Refractory Material Selection For Steelmaking

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Refractory
Material Selection
for Steelmaking
Thomas Vert, P.Eng., M.B.A.
Foreword by Dr. Jeff Smith
Copyright © 2016 The American Ceramic Society and John Wiley & Sons, Inc. All rights reserved.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.
Published simultaneously in Canada.
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Library of Congress Cataloging-in-Publication Data:
Names: Vert, Thomas, 1964- author.

Title: Refractory material selection for steelmaking / Thomas Vert.
Description: Hoboken, New Jersey : John Wiley & Sons, 2016.
Includes bibliographical references and index.
Identifiers: LCCN 2016003691| ISBN 978-1-119-21986-6 (cloth) | ISBN 978-1-119-21988-0 (epub)
Subjects: LCSH: Refractory materials. | Metallurgical plants--Equipment and supplies. | Steel--Metallurgy.
Classification: LCC TN677.5 .V47 2016 | DDC 669/.82--dc23 LC record available at
http://lccn.loc.gov/2016003691
Printed in the United States of America.
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Introduction
Introduction
9*7
Chapter 1
1. Safety
Refractory Material Selection for Steelmaking

By Thomas Vert
Copyright © 2016 The American Ceramic Society and John Wiley & Sons, Inc.

1. Goal of Availability

1. Total Cost of Ownership (TCO)

1. Energy and Heat Flow Overview

1. Quality - Inert to the Steel Process

1. Environment

Chapter 2
2. TMC Analysis Overview

By Thomas Vert

2. Thermal – High 5emperature 0verview

2. Thermal Shock

Ex of brittle = 90% Al2O3
Purity = weakness
i.e. coffee cup
Ex of “Pillow” or ductile
material = 65% Al2O3
Impurities soften

2. Mechanical Impact
3
4
5
6
2. Mechanical Abrasion
7
8
2. Wear of Refractories – Dissolution
9

2. Wear of Refractories – Penetration

2. Interactions of TMC / SatVSEBZ /ight
%esign / Rubble Pile Analysis

Chapter 3
3.0 Selection - Raw .aterials Overview

By Thomas Vert

3.1 Magnesia Overview (MgO)

3.2 Alumino-Silicate Overview (Al2O3 – SiO2)

3.3 Carbon – Graphite Overview (C)

3.4 Antioxidants (Aka Preferential Oxide Formers)

3.5 Resins, Pitches and Binders Overview

3.6 4QFDJBM 3aw .aterials

3.7 Dolomite

Chapter 4
4.0 Refractory Dryout and Anchoring Overview

By Thomas Vert

4.1 Bricks

4.2 Castables, Gunning and Shotcreting Overview

4.3 Plastics, RamsBOE Mortars Overview

4.4 Refractory Dryout and Anchoring Overview

4.5 Selection – Insulation Board and Blanket Overview

Chapter 5
5.0 Refractory texture, TestingBOE5FDIOJDBM
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By Thomas Vert

Chapter 6
6.0 Hot Metal Ladle Overview

By Thomas Vert

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6. 4QPVU

Chapter 7
7.0 Basic Oxygen Furnace (BOF) Refractory Overview

By Thomas Vert

7.1 BOF Safety Bottom/Wall

7.2 BOF Top Cone Overview

7.3 BOF Tapping Pad Overview

- The brick above the taphole are normally
the same as the tap pad brick as the slag and
liquid steel also rest in this area.

7.4 BOF Charge Pad Overview

7.5 BOF Trunnions Overview

7.6 BOF Stadium Overview

7.7 BOF Bottoms – #ricks, "rgon 4tirring 4ystems and +oints

7.8 BOF Refractory Tapholes

Chapter 8
8. Electric Arc Furnace (EAF) Overview

By Thomas Vert

8. Safety Bottom/Wall

8. Working Bottom - Hearth / Fettling

8. Working Walls

8. Argon Stirring 4ystems for EAFs

8. EAF Refractory Delta

8. EAF Refractory Tapholes

Chapter 9
9.0 Steel Ladle Refractory Overview

By Thomas Vert

9.1 Steel Ladle Safety Bottom/Wall

9.2 Steel Ladle Working Bottom

9.3 Steel Ladle Stir Systems

9.4 Steel Ladle Flow Control Systems

9.5 Steel Ladle Working Sidewall (Barrel)
1650 C

9.6 Steel Ladle Working Slagline

9.7 Steel Ladle Lip Ring

9.8 RH Degasser Refractory Overview

Chapter 10
10.0 Caster / Tundish Refractory Overview

By Thomas Vert

10.1 Caster Tundish Safety Lining

10.2 Caster Tundish Working Lining

10.3 Caster Tundish Flow Control

10.4 Caster Flow Control Systems

Oxygen lancing
of the top of the
shroud creates
high wear
mechanism

Tundish Slag:
- Al2O3: 3 -35%
- CaO: 1 -40%
- SiO2: 3-90%
- MgO: 1-20%
- FeO: 1-3%

