cases: (the waste materials are supplied to the user from a refractory ‘manufacturer and castables are produced at the job site, and & ‘astables are produced by a refractory manufacturer using recycled ‘materials and shipped to users. ‘Two general types of recycled waste materials are: ) used bricks that are utilized in unshaped eastables, and @ used castables that are utilized in unshaped refractories. 3.2 Material Design of Recycled Products In most eases, the performance of recycled materials is not as good as virgin materials, because they are used materials that have been exposed to service conditions. Therefore, the material design of recycled products should maintain the basic characteristics of the model refractory. When the life of refractories containing recycled materials is significantly decreased and becomes higher rok acceptable. There following key points apply tothe material design of recycled products: ve cost, the industrial use of recycled materials is not 32.1 Selection of Used Materials ‘The combination of used and virgin materials, which gives lower performance, is not acceptable, If possible, the combination ff materials should include materials of similar characteristics. Figure 3 shows the effect of used material content in castables on the corrasion behavior. The addition of used materials in high alumina refractories gives a corrosion behavior. However, the addition in alumina-magnesia catables resulted in worse corrosion resistance, and no suitable combination of used materials and virgin matrix was found. 32.2 Treatment of Reused Materials Its desirable to eliminate the metals and slags contained in used materials, however their complete elimination is virwally impossible. For particular uses, itis necessary to blend the materials of controled particle size and then dry after the crushing process. 323 Particle Size of Used Materials ‘To maintain the basic performance of unshaped refractories, it is desirable to use coarse grains of used materials. If used materials of fine particle size are dispersed in the matrix materials that determine the characteristics of refractories, various characteristic properties willbe decreased, 324 Content of Used Materials “The goal for recycled materials is o use a high content in the ‘matrix. However, the usable content must be determined by ‘balancing the cost merit and the performance of the products Generally, the content of used material ranges between 10 and 30 mass‘. Figure 4 shows the effect of different used material contents in alumina-magnesia castables on the corrosion of ladle refractories. Figure 5 shows the effect of used material (MgO-C ‘converter bricks) content on the hot flowability, The hot flowability was evaluated by the size ofthe extended material after beating of an 800 g. sample on a brick at 100°C. Both figures show thatthe performance decreases for products containing used ‘material. 325° Mixing Technique ‘Coarse paticles of used bricks from a blast Furnace were used as raw materials in castables. Also, ecycling technology is being developed for used castables - used castable materials are crushed and mixed with virgin castable materials. The effects of used ‘material content on the quality of castables are evaluated by their Hi-Alz03(Al,05 :80%) ‘AlzO3-MgO (MgO :9%) Used material content 0% 20% 0% | 10% | 30% Cross section Corrosion Index Test condition 1550°C—Sh 4, FeO=20% Slag:C/ Fig. 3 Effect of used material additions on the corrosion of castables. 124 250 Grain size of used material: — 10mm 200 Z = 150 po | 8 100 8 1650°0—4h 50 BOF Slag ee | 0 10 20 30 Used material content / 9% Fig. 4 Effect of used material additions on the corrosion of AlOs-MgO castables. 260 £ E 240 C= 2 220 5 200 € E100 } [Grain size of used material: 15—Smm 160 o 10 20 30 Used material(MgO-C) content /% Fig.5 Effect of used material adltions on the flowability (of a hot repair mix for BOF. performance in a working fumace. It is considered that the proper imix ratio of recycled and virgin materials will control the performance of castables. By proper material design it is possible to increase the content of recycled materials, while maintaining ‘g00d performance in the Furnace. 33. Recycling of Alumina-Magnesia Castables for Stel Ladle 33.1 Sample Preparation “The penetrated layer of used alumina-magnesiacastable fom a steel ladle was separate from the layer of orginal unpenetrated smateral The two ayers were pulverized andthe ron components ‘wer eliminated, The powders were classified into thre groups. namely, couse, medium, and fine powder Each powder was used 2 staring material instead of alumina medium, and fine powder. ach powder was used as staring materials instead of alumina aggregate, Test samples were prepared using these recycled Powders with additions of 20, 40, and 60 mass%. A standard sample, consisting of vein raw materials was prepared fo testing ina ste ladle. The composition ofthe matrix (alumina, slca, Penetrated layer Original layer Fig. § Cross section of used castable from a steel ladle. Table 1 Particle sizing of samples.

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