Innovations in Refractory Ceramic Technology for Iron and Steel Applications: Innovations in Refractory Ceramic Technology for Iron and Steel Applications
Sponsored by: ACerS Manufacturing Division, ACerS Refractory Ceramics Division
Program Organizers: James Hemrick, Oak Ridge National Laboratory; Josh Pelletier, Imerys Aluminates
Monday 2:00 PM
November 2, 2020
Room: Virtual Meeting Room 17
Location: MS&T Virtual
2:00 PM
Aging of Refractory Castables: Joshua Sayre1; Margaret Raughley1; Jeffrey Bogan1; 1HarbisonWalker International
Refractory castables are susceptible to degradation of the hydraulic binders and superplasticizers over time. The hydroscopic nature of these materials makes them prone to deterioration before use when exposed to environmental moisture either through extended storage or humidity. The flow, set time and physical properties can all be negatively impacted as castables age. The degradation in these properties can cause installation and potentially service performance problems. There are several measures that can be taken to minimize the effects of aging including controlling raw materials, product design, packaging and storage. Both real-time and accelerated aging tests will demonstrate the variables of aging. Different binder types will be compared for their effect on shelf life stability. The effect of paper versus plastic packaging and the proper storage conditions will be reviewed.
2:20 PM
New Refractory Solutions: Supporting Induction Melting Manufacturing Challenges: Dana Goski1; Ryan Hershey1; Gary Hallum1; Benjamin Hunsicker1; Yuechu Ma1; 1Allied Mineral Products LLC
Casting operations utilizing induction furnaces for metal melting are under constant pressure for improved metal quality, lower refractory costs, extended operations, and cleaner environmental working conditions for their employees with respect to respirable crystalline silica exposure. A number of engineered ceramic material solutions for coreless induction linings are presented in this paper with respect to these issues. Boron free binders to improve product quality; optimization of the lining campaign and refractory costs by zoning; and reduction in exposure to crystalline silica. These solutions are already in applications in the induction melting industry showing positive results.
2:40 PM
Refractory Developments for BOF and Furnace Taphole Applications: Sean Carden1; Keith Beale1; 1Vesuvius
The performance and lifetime of refractories used in basic oxygen furnace and taphole applications can be a critical factor in governing productivity and operational costs for the steelmaker. These products demand specific attributes in order to provide adequate performance in the field. The design of the furnace, the cyclic thermal nature of the steelmaking process and the arduous environment require that the thermomechanical properties of refractories used in these functions are optimised whilst maintaining excellent resistance to slag corrosion, mechanical erosion and oxidation. This paper aims to discuss the properties of BOF and taphole refractories, how they influence their performance in service, and introduce recent developments that have demonstrated further improvements in refractory lifetime and performance consistency.