26/8/2021 Refractory Lining of the Electric Arc Furnace – IspatGuru

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Refractory Lining of the Electric Arc Furnace

 Satyendra  May 6, 2020  0 Comments

 AC EAF, DC EAF, EAF, EBT, Fettling, Guniting, Hearth, Magnesite, Monolithic Lining, Roof, Taphole

Refractory Lining of the Electric Arc Furnace

Refractories are those materials which withstand high temperature

without a significant change in chemical or physical properties. Refractory
materials are very important to the electric arc furnace (EAF) operation as
they allow the containment of the liquid steel in the furnace hearth without
damaging the furnace structure. The EAF needs a variety of refractory
products out of which the most important are those refractory products
which are in direct contact with the liquid steel.

Refractories for the lining of the EAF depend on the design of the EAF. The
operating conditions also have a big influence on the refractory
performance. The operating conditions in the EAF require refractories
which are chemically basic and have very good resistance to high
temperature and thermal cycling. The design of the present day EAFs
features the eccentric bottom tap-hole (EBT) and these furnaces need
specialized refractories for their lining.  Typical cross-section of the EAF
showing different zones of the furnace is at Fig 1.

Fig 1 Typical cross-section of the EAF showing different zones

There are different design features of the EAF but they are mainly grouped
into three areas namely (i) tapping design such as side tapping or bottom
tapping, (ii) power source such as AC (alternating current) or DC (direct
current), and (iii) the use of supplementary oxygen (O2) for increase of the
melting rate.
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Side tapping EAFs have a spout extending from their furnace side wall for
the tapping of the liquid steel in the ladle. The spout is refractory lined, and
a taphole through the furnace side wall connects the furnace inside with
the spout. Side tapping EAFs tilt around 45 degrees, and hence need a
higher refractory side wall lining on the tapping side of the furnace for
containing the liquid steel. Bottom tapping EAFs have their taphole
through the bottom hearth section of the furnace and need special taphole
refractory products. Bottom tapping also enables reduced height of the
refractory side wall because of the lower tapping tilt angle of around 15
degrees to 20 degrees. These two types of the tapping designs are
typically shown in Fig 2.

Fig 2 Two types of the tapping designs

AC power source needs three electrode columns within the furnace for the
three electrical phases. These electrodes have increased the arc flare
during operation which can impinge on the refractory side walls resulting
into hot spots. The hot spots are to be taken care by the refractory design.
AC EAF also needs three holes through the refractory roof and the centre
section of the refractory roof between the electrodes is often an area
which limits the furnace performance. The DC EAF has a single electrode
through the roof with the electric arc passing directly to the liquid steel
bath which contacts the bottom anode electrode to complete the electric
circuit. DC EAF has lesser arc flare to the refractory side wall and hence no
hot spots. Roof design is simpler with less difficult operating conditions.
However, the furnace hearth is to contain the bottom electrode, which
complicates the refractory design of the furnace bottom.

The use of supplemental O2 lances and burners for the increase of the
melting rate impact refractory design and performance. O2 directed from
the lances or burners can be deflected by scrap or charge materials and
can impinge on the refractory lining. This results in localized overheating
and accelerated wear of the refractory. Localized oxidizing conditions can
also occur because of O2 and this can result into speedy erosion of the
refractory lining.

Refractory wear mechanisms in EAF

There are several types of refractory wear mechanisms as described

below to which EAF refractories are subjected to during the making of
steel. It is necessary to understand properly the wear mechanisms
operating in the each zone for proper designing and managing of the EAF
refractory system.

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Corrosion – It is the most important wear mechanism in case of EAF

refractories. Corrosion takes place due to the chemical reactions of the
metallic oxides (FeO, SiO2, or MnO) in the slag with the refractory
materials. Magnesia (MgO) from the refractory lining is soluble in the
liquid slag, with saturation levels ranging from 6 % to 14 %, depending on
the FeO content and the bath temperature. The chemical corrosion
reactions result in the wearing of the lining and the product of the
reactions become part of the slag. Corrosion reactions can be minimized
by neutralizing FeO with fluxes and controlling the O2 content of the slag.
Corrosion can also be minimized by saturating the slag with MgO through
external means (e.g. addition of calcined dolomite or calcined magnesite).
Another way to control corrosion is to use refractory bricks which contain
carbon (C). The C in the refractory deoxidizes corrosive slag at the
refractory / slag interface thus minimizing lining corrosion.