Chapter 11
11.0 Purchasing 4trategies

By Thomas Vert

Chapter 12
12.0 Final Summary

By Thomas Vert
#JCMJPHSBQIZ

By Thomas Vert

*OEFY
$
$$ per kg of refractory ...................................................................................................................................................................... 355
$$ per piece of refractory................................................................................................................................................................ 355
$$ per tonne of steel including gain sharing .......................................................................................................................... 355
$$ per tonne of steel produced..................................................................................................................................................... 355
%
% B2 O3 ........ 2, 5, 6, 7, 22, 23, 26, 47, 48, 49, 52, 60, 64, 70, 75, 89, 97, 99, 101, 111, 113, 114, 121, 127, 151,
152, 157, 194, 196, 201, 206, 213, 223, 226, 231, 245, 252, 271, 274, 294 296, 300, 327
A
brasion ...... 2, 36, 77, 78, 89, 90, 125, 196, 200, 204, 210, 216, 221, 230, 236, 237, 243, 250, 257, 267, 270,
276, 284, 287, 295, 304, 309, 314, 318, 327, 331, 336, 340, 342, 344, 346, 348
absorption .......................................................................................................................................27, 33, 66, 67, 71, 73, 113, 209
AC furnace .................................................................................................................................................................................... 241, 253
accelerant ...................................................................................................................................................... 135, 137, 142, 143, 145
dministration costs ............................................................................................................................................................................ 17
aggregates ................................................................................................................................... 83, 111, 135, 144, 150, 163, 164
air entrainment ..................................................................................................................................................................26, 324, 349
air ingress.................................................................................................................................................................................................. 31
ir set bonding .................................................................................................................................................................................... 151
air/ oxygen aspiration ....................................................................................................................................................................... 338
alkemade triangles .........................................................................................................................................................................54, 55
lumina ................................................................................................................. 11, 57, 72, 84, 109, 110, 111, 112, 149, 163
alumina graphite ................................................................................................................................................................................. 128
alumina-magnesia-carbon (AMC) ............................................................................................................................................... 310
aluminum carbide .............................................................................................................................................................................. 119
amorphous ................................................................................................................................................................................................ 12
nchoring....................................................................................................................................................................... 2, 133, 153, 154
andalusite ...........................................................................................................................................................................110, 111, 164
ngle of Impact ..............................................................................................................................................................74, 75, 77, 210
angle of wetting ...............................................................................................................................................................................86, 88
ntioxidants
Al 2, 118
Al-Mg .................................................................................................................................................... 118
B4C........................................................................................................................................................ 118
Mg......................................................................................................................................................... 118
MgB2 .................................................................................................................................................... 118
pplied stress 36, 196, 200, 204, 211, 216, 221, 230, 236, 237, 243, 251, 257, 267, 270, 276, 284, 287, 295,
305, 310, 314, 318, 327, 331, 336, 340, 342, 345, 347, 348
rches ...................................................................................................................................................................................................... 139
rch-key-wedge .................................................................................................................................................................................. 139
argon flow system .............................................................................................................................................................................. 294
argon stir plug ....................................................................................................................................................... 265, 268, 295, 297
rgon Stirring........................................................................................................................................................ 263, 264, 268, 298
asbestos .........................................................................................................................................................................................................9
ASTM .......................................................................................................................................................................... 61, 65, 94, 95, 165
availability .....................................................................................................................................................13, 18, 73, 90, 137, 209
B
baffle ............................................................................................................................................................................................... 334, 335
barrel ..........................2, 29, 37, 200, 203, 204, 205, 208, 211, 212, 215, 216, 217, 221, 308, 309, 310, 311, 317
asic xygen urnace (BOF)
BOF bottom joint ...................................................................................................................................... 5
BOF charge pad impact ............................................................................................................................ 5
BOF furnace .............................................................................................................................................. 5
BOF inclined stadium................................................................................................................................ 5
BOF lining.................................................................................................................................................. 5
BOF mouths .............................................................................................................................................. 5
BOF safety lining....................................................................................................................................... 5
By Thomas Vert
BOF stadiums ............................................................................................................................................ 5
BOF taphole .............................................................................................................................................. 5
BOF tapped steel chemistry ..................................................................................................................... 5
BOF trunnion ............................................................................................................................................ 5
bath stirring ......................................................................................................................................................................................80, 83
bauxite ..................................................................................................................................................110, 111, 144, 150, 163, 164
binders ............................................................................................................................................................ 113, 123, 130, 131, 163
bio-soluble .........................................................................................................................................................................................10, 12
lanket............................................................................................................................................. 2, 135, 137, 159, 161, 283, 326
oard ......................................................................................................................................2, 135, 137, 159, 161, 198, 283, 326
bore .....................................................................................................................................................................31, 304, 346, 348, 349
oron arbide (B4 C) ......................................................................................................................................................................... 120
bottleneck ..........................................................................................................................................................................................13, 18
bottom ........ 2 6, 13, 17, 18, 61, 68 70, 72 4, 90, 91, 100, 115, 116, 140, 148, 150, 151, 156, 172,
173, 185, 187, 191, 193, 196, 197, 209, 210, 224 228, 230 233, 241, 243, 244, 247, 250 254, 263, 265,
267, 268, 273, 276, 282, 284, 286 292, 295, 296, 298, 299, 301, 309, 310, 314, 322, 331, 338
breakouts ... 2 6, 14, 126, 183, 191, 194, 233, 241, 280, 282, 286, 291, 299, 300, 301, 307, 308, 311, 312,
316, 322, 324, 326, 338, 345
brick 6, 7, 8, 14, 17, 18, 21, 27, 29, 33, 34, 37, 38, 43, 44, 46, 47, 56, 60, 64, 65, 67, 68, 69, 70, 71, 72, 76, 79,
83, 84, 87, 92, 95, 100, 104, 111, 114 119, 122 123, 125 127, 130, 131, 135, 137, 139 141, 149, 150,
154, 164, 165, 166, 173, 180, 181, 190, 191, 196 206, 208, 211, 212, 213, 215 224, 228 231, 236, 237,
239, 243, 244, 247, 251 254, 256 259, 262, 267, 274, 275, 276, 277, 284, 288, 296, 309, 310, 314, 315,
322, 328, 332, 336, 341, 343, 355, 356, 357
brick coatings .............................................................................................................................................. 200, 204, 211, 216, 221
brick quality ................................................................................................................................................................................ 199, 357
Brine .....................................................................................................................................................................................................97, 99
brittle...................................................................................................................................................65, 66, 86, 112, 213, 239, 247
brown fused alumina ........................................................................................................................................ 110, 144, 150, 164
buildup ..................................................................................................................................................................... 199, 200, 348, 349
ulk patching .............................................................................................................................................................................. 207, 214
burners / injectors ...................................................................................................................................................................................6
C
C/ S atio ................................................................................................................................................................................................. 104
Ca vapour attack ....................................................................................................................................................................... 305, 347
calcium aluminate .................................................................................................................................................................. 31, 43, 56
alcium chloride ................................................................................................................................................................................. 145
calcium magnesium carbonate CaMg(CO3 ) 2 ......................................................................................................................... 130
aptive source purchasing ............................................................................................................................................................. 356
.................................................................................2, 26, 27, 33, 57, 113, 114, 118, 123, 126, 135, 253, 277, 362
carbon black .......................................................................................................................................................................................... 125
carbon pickup................................................................................................................................................................................34, 127
carcinogens .............................................................................................................................................................................................. 11
cardboard expansion paper .................................................................................................................. 200, 204, 211, 216, 221
castable........38, 43, 65, 135, 142, 143, 144, 145, 154, 155, 156, 157, 163, 173, 233, 270, 309, 322, 325, 328,
332, 336, 341, 343, 345
caster refractories ............................................................................................................................................... 111, 129, 324, 338
eramic ibres ...................................................................................................................................................................................... 2, 9
charge pad............................................................................................................................73, 74, 208, 209, 210, 212, 213, 214
charging angle ...................................................................................................................................................................................... 230
hrome re .............................................................................................................................................................................................. 33
hromite ................................................................................................................................................................................................. 126
linoenstatite .......................................................................................................................................................................................... 48
clogging ....................................................................................................................31, 304, 325, 338, 342, 344, 346, 348, 349
losed porosity ............................................................................................................................................................................. 86, 167
cobblestoning .......................................................................................................................................................................................... 64
coked porosity .................................................................................................................................................................165, 167, 169
old rushing strength (CCS) ....................................................................................................................................................... 165
commodities ......................................................................................................................................................................................... 354
compression .....................................................................................................................61, 171, 236, 237, 276, 305, 317, 347
onduction................................................................................................................................................................................................ 21
conductor .................................................................................................................................................................................................. 69
consignment...................................................................................................................................................................................17, 354

ontainment ........................................................................................................................................... 2, 183, 194, 241, 280, 324
ontinuous aster .............................................................................................................................................................................. 279
contractor.................................................................................................................................................................................................. 17
onvection ................................................................................................................................................................................................ 22
corrosion .. . 24, 25, 38, 39, 41, 47, 49, 51, 55, 71, 79, 80 84, 86, 89, 113, 116, 121, 123, 159, 161,
165, 167, 168, 173, 176, 177, 178, 179, 223, 229, 231, 237, 271, 276, 283, 306, 315, 319, 322, 326, 327,
330, 347, 349, 361
orrosion resistance ......................................................................................................................................................................... 165
corundum ...........................................................................................................................................................................................46, 47
crack bridgers ...............................................................................................................................................................................71, 229
crack initiation .............................................................................................................................................................................67, 175
crack propagation ............................................................................................................................................................... 67, 73, 175
creep ...................................................................................................................................................................................38, 65, 91, 289
cristobalite ............................................................................................................................................................................ 9, 12, 48, 60
rucible testing .................................................................................................................................................................................... 177
crust ......................................................................................................................................................................................113, 247, 248
crystal size ..................................................................................................................... 101, 102, 106, 164, 206, 213, 218, 239
crystalline ............................................................................................................................................................................................. 9, 12
customers .................................................................................................................................................................................................. 26
D
dam.................................................................................................................................................................................................. 334, 335
DC furnace ..................................................................................................................................................... 241, 253, 262, 271, 277
ecarbonization .................................................................................................................................................................................. 320
deflocculent ........................................................................................................................................................................................... 145
degasser ................................................................................................................................................................... 126, 127, 320, 321
dehydrogenization ............................................................................................................................................................................. 320
demolition costs ..............................................................................................................................................................................15, 17
dense layer formation ....................................................................................................................................................................... 118
density ...... 27, 28, 61, 67, 86, 94, 142, 143, 144, 145, 146, 148, 150, 151, 165, 166, 169, 175, 176, 213, 248,
254, 330, 331, 332
de-oxidation ............................................................................................................................................................................................. 26
deskulling ...................................................................................................................................................... 204, 216, 322, 330, 331
iameter of impact ............................................................................................................................................................. 74, 75, 210
diaspore .................................................................................................................................................................................................. 110
dicalcium ferrite .................................................................................................................................................................................. 249
di-calium silicate ................................................................................................................................................................................. 131
ilatent .................................................................................................................................................................................................... 145
direct contact plugs ........................................................................................................................................................................... 267
disposal .................................................................................................................................................................................... 15, 18, 354
issolution 2, 36, 79, 89, 92, 125, 197, 201, 205, 211, 217, 222, 230, 236, 244, 251, 258, 267, 270, 276, 284,
296, 305, 310, 314, 318, 328, 332, 336, 341, 343, 345, 347, 349
olomite ............................................................................................................................................................... 2, 44, 130, 149, 313
down-leg ................................................................................................................................................................................................. 322
dry vibratable ........................................................................................................................................................ 244, 247, 275, 331
dryout ............................................................................................................................ 7, 91, 125, 153, 154, 158, 260, 289, 357
ductile ..................................................................................................................................................................................................65, 66
usting .................................................................................................................................................................................................... 146
E
EBT ( ccentric ottom apping) ................................................................................................................................................ 273
Electric rc urnace (EAF)
EAF delta ........................................................................................................................................... 6, 241
EAF hearth measuring device ................................................................................................................... 6
EAF injection ............................................................................................................................................. 6
EAF slag chemistry .................................................................................................................................... 6
EAF taphole .............................................................................................................................................. 6
EAF tapped steel chemistry ...................................................................................................................... 6
emissivity .................................................................................................................................................................................................. 23
energy ...................................................................................... 15, 19, 21, 23, 28, 29, 36, 75, 159, 183, 210, 241, 292, 313
eutectic temperature ....................................................................................................................................................................41, 43
eutectoid .............................................................................................................................................................................................42, 48
expansion allowance . 64, 65, 72, 141, 196, 197, 200, 204, 211, 221, 229, 230, 244, 251, 25 8, 259, 284, 310,