Oxidation – In refractory wear by oxidation, C of the refractory lining is

oxidized by reacting either with O2 or FeO in the slag. As the C of the
refractory lining reacts, the C content of the refractory decreases and the
refractory loses its strength and is washed away. The C oxidation
mechanism also occurs at the cold face of the brick if there are holes in
the steel shell. O2 from the air reacts with the brick C, and the back part of
the brick lining turns into powder.

Erosion – It is another refractory mechanism which is taking place in the

EAF. Erosion is the physical wearing of the refractory since the liquid steel
and the liquid slag is moving over the face of the refractory lining and
physically abrading or eroding the lining. Erosion is a common mechanism
for the refractory wear at the taphole, slag line, roof electrode openings
and the off-take ducts.

Melting – It is one of the wear mechanism for refractories in the EAF. The
unshielded electric arc generates temperatures which are well above the
melting point of many refractories. Melting is the simple phase change of
the refractory from the solid to the liquid, and the liquid phase when
formed is then washed away. Melting can be a serious problem in linings if
it is not detected in time and not corrected immediately.

Hydration – Since water is being extensively being used in present day

EAFs, there are incidences of water leaks. Refractories are easily damaged
by water or steam due to the hydration of the MgO or lime contents of the
refractory product. Hydration results in expansion of the individual grains
comprising the refractory lining. These grains grow and burst, disrupting
the lining.

Spalling – Refractory wear due to spalling takes place when the refractory
is subjected to rapid heating or rapid cooling. Rapid heating or rapid
cooling cause stresses in the lining and when these stresses exceed the
inherent strength of the refractory material, then it results into the
cracking. When these cracks intersect, chunks of refractory fall out of the
lining. This mechanism of refractory damage is frequently observed in the
roof refractories since they are exposed to cyclic heating and cooling.

Zones of the EAF

Based on the operating conditions existing in the EAF, the furnace can be
divided into specific zones. Each of these zones has the refractory
requirements of varying nature. These zones have been shown in Fig 1 and
Fig 2. Major zones of EAF are (i) the hearth which contains the liquid steel
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as well as the initial charge materials, (ii) the slag line which is the
transitional area between the hearth and the side wall, (iii) the upper side
wall which lies above the slag line, and below the water cooled panels, (iv)
the taphole which is the opening provided for tapping of the liquid steel,
and (v) the roof which has a refractory portion (occasionally referred to as
the delta), to provide openings for the electrodes to enter the furnace and
for the furnaces exhaust gases to exist the furnace.

Present day EAFs are EBT furnaces and they generally use magnesite
(MgO) or magnesite-carbon (Mag-C) refractories in the contact zones of
the liquid steel. Specialized refractories with good thermal shock
resistance are generally used in the roof/delta, the taphole, and the spout
or runner of the furnace. The following descriptions give general refractory
recommendations for each zone of the EAF..

Hearth – The hearth zone of the EAF holds liquid steel at a high
temperature and resists the impact of heavy charge materials. In addition,
the hearth is to withstand the corrosion by the liquid slag as the furnace is
tapped. A typical EAF uses a two component refractory hearth of around
230 mm of brick as a safety lining on the bottom steel shell (sometimes
called sub-bottom) and 300 mm to 600 mm of monolithic magnesite as
working lining. Some EAFs have all brick hearths, where the initial lining is
totally of brick, and monolithic materials are only used to repair holes in
the brick hearth after some period of operation. Tar-impregnated MgO
bricks are generally used for the safety lining. Bricks used for safety lining
have MgO content in the range of around 90 % to 97 %. These bricks have
the strength and slag resistance properties to hold the liquid bath in an
unlikely event of liquid steel or liquid slag penetrating the working lining.
The safety lining functions as permanent lining and does not need
frequent changing.

The monolithic working lining also has high content of MgO (60 % to 95 %)
and consists of a dry granular material. The grain sizing of the hearth
material is formulated so that it can be compacted easily by using
vibrators during the lining installation. Monolithic hearth materials
generally have impurity oxides, like FeO, to facilitate sintering. High
temperature from the initial heat causes sintering (bonding, densification,
and strengthening) of the monolithic lining. Sintering causes the lining to
become quite strong and penetration resistant. The hearth lining is
designed so that around the top one third of the thickness of the
monolithic lining material is fully sintered, while the middle one third of the
lining is only partially sintered, and the bottom one third of the monolithic
lining material against the safety lining is not sintered at all. This layering
effect facilitates patching the hearth refractories when the hearth
refractories get damaged by penetration or corrosion. The damaged area
can be cleaned out by removing the penetrated, sintered magnesite and
repaired with the new monolithic material, which sinters during the next
heat made in the furnace.

Present day EAF bottom design often includes gas stirring elements which
require porous refractory materials or tuyeres through dense refractories
to deliver the stirring gas to the liquid steel. These stirring gases can
cause erosion of the hearth refractories resulting into the regular
maintenance requirement of the hearth refractories.

Slag line – The slag line of EAFs is the transitional area between the
hearth and the side wall. This area is subjected to high temperatures due
to the exposure to the electric arc, oxidation, and flame impingement from
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supplemental O2 injection, and most importantly to the slag attack from

high temperature slags containing FeO, SiO2, and MnO. Refractory
selection in the slag line is to be carefully coordinated with the expected
slag chemistry. In case of EAFs producing C steels, there is generation of
lime rich, FeO -SiO2 slags with a lime: silica ratio of plus 2:1. This
demands basic refractories. In the slag line area of the EAFs generally
Mag-C bricks or tar impregnated magnesite bricks are used. In EAFs for
stainless steel production, a more neutral fused grain magnesite chrome
brick can be used.

Slag line refractory design in EAFs is the combination of bricks and

monolithic refractories. A very common design for the slag line is Mag-C
bricks of 300 mm to 450 mm in thickness and with 10 % to 20 % of C
content. The C phase of the brick is composed of graphite and a
carbonaceous resin bond. These C materials have very good resistance to
slag attack as well as a very good resistance to high temperatures.
However, the C is susceptible to the oxidation and to protect the slag line
refractories from oxidation metal powders such as aluminum, silicon, or
magnesium are added. These metallic powders combine with C to form
carbides which have higher oxidation resistance. The carbides also
strengthen the refractory bricks. Strength is needed for resisting the
erosive action of the liquid slag and the steel washing taking place the
slag line zone of the furnace. Mag-C bricks in the slag line are additionally
protected by  the monolithic refractories. Initial installation of the
monolithic refractories normally covers all or the part of the slag line
bricks. However, because of the difficult operating conditions in this zone,
the refractories corrode. Additional protection of the slag line is done by
guniting with the MgO based guniting mix to build-up a protective layer on
the slag line. The build-up activity of the slag line refractories is required to
be carried out frequently depending upon the severity of the operating
conditions.

Upper side wall – The upper side wall of the EAFs are lined with Mag-C
bricks which are similar to the bricks of the slag line. The upper side wall
is subjected to the arc flare (very high temperatures) and impingement by
heavy scrap during the process of charging of the furnace. During the
furnace tapping, when the furnace tilts, liquid steel and liquid slag is in the
contact of the upper sidewall on the tapping side of the furnace. Also, the
upper side wall bricks are required to withstand corrosion by the slag and
flame impingement from O2 lances and oxy-fuel burners. Mag-C bricks
having C content of 5 % to 20 % are suitable for the lining of upper side
wall. Various qualities and purities of magnesite, graphite and metal
powders are used. In the AC EAF, which has hot spots in the upper side
wall, bricks of higher quality are needed. These higher quality bricks are to
be based on fused magnesia grains compared to the sintered magnesia
grains used for the standard quality bricks. The fused magnesia bricks
have improved high temperature resistance but they cost considerably
higher.