314, 315, 318, 319
expansion/ contraction .............................................................................................................................................................59, 173
xposure imits ..................................................................................................................................................................................... 10
F
anning.................................................................................................................................................................................................... 148
feed rate .................................................................................................................................................................................................. 146
ettling
fettling machines .......................................................................................................................... 247, 252
fettling materials .................................................................................................................................. 247
field conditions .................................................................................................................................................................................... 179
filaments .......................................................................................................................................................................................................9
iller ......................................................................................................................................................................................235, 274, 277
inger testing........................................................................................................................................................................................ 178
fireclay ..................................................................................................................................................................................................... 109
lake size ............................................................................................................................................................................114, 115, 116
flakes ................................................................................................................................ 113, 114, 115, 116, 164, 166, 213, 239
lat ............................................................................................................................................................................................................. 140
locculant ............................................................................................................................................................................................... 145
flow control hardware ............................................................................................................................ 330, 332, 335, 336, 337
flow dynamics ...................................................................................................................................................................................... 324
fluorspar ................................................................................................................................................................................................. 314
orced convection ................................................................................................................................................................................. 22
formaldehyde ...................................................................................................................................................................................7, 125
orsterite ............................................................................................................................................................................................48, 72
full service package ........................................................................................................................................................................... 356
umes ........................................................................................................................................................................................................ 2, 7
urnace angle ................................................................................................................................................................................ 73, 209
furnace shells.................................................................................................................................................................................21, 282
fused grain ........................................................................................................................................16, 19, 71, 206, 213, 218, 239
fused silica .................................................................................................................................................. 60, 63, 67, 108, 144, 150
G
gate system ................................................................... 31, 274, 276, 277, 301, 303, 304, 305, 306, 338, 346, 347, 348
grain boundaries ...........................................................................................................................................58, 101, 102, 103, 164
grain size....................................................................................................................................101, 130, 131, 134, 164, 175, 252
graphite ....... 16, 17, 69, 104, 113 117, 120, 123, 124, 164, 206, 213, 218, 223, 231, 239, 259,
gunning
gunning machine .................................................................................................................................. 135
gunning nozzle ...................................................................................................................................... 135
H
hazardous waste .................................................................................................................................................................................... 18
hearth ................. .. 6, 243, 245, 247 254, 256, 257, 263, 264, 268, 274, 275, 277
eat apacity ....................................................................................................................................................................................21, 69
heat flow .............................................................................................................................................. 21, 23, 24, 37, 159, 283, 326
eat set bonding ................................................................................................................................................................................. 151
heat up ...............................................................................................21, 60, 67, 69, 108, 139, 154, 158, 169, 173, 348, 357
heating ...................................................59, 83, 99, 123, 128, 154, 166, 176, 177, 181, 292, 298, 313, 315, 318, 322
heel size ......................................................................................................................................................................................... 250, 266
hercynite ................................................................................................................................................................................................. 126
erringbone .......................................................................................................................................................................................... 140
ex mesh ................................................................................................................................................................................................ 157
........................................................................................................................................................................... 157
hexavalent chrome............................................................................................................................................................................. 126
high alumina .......................................................................................................110, 288, 296, 310, 328, 332, 336, 341, 343
high temperature .... 4, 11, 34, 37, 38, 46, 56, 57, 108, 111, 128, 135, 139, 142, 203, 206, 215, 218, 220, 228,
235, 236, 250, 256, 258, 266, 269, 270, 271, 275, 286, 295, 303, 306, 308, 313, 318, 331, 335, 339, 341,
342, 343, 346, 347
hot metal charging ................................................................................................................................................................... 208, 209
hot metal chemistry .......................................................................................................................................................................... 184
ot metal impact ......................................................................................................................................................................... 74, 210

hot metal ladle......................................................................2, 5, 183, 184, 185, 186, 187, 188, 189, 190, 191, 243, 360
hot metal slag ....................................................................................................................................................................................... 184
ot odules of upture (HMOR) ................................................................................................................................................... 65
hot spots .......................................................................................................................................................................................................6
ydrated lime....................................................................................................................................................................................... 145
hydration ...........................................................................................................................44, 130, 131, 135, 197, 244, 252, 259
I
mpact ..... 2, 20, 36, 73, 76, 77, 89, 90, 125, 151, 152, 196, 200, 204, 209, 210, 216, 221, 230, 236, 237, 243,
250, 257, 267, 270, 276, 284, 287, 289, 290, 295, 304, 309, 313, 318, 327, 331, 336, 340, 342, 344, 346,
348
impact pad ..................................................................................................................................... 90, 91, 287, 289, 334, 335, 336
impact zone ........................................................................................................................................................................................... 325
impurities ............................................................... 19, 26, 48, 58, 67, 99, 102, 103, 106, 111, 114, 135, 308, 312, 320
incinerator .............................................................................................................................................................................................. 7, 8
inclined brick .............................................................................................................................................................................. 202, 224
inclusion ..................................................................................................................................................................................... 26, 27, 31
nstallation costs .................................................................................................................................................................................... 17
nstallation packages ........................................................................................................................................................................ 356
insulating layer .................................................................................................................................................................................... 197
insulation . 9, 11, 23, 24, 25, 109, 135, 137, 159, 160, 161, 167, 170, 176, 197, 198, 245, 246, 283, 285, 326,
327, 328
nsulation lanket .............................................................................................................................................................................. 137
nsulation oard ................................................................................................................................................................................. 137
insulator ..............................................................................................................................................................................................21, 69
intermediate vessel ................................................................................................................................................................. 324, 338
internal loading .................................................................................................................................................................... 62, 65, 173
isostatic press ....................................................................................................................................................................................... 325
J
joints ........31, 46, 64, 72, 92, 135, 137, 140, 141, 150, 151, 161, 191, 225, 229, 230, 235, 258, 274, 283, 284,
296, 322, 325, 326, 327, 328
K
keys ............................................................................................................................................................................... 92, 139, 149, 298
kyanite ..................................................................................................................................................................................................... 110
L
ladle barrel ............................................................................................................................................................................................ 310
ladle bottom .......................................................................................................................................................................................... 140
ladle metallurgy ..................................................................................................................................47, 126, 279, 292, 313, 318
ladle sand ...........................................................................................................................................................................128, 304, 305
ladle stirring ...................................................................................................................................................................................77, 292
- ........................................................................................................................................................................................... 155
ever ule ................................................................................................................................................................................................. 42
lime....................................... 13, 14, 30, 31, 41, 42, 43, 44, 45, 51, 53, 55, 56, 58, 59, 102, 104, 130, 131, 252, 322
linear change ................................................................................................................................................62, 63, 64, 91, 174, 289
................................................................................................................................................................................................ . 317
lip skull removal........................................................................................................................................................................ 313, 318
liquid iron........................................................................................................................................2, 5, 6, 129, 183, 191, 193, 195
liquidus line .......................................................................................................................................................................................41, 47
liquidus surfaces .................................................................................................................................................................................... 55
ogistical costs .................................................................................................................................................................................15, 17
ow alumina ............................................................................................................................................................................... 107, 109
ow cost country (LCC) purchasing ........................................................................................................................................... 356
lower cones ........................................................................................................................................................................................... 221
ower sidewalls .................................................................................................................................................................................. 256
M
magnesia ..... ..18, 44, 46, 48, 49, 56 58, 67, 79, 80, 84, 89, 91, 99, 107, 125, 126, 130, 131, 163, 164, 180,
181, 197, 200, 201, 204, 205, 211, 213, 216, 217, 221 223, 230, 237, 244, 251, 252, 258 260, 267, 276,
277, 284, 289, 310, 322, 333, 344, 345, 356
agnesite .................................................................................................................................................................................................. 72

agnesium .................................................................................................................................................................................. 119, 120
magnesium ferrite .............................................................................................................................................................................. 249
maintenance ....................................................................................................................................... 7, 9, 13, 14, 15, 18, 247, 356
matrix ......................................................................................... 36, 71, 78, 83, 92, 123, 142, 144, 150, 163, 164, 172, 229
echanical impact .........................................................................................................................................................................37, 73
mechanical impact resistance .......................................................................................................................................................... 76
elting properties .........................................................................................................................................................................38, 95
MgO-C. 18, 22, 27, 33, 56, 57, 71, 104, 116, 117, 118, 139, 166, 180, 181, 207, 213, 214, 229, 239, 305, 313,
314, 315, 347
Micro-board ......................................................................................................................................................................161, 283, 326
microcracks ........................................................................................................................................................................................... 164
micro-defects .................................................................................................................................................................................71, 229
micrographs .........................................................................................................................................................................84, 164, 176
mineralogy ..................................................................................................................................... 39, 91, 169, 247, 249, 289, 354
mini-keys ................................................................................................................................................................................................ 139
modulus of elasticity ....................................................................................................................................65, 67, 68, 70, 91, 289
moisture .................................................................................................19, 44, 119, 130, 143, 144, 145, 150, 154, 330, 331
monolithic ...... 95, 135, 136, 139, 140, 143, 150, 153, 191, 196, 197, 201, 233, 244, 247, 251, 252, 253, 284,
285, 287, 288, 310, 318, 319, 327, 328, 357
mortar ................................................................................ 31, 72, 135, 141, 150, 151, 152, 229, 298, 299, 300, 305, 354
mould powder .....................................................................................................................................................................31, 176, 349
mouth cleaning .................................................................................................................................................................................... 200
mullite ............................................................................................................................ 12, 47, 55, 107, 109, 110, 111, 144, 150
ultiple ins ......................................................................................................................................................................................... 253
N
natural convection ................................................................................................................................................................................ 22
natural mineral fibres .............................................................................................................................................................................9
nitrogen pickup ...................................................................................................................................................................................... 26
non metallic inclusions .......................................................................................................................................................... 301, 338
nozzles ............................................................. 30, 31, 34, 116, 128, 176, 306, 307, 325, 343, 344, 345, 349, 352, 354
O
livine ...................................................................................................................................................................................................... 332
open porosity ......................................................................................................................................................................86, 169, 170
perational impact ............................................................................................................................................................................... 15
rganic polymers ............................................................................................................................................................................... 145
oxidation resistance ..........................................................................................................................99, 113, 114, 116, 120, 125
oxygen blowing processes .............................................................................................................................................................. 193
oxygen lancing ............................................................................................................................................ 200, 296, 306, 341, 347
oxygen pickup ............................................................................................................................................................................ 330, 334
oxygen stirring .................................................................................................................................................................225, 228, 231
P
panel spalling test .................................................................................................................................................................... 176, 181
article hardness ................................................................................................................................................................................... 77
particle packing theory .................................................................................................................................................................... 166
article shape .......................................................................................................................................................................................... 77
particle size .....................................................................................................................................................................37, 77, 95, 145
particle size distribution .................................................................................................................................................................... 95
passivation layer .................................................................................................................................................................................... 80
patching .............................................................................................................................................................7, 18, 19, 74, 148, 213
eak temperature ..36, 125, 196, 199, 203, 208, 215, 220, 228, 235, 236, 243, 250, 256, 266, 269, 275, 284,
286, 295, 303, 308, 313, 318, 327, 331, 335, 339, 342, 343, 346, 347
enetration ........2, 36, 86, 88, 89, 106, 125, 197, 201, 205, 212, 217, 222, 230, 236, 237, 244, 251, 258, 267,
270, 276, 284, 288, 296, 306, 310, 315, 318, 328, 332, 336, 341, 343, 345, 347, 349
Penn State University .............................................................................................................................................................................8
permeability ....................................................................................................................................................86, 134, 167, 168, 169
phase changes ...................................................................................................................................................................................... 108
phase diagram
Al2O3 - SiO2.......................................................................................................................................... 109
Al2O3-ZrO2 ........................................................................................................................................... 109
CaO-Al2O3 ............................................................................................................................................ 109