Taphole refractories – Taphole refractories are needed for both the side
tapping EAFs and the bottom tapping EAFs. Operating conditions in both
these type of the furnaces are similar consisting of flowing at high velocity
of liquid steel and to a lesser extent liquid slag through a 125 mm to 200
mm diameter taphole. High velocity flow erodes the taphole refractories.
In the side tapping furnace, the taphole refractories have many alternative
designs. The alternative having the simplest design consists of leaving an
opening in the side wall while installing the initial lining and when the
brickwork is completed, either a refractory taphole sleeve or a steel pipe is
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positioned in the taphole opening. Then the MgO based guniting mix is
used to fill in the voids between the sleeve or pipe and the adjacent
brickwork. The second alternative consists of using a large taphole
assembly with a pre-formed taphole. This assembly is set in place in the
EAF prior to the laying of the side wall brickwork. Once the taphole
assembly is properly positioned,, the adjacent brickwork is completed,
creating a tight fit between the taphole assembly and the side wall
brickwork.

Taphole refractories need to be of have high quality. If the taphole is made

with guniting mix sprayed around the steel pipe mandrel, the guniting mix
is to be of the highest quality. The guniting mix is to have maximum
strength and erosion resistance for minimizing the erosive action of the
flowing liquid steel. In case of the taphole assembly where a refractory
sleeve is used, the sleeve is also to be of high quality MgO brick with C and
metal powders.  Metallic additions to Mag-C taphole brick assemblies
provide added strength and oxidation resistance to the brick in this critical
application.

The side tapping furnace has a spout extending from the taphole to enable
the liquid steel to flow into the ladle. The spout is a precast monolithic
runner shape placed in the runner steel shell during the process of the
lining. The precast runner shape is made of MgO based castable if furnace
operating practices result in slag entering the taphole and the furnace
runner. The slag resistance of the MgO is needed for counteracting the
slag attack. On the other hand, if the operating practice of the EAF limits
the introduction of slag into the taphole and the runner, then high strength,
high alumina castables are used for the precast runner. The high alumina
runner generally has higher life because of improved thermal shock
resistance and higher strength as compared to the magnesite precast
runner.

Bottom tapping EAFs need specially designed taphole sleeves and an end
block for the taphole design. The taphole sleeve sits within the hearth in a
taphole seating assembly. The assembly can be made up of either brick
shapes or precast shapes which results in an around 450 mm diameter
hole through the furnace hearth refractories. The taphole sleeve is centred
within the taphole seating assembly and a basic castable or ramming mix
is packed in the annular opening between the sleeve and the seating
blocks. Taphole sleeves are Mag-C blocks made from high purity
magnesia or fused magnesia grain with 10 % to 15 % of C content. Metal
powders are used as a strengthening agent for maximizing erosion and
oxidation resistance. The bottom of the taphole extends beyond the
furnace shell utilizing a shape called an end block. The end block is a
similar Mag- C brick which is held in place by an end block casting
attached to the EAF. The end block is exposed to the outside environment
and is required to have very good oxidation resistance a well as a high
erosion resistance for withstanding the erosive action of the taphole
stream. The end block is quite often the limiting factor for the taphole
performance. As the refractory erosion occurs, the tapping stream begins
to flare, increasing the reoxidation of the liquid steel. It is essential then to
carry out a hot repair to replace the end block and taphole sleeve.

Roof and Delta – EAF roof refractories for both the AC and the DC
furnaces are normally high alumina (70 % Al2O3 to 90 % Al2O3) precast
shapes having high strengths. Since, the roof lifts and swings away from
the furnace body during the charging process, refractories in the roof are
subject to extensive thermal shock. The lesser thermal expansion of high
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alumina castables compared to the basic castables offer an advantage in

withstanding thermal shock. Further, high alumina castables have higher
strength than the basic castables. Hence, high alumina roofs are better
able to resist the stresses developed as the roof is lifted and moved during
the furnace operations. EAF roof refractories normally last for a longer
time.

The roof also enables the furnace exhaust gases to leave the furnace
through a duct. While the immediate exit from the furnace is normally
water cooled, there is a refractory lined zone in the duct system.
Refractories in the exhaust ductwork are to be capable of withstanding the
slag carryover and slag abrasion from particulate laden exhaust gases
moving at high velocity. Refractories in the ductwork are alumina bricks
(50 % Al2O3 to 70 % Al2O3) or fire clay/alumina guniting mix (40 % Al2O3
to 60 % Al2O3). Both of these materials have the needed combination of
the thermal shock resistance and slag resistance for withstanding the
operating conditions.