CaO-MgO .............................................................................................................................................. 109
CaO-MgO-Al2O3 ................................................................................................................................... 109
CaO-MgO-SiO2 ..................................................................................................................................... 109
CaO-SiO2............................................................................................................................................... 109
MgO-Al2O3 ........................................................................................................................................... 109
MgO-Al2O3-SiO2 .................................................................................................................................. 109
MgO-B2O3 ............................................................................................................................................ 109
Mgo-Cr2O3 ........................................................................................................................................... 109
MgO-SiO2 ............................................................................................................................................. 109
SiO2-ZrO2 ............................................................................................................................................. 109
phenols ..........................................................................................................................................................................................................7
pickup ..................................................................................................................................................................................................26, 27
picrochomite ......................................................................................................................................................................................... 126
itches ..................................................................................................................................................................................................2, 123
plastic ...........................................................................................................131, 135, 143, 150, 151, 152, 157, 158, 201, 244
pneumatic .................................................................................................................................................................................... 236, 237
polycrystalline ..............................................................................................................................................................................83, 163
pore diameter .......................................................................................................................................................................................... 86
porosity ..... 21, 71, 83, 84, 86, 94, 134, 142, 144, 145, 150, 164, 165, 166, 167, 168, 169, 170, 173, 181, 229
ports................................................................................................................................................................................................ 348, 349
post combustion ........................................................................................................................................................................................7
powders .......................................................................................................................................... 29, 71, 113, 123, 125, 229, 349
precast .......................................................................... 18, 37, 90, 91, 135, 137, 142, 144, 164, 190, 191, 270, 355, 356
referential xide ormers ........................................................................................................................................................2, 118
pre-formed or pre-fused spinel ...................................................................................................................................................... 46
preheaters ......................................................................................................................................................................................... 7, 90
rism spalling tests............................................................................................................................................................................ 175
P-series .................................................................................................................................................................................................... 139
pumpable...................................................................................................................................................................................... 143, 145
urchasing..................................................................................................................................................... 8, 13, 354, 355, 357, 358
pure alumina ...................................................................................................................................................................42, 47, 55, 112
purity ....... 16, 17, 19, 36, 43, 47, 58, 71, 99, 100, 101, 114, 115, 116, 125, 130, 146, 201, 203, 206, 208, 213,
215, 218, 220, 223, 229, 231, 239, 277
Q
uality ssurance............................................................................................................................................................................... 171
uality ontrol..................................................................................................................................................................................... 171
quartz ..............................................................................................................................................................................................8, 12, 60
R
radiation ..................................................................................................................................................................................... 22, 23, 34
adioactivity ............................................................................................................................................................................................ 34
amming material..........................................................................................................................................................135, 137, 150
raw materials . 2, 12, 38, 47, 48, 58, 62, 72, 78, 94, 95, 97, 109, 110, 111, 123, 125, 126, 130, 131, 133, 134,
135, 144, 150, 153, 163, 164, 173, 174, 180, 203, 208, 215, 220, 229, 356, 357, 360
reaction layer ...................................................................................................................................................................................80, 83
ectangular spalling tests............................................................................................................................................................... 175
refractory ceramic fibres .............................................................................................................................................................. 9, 10
refractory manufacturing ............................................................................................................................................................... 133
refractory suppliers .................................................................................................................................................. 8, 117, 355, 356
efractory texture ..........................................................................................................................................................................2, 163
removable bottoms........................................................................................................................................................................5, 224
re-oxidation ....................................................................................................................................................................................26, 118
residual carbon .................................................................................................................................................................................... 123
resin bonded ........................................................................................................................................................... 7, 8, 118, 123, 191
resins ..................................................................................................................................................................19, 113, 123, 125, 163
rheology ..............................................................................................................................................................................135, 143, 145
R-HOB .....................................................................................................................................................................................33, 126, 127
ing construction ............................................................................................................................................................................... 140
obotic installation............................................................................................................................................................................ 330
otary slag testing............................................................................................................................................................................. 178
owlock................................................................................................................................................................................................... 140
ubble ile nalysis ................................................................................................................................................................2, 89, 92

S
safety .....13, 2, 7, 17, 18, 23, 123, 125, 145, 183, 185, 186, 191, 194, 196, 197, 202, 207, 214, 233, 241, 243,
244, 245, 251, 254, 262, 280, 282, 284, 285, 287, 288, 291, 301, 314, 324, 326, 327, 328, 329, 330, 354
afety ottom ....................................................................................................................................................2, 185, 196, 243, 282
safety lining ..............................................................................................................................196, 197, 244, 245, 284, 285, 328
aturday night designing ................................................................................................................................................................... 89
scrap charge .......................................................................................................................................................................................... 208
crap force ...................................................................................................................................................................................... 73, 209
scrap impact .......................................................................................................................................................................................... 210
.................................................................................................................................................................274, 275, 277
self flow .................................................................................................................................................................... 135, 137, 142, 144
emi-universal ..................................................................................................................................................................................... 139
shell protection ..............................................................................................................................................24, 159, 164, 283, 326
shell temperature ..........................................................................................................................22, 24, 25, 161, 245, 283, 327
helving ................................................................................................................................................................................................... 148
hotcrete (wet gunning) ................................................................................................................................................................. 143
hotcreting .............................................................................................................................................. 2, 142, 143, 145, 146, 190
sidewall ...................................................................6, 175, 176, 196, 197, 243, 257, 284, 308, 309, 310, 311, 327, 328
silica ... 9, 12, 26, 29, 34, 38, 45, 47, 48, 51, 53, 55, 57, 58, 60, 78, 84, 102, 104, 108, 109, 110, 111, 119, 129,
130, 131, 144, 150, 163
ilicon (Si) .............................................................................................................................................................................................. 119
ilicon arbide (SiC) .......................................................................................................................................................................... 120
silicosis ....................................................................................................................................................................................................... 12
sillimanite .............................................................................................................................................................................................. 110
single crystal ......................................................................................................................................................................................... 100
intered ......................................................................................................................... 71, 97, 99, 105, 106, 111, 229, 245, 248
sintered layer......................................................................................................................................................................................... 248
sintering ........................................................................................................ 39, 123, 131, 166, 173, 248, 249, 250, 251, 252
skull.........................................................................................................................................36, 73, 199, 209, 313, 318, 327, 333
labbing / palling / laking / eeling ........................................................................................................................................ 61
lag oating .............................................................................................................................................................................................. 84
slag stopper ................................................................................................................................................................................. 236, 237
slagline........ 2, 4, 5, 6, 17, 92, 100, 115, 117, 126, 176, 217, 256, 312, 313, 314, 315, 316, 317, 343, 349, 357
leeve ....................................................................................................................................................................... 274, 275, 277, 294
lide ate echanism
lide gate plates ................................................................................................................................... 302
lide gate system .................................................................................................................................. 302
lidegates ............................................................................................................................................. 302
.......................................................................................................................................................................................... 30
slumping ................................................................................................................................................................................38, 135, 197
snorkels ......................................................................................................................................................................................... 176, 322
odium aluminate .............................................................................................................................................................................. 145
sodium silicate ..................................................................................................................................................................................... 151
softening .................................................................................................................................... 39, 65, 71, 95, 124, 125, 197, 229
soldier ...................................................................................................................................................................................................... 224
spinel .....................38, 46, 56, 57, 91, 95, 118, 119, 126, 181, 288, 289, 296, 310, 328, 332, 336, 341, 343, 349
spiral construction ............................................................................................................................................................................. 139
splitline ..........................................................................................................................................................................................................6
spoke area .............................................................................................................................................................................................. 271
spout .....................................................................................................................................................................................189, 190, 273
stabilized ................................................................................................................................................................................................... 59
stadium .....................................................................................................................73, 209, 220, 221, 222, 223, 224, 230, 233
tainless steel needles ............................................................................................................................................................... 71, 229
standard testing ................................................................................................................................................................... 94, 95, 165
steel cleanliness .................................................................................................................................................................29, 330, 334
steel defects ........................................................................................................................................................................................... 325
steel fins ..................................................................................................................................................................................................... 31
steel flow control system ................................................................................................................................................................ 325
steel ladle
teel ladle argon system.. 2, 3, 4, 22, 43, 47, 83, 90, 92, 99, 110, 111, 114, 131, 139, 154, 160, 175, 176,
279 287, 290, 292, 301, 308 309, 311 313, 315, 317 319, 325, 356
teel ladle bottom ................................................................................................................................ 357