Refractories for DC EAFs

DC electric furnaces have special refractory requirements due to the fact

that the return electrode is usually installed in the bottom of the furnace
(some DC furnaces use an alternative arrangement with two graphite
electrodes). In the case of a current conducting bottom, the refractory
lining at the centre of the furnace bottom acts as the anode. A copper
plate is usually connected below the conductive refractory and the return
copper bus bar is connected to the plate. In this case special requirements
for the refractory are low electrical resistance (preferably less than 0.5
milli-ohms per metre), low thermal conductivity, and high wear resistance.

In case of DC EAFs, the hearth refractory design is to incorporate a bottom

electrode. Operating conditions for the bottom electrode refractories are
harsh. Localized high temperatures and intense turbulence are common at
the surface of the bottom electrode. These conditions need refractories
with high temperature stability and strength. For DC EAFs using pin or fin
bottom electrodes, the dry vibratable magnesite monolithic refractory
containing 5 % to 10 % C can be used. However, it is preferable if the
monolithic refractory is more temperature resistant and with higher MgO
content. The monolithic materials can be installed either hot or cold.
Below the working lining a three layer Mag-C brick is installed. The
residual C content of the bricks ranges from 10 % to 14 %.

The billet return electrode configuration employs from one to four large
steel billets (around 250 mm in diameter) depending on the size of the
furnace. The billets are embedded in the bottom refractory. The billets are
surrounded with a basic refractory brick. For the remainder of the hearth, a
special magnesite ramming mix is used. Magnesite ramming mix is used
to maintain the brick area around the electrode.

The pin type of return electrode uses multiple metal pins of 250 mm to
500 mm in diameter to provide the return path for the electrical flow.
These pins actually penetrate the refractory down to the bottom of the
furnace where they are attached to a metal plate. Dry magnesite ramming
mix is used for the entire hearth lining. This mix is rammed between the
metallic pins. Alternatively Mag-C brick can be used in the area around the
anode. This helps to improve the furnace bottom life but is more costly.

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The steel fin return electrode uses steel fins arranged in a ring in the
furnace bottom to form several sectors. Each sector consists of a
horizontal ground plate and several welded steel fins which protrude
upwards through the refractory. Dry magnesite ramming mix is used
between the fins. The hearth is also lined with this material.

There is another design which uses conductive refractories, either brick or

monolithic, which are a combination of C and magnesite, for carrying the
electrical current from the bath to the copper electrical connections at the
bottom of the furnace. Conductive refractories consist of complicated
blend of high purity magnesite, graphite, and metal powders for achieving
the needed combination of high temperature refractoriness and electrical
conductivity for holding the liquid steel as well as to conduct the electrical
current.

The important points to consider during installation of the refractories in

the DC EAFs are the zoning pattern, hearth contour, slag line location,
furnace steel capacity, taphole location, taphole size and angle, roof/delta
orientation, expansion allowances, burner port location, slag door
construction, bottom stirring elements, and DC furnace bottom electrode.

Procedure for installing new lining in EAF

Typical procedure for the installation of a complete new lining of the EAF
is described below.

The furnace is brought to the level position and the shell is cleaned from
all debris prior to starting the lining of the furnace. It helps to locate the
exact centre of the furnace and to punch a mark in the bottom centre of
the shell. The preferred construction is rectangular magnesite brick laid on
flat using a basic granular material as fill to provide a flat surface against
the rounded steel shell. After locating the EBT taphole seating blocks, any
bottom stirring elements and allowing for the furnace bottom electrode in
case of DC EAF, the first course of sub-hearth brick is laid dry, tight and
level, and a dry magnesite mortar is swept into the brick joints. Additional
fill material is placed around the perimeter of this first course and leveled
out. The second course is laid at a 45 degree angle to the first course and
again the dry magnesite mortar is swept into the joints. This process is
repeated for three or four flat courses. (There is an alternate, less
preferable, safety lining design which lays two to four flat courses which
follow the curved contour of the steel shell. This can be used in EAFs
where the shell has a small spherical radius and gives more uniform
thickness in the monolithic hearth material).