teel ladle insulation ............................................................................................................................ 357
teel ladle processing routes ................................................................................................................ 357
teel/slag dumping process .................................................................................................................. 357
tiffness ...................................................................................................................................................................................................... 67
stir plug .................................................................................................................................................................... 232, 265, 267, 295
tokes law ..........................................................................................................................................................................................27, 31
stopper rod ......................................................................................................................................................31, 339, 342, 343, 344
torage costs ............................................................................................................................................................................................ 17
traights .................................................................................................................................................................................................. 139
train-controlled load ......................................................................................................................................................................... 61
trength and mechanical resistance .......................................................................................................................................... 119
tress / train .......................................................................................................................................................................................... 61
tress-controlled load ......................................................................................................................................................................... 61
submerged entry nozzle (SEN) .................................................................................................................................................... 325
urface ondition ..................................................................................................................................................................... 148, 149
surface tension.................................................................................................................................................................................86, 87
ynthetic itreous ibres...................................................................................................................................................................... 9
T
tabular alumina ...............................................................................................................................................................110, 144, 150
amman temperature ......................................................................................................................................................................... 39
tap pad ............................................................................................................................................. 6, 203, 204, 205, 206, 207, 235
taphole .........................................6, 75, 206, 210, 213, 234, 235, 236, 237, 238, 239, 256, 273, 274, 275, 276, 277
aphole lock ....................................................................................................................................................................................... 235
aphole epairs ........................................................................................................................................................................ 238, 277
tapping force ............................................................................................................................................................. 90, 287, 288, 309
tapping height/ angle .................................................................................................................................................................90, 309
apping ad ......................................................................................................................................................................................2, 203
tapping rate ....................................................................................................................................................................................75, 210
tapping time ................................................................................................................................................................................ 234, 274
tearout profile ...................................................................................................................................................................................... 259
echnical ata heets ...................................................................................................................................................................2, 163
tension ......................................................................................................................................................................... 87, 171, 348, 357
ernary iagrams ................................................................................................................................................................................. 50
thermal conductivity ................................................................................................................................... 69, 114, 116, 125, 228
thermal cycling ....... 13, 66, 84, 86, 88, 112, 175, 176, 178, 179, 191, 205, 212, 217, 222, 235, 237, 258, 270,
276, 306, 310, 315, 331, 336, 347, 349
thermal diffusivity .......................................................................................................................................................................69, 228
thermal expansion ...... 37, 61, 62, 64, 65, 67, 69, 70, 72, 84, 90, 108, 110, 114, 125, 131, 141, 155, 166, 173,
174, 197, 201, 205, 212, 217, 222, 228 30, 235 7, 244, 251, 258, 267, 270, 274, 276, 284, 288, 296,
306, 310, 315, 319, 328, 332, 336, 341, 343, 345, 347, 349
hermal xpansion llowance........................................................................................................................................................ 64
hermal expansion curves ........................................................................................................................................................... 174
thermal gradient .................................................................................................................................................................. 65, 69, 173
thermal losses .......................................................................................................................................................... 24, 159, 283, 326
hermal modeling ................................................................................................................................................................................. 23
hermal shock 36, 61, 121, 125, 165, 175, 196, 199, 203, 208, 215, 220, 228, 235, 236, 243, 250, 257, 266,
270, 275, 284, 287, 295, 304, 309, 313, 318, 327, 331, 336, 340, 342, 343, 346, 348
thermal shock resistance ...... 46, 68, 69, 70, 113, 121, 123, 125, 131, 164, 165, 176, 198, 213, 228, 231, 239
thermal stress resistance .................................................................................................................................................... 67, 68, 70
thermal stresses.................................................................................................................................................................................. 175
hixotropic ............................................................................................................................................................................................ 145
TMC analysis .......37, 89, 90, 117, 124, 196, 199, 203, 208, 215, 220, 227, 235, 236, 243, 249, 250, 256, 266,
269, 274, 275, 284, 327, 331, 335
op one ..............................................................................................................................................................2, 194, 199, 200, 201
otal ost of wnership .................................................................................................................................................2, 15, 354
transfer ladle desulphurization ................................................................................................................................................... 183
transfer vessel .....................................................................................................................................................................55, 183, 279
ransport costs ....................................................................................................................................................................................... 17
tri-calcium silicate .............................................................................................................................................................................. 131
ridymite ............................................................................................................................................................................................12, 52
trivalent chromium ............................................................................................................................................................................... 33

trunnion refractory............................................................................................................................................................................ 215
tundish
undish boards . . 2, 6, 12, 29, 30, 31, 32, 73, 209, 221, 230, 286, 324
undish gate ......................................................................................................................................... 286
undish lining ....................................................................................................................................... 286
undish nozzle ...................................................................................................................................... 286
undish powder .................................................................................................................................... 286
undish shroud ..................................................................................................................................... 286
undish spray ....................................................................................................................................... 286
undish stopper rod ............................................................................................................................. 286
tuyeres .......................................................................................................................................................... 5, 68, 225, 250, 268, 322
U
unformed refractory ............................................................................................................................................................... 135, 150
V
vacuum tank degasser ...................................................................................................................................................................... 293
V- ........................................................................................................................................................................................... 156
velocity of slag movement ..........................................................................................................................................................79, 83
vibrated .................................................................................................................................................................... 131, 135, 137, 142
vibration machines ............................................................................................................................................................................ 254
viscosity of slag ................................................................................................................................................................................79, 83
W
ater cooled rods .............................................................................................................................................................................. 253
wear patterns ................................................................................................................................................................................18, 281
wedge brick ........................................................................................................................................................................................... 219
wedges ........................................................................................................................................................................................................ 31
wedge-splitting test .............................................................................................................................................................................. 68
weirs .....................................................................................................................................................................................334, 336, 337
welded wire mesh .............................................................................................................................................................................. 155
white fused alumina .......................................................................................................................................................................... 110
wools ...................................................................................................................................................................................................... 9, 10
work of fracture ............................................................................................. 36, 37, 68, 70, 71, 76, 91, 125, 228, 229, 289
ork of fracture tests....................................................................................................................................................................... 181
orking ottom................................................................................................................................................... 187, 247, 286, 290
orking ining ................................................................................................................................................................................6, 330
orking idewall ............................................................................................................................................................................... 308
Y
Y- .................................................................................................................................................. ......................................... 157
yttria ............................................................................................................................................................................................................ 59
Z
zircon........................................................................................................................................................................................................... 34
zirconia (zirconium oxide) ................................................................................................................................................................ 34
zirconium silicate .................................................................................................................................................................................. 34

Refractory Material Selection For Steelmaking

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Refractory Material Selection For Steelmaking

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Published by John Wiley & Sons, Inc., Hoboken, New Jersey.

Published simultaneously in Canada.

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Names: Vert, Thomas, 1964- author.

Printed in the United States of America.