At the proper elevation, key shaped brick are used to begin the first
stadium course. It is preferable to start with the largest ring 25 mm from
the shell and work towards the centre. To close the ring, a key brick is cut
on a brick saw to the exact dimensions required to close the ring. If the cut
shape is less than a half brick, two cut shapes are to be used. The void at
the end of the course upto the shell is filled with granular magnesite
material. The next stadium ring is installed in similar fashion. The contour
of the stadium hearth shown on the refractory drawing of the furnace is to
be carefully followed to leave sufficient room to add the monolithic hearth
material at the appropriate thickness.

For the EBT furnaces, it is even more critical to follow the refractory
bottom drawing exactly. There are partial rings of brick with varying radii
extending out into the nose section of the furnace which is to be kept
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level. One way to facilitate this is to drill a hole in the top flat course of
bottom brick in the exact centre of the furnace and then utilize a
broomstick with a nail on it extending up from this centre brick as a
mandrel to draw circles and arcs for the stadium rings and partial rings
extending into the nose.

If a monolithic hearth material is not used, the final course or final two
courses in the all-brick hearth are laid in rowlock (on edge) or soldier (on
end) construction. Rowlock or soldier construction gives much greater
brick-to-brick contact and minimizes heaving of the hearth in service.
Again, all courses in the hearth and stadium are laid dry and swept with
magnesite mortar to fill the joints.

Once the stadium rings are completed, the slag line brick are installed
course by course using the same keying up concept utilized for the
stadium rings. The slag line is also to be installed in excess of 25 mm
away from the steel shell to permit thermal expansion without spalling or
heaving the brick. Brick rings or partial rings are to be continued up into
the sidewall and hot spots until the water-cooled panels or the top of the
furnace is reached.

The door jambs are a critical design area for the refractory lining. Several
designs simply utilize regular key shapes in interlocked courses as their
door jamb, and these designs are quite successful. Other designs use
special door jamb shapes which have greater surface area for better
interlocking between courses and a sharper angle which opens up the
door opening and eliminates or reduces refractory damage when slagging
off. Still other door jamb designs involve brick or precast shape
assemblies which are welded or bolted to the steel shell. These are
generally installed first and the slag line and side wall brick is laid directly
against these assemblies, with side wall rings keyed up halfway between
the door and the taphole.

Conventional tilting EAFs generally use taphole module shapes set with a
crane at the proper elevation prior to bricking the slag line and side walls.
One alternative is to leave an opening in the side wall rings and then ram
or gunite around a steel pipe forming the taphole. This pipe is then melted
out on the first heat. Refractory taphole shapes can also be used in this
same manner with monolithic material holding them in place at the proper
elevation and angle.

The roof or the delta section in a water-cooled top is normally installed in a

refractory reline area, and a finished roof is waiting for the furnace to be
rebuilt. With water-cooled roofs and precast deltas, a castable refractory is
often placed around the perimeter of the precast shape to lock it in place
against the water-cooled roof. For brick refractory roofs, a roof form is
required (generally concrete) which creates the appropriate dome shape
for the inside contour of the roof. The mandrel(s) are set for the
electrodes. Triple tapered electric furnace roof shapes are laid in
concentric rings against the roof ring for the outer two-thirds of the roof.
Often partial rings of brick are laid in a wedge pattern between electrodes.
Electrode ring brick surround each mandrel and are held in place with steel
bands. A castable refractory is cast or rammed into place in the cavity
between the outer rings and electrode ring brick.

Most of the EAF designs use a monolithic hearth material. This material
has high magnesite content and is a self sintering product which is
granular in nature. After installing any EBT taphole seating blocks, bottom
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stirring elements, and bottom electrode forms in case of DC EAF, the

monolithic hearth laying is started. The hearth material comes ready to
use in large bulk bags. A crane holds the bulk bag in position over the
brick sub hearth (safety lining) while the bag is split and the material is
shoveled into the place. After two or three bulk bags are in the furnace,
several workers using shovels or pitch forks repeatedly jab the granular
material in order to remove air and densify the refractory hearth. As the
material densifies, the workers further compact it with mechanical
vibrators or by simply walking on the hearth to achieve the proper contour.
Additional bags of hearth material are added and de-aired and densified
until the final contour is reached (usually measured with chains or a form).
The new hearth sinters in place during the initial heat.

Heat up schedule

 On a new EAF lining with a completely new monolithic hearth, steel plates
or light scrap are generally lowered by magnet into the bottom of the
furnace to provide protection for the unsintered hearth material. After this
cushioning scrap is in place the first bucket is charged and the arc is
struck, utilizing a long arc to avoid boring down into the new monolithic
bottom. The bottom is usually sintered after the first heat, although it is
important to inspect the bottom and banks for any holes or erosion due to
unsintered material leaving a void in the lining. Since the new EAF lining
has very little moisture in it, no special precautions are required during the
initial heat up, other than using a long arc to avoid eroding the bottom prior
to sintering.

Lining maintenance practices

EAF linings are maintained by guniting, fettling, and patching with brick.

Guniting maintenance – Guniting maintenance consists of mixing water

with a magnesite based gunning mix and spraying this mixture onto the
refractory lining. Guniting is used to maintain hot spots, slag line erosion,
taphole, the door breast area, or any other portion of the lining which
experiences selective refractory wear. Gunning material is usually a
temporary measure and there is need to re-guniting in the same place
within the next several heats. Guniting maintenance, while temporary, does
offer balanced life by evening out the highly selective wear pattern in the
EAF lining. That is, refractory wear in AC furnaces is usually greater in the
sidewall closest to the mast electrode and guniting this area maximizes
overall lining performance. Most refractory guniting maintenance is done
with a pressurized gun. The gun delivers dry material pneumatically to a
water mixing nozzle, and the air pressure sprays the wet gunning mix onto
the surface of the lining. The nozzle operator skill is a factor in the quality
of the gunited patch. Guniting can be automated by using a mechanical
centre-throw guniting device which shoots the guniting material in a
circular pattern while suspended from a crane. This mechanical guniting is
faster and easier, but often wastes material by placing it where it is not be
needed.

Basic guniting mixes range from 40 % MgO to 95 % MgO in quality. High

temperature operations and high power EAFs generally use higher MgO
content guniting mixes, while moderate temperature operations uses
lower MgO content guniting mixes.

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Fettling maintenance – Fettling maintenance is the technique used to

patch holes in the monolithic bottom. A rapid sintering version of the
granular hearth material, or the original product, is used for fettling. The
dry material is shoveled or dropped by crane wherever there is a hole in
the monolithic bottom, or a mechanical chute suspended by crane delivers
material onto the sloped banks of the hearth. Occasionally the magnet is
used to level this patch material, which then sinters in place during the
next heat.

Brick patching – After several weeks of operation, guniting maintenance

becomes less efficient in maintaining the refractory lining. In such cases,
the furnace is cooled to dig out anywhere from 30 % to 80 % of the
sidewall and hot spots. The rubble is then removed from the furnace and
new bricks in all areas of the hot spots and sidewall are installed in these
areas. Often the same refractory quality and thickness are reinstalled as
was used in the initial lining. Alternatively, lesser quality or thinner linings
are installed during this patch since slightly less lining life is needed than
the anticipated from the patch made as per the new complete lining. The
brick patch is completed by guniting MgO guniting mix into all the voids
and cracks in the patched brickwork.

Normally during a brick patch, the taphole is completely replaced or

repaired with ramming mix or guniting material, if not replaced with brick
work. In many EAF operating practices, a regular brick patching schedule
is followed. This schedule can include one or two intermediate patches for
every complete sidewall job. These maintenance and patching decisions
are normally dictated by the severity of the operating conditions.

Miscellaneous refractory maintenance – Each EAF has unique features or

conditions requiring specific refractory maintenance. Roof delta sections
are to be replaced at failure or on a regular schedule. Tapholes are to be
replaced or repaired when the tap time gets too short or slag carry over
starts. Conventional EAF tapholes are normally replaced with a high MgO
guniting mix shot around a steel pipe, while EBT tapholes are knocked out
and a new assembly or one-piece tube inserted by crane from above.
Bottom stirring elements and bottom electrodes each require specialized
maintenance procedures which vary with design.

Technical

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