Longer running times and shorter downtimes for new linings or repairs mean that specific solutions are required increasingly often for the refractory lining of blast furnace stacks and runner systems. Carbon and graphite refractories are primarily used for blast furnace linings because of their high temperature conductivity and their ability to reduce the heat load by moving the excessive heat to the shell where the heat can be transferred to the water by film cooling or through the cast iron or copper staves. The estimation was based on temperatures of thermocouples placed in control boreholes on three levels of. Copper coolers of a special design were developed by the companies mechel and mifibu in 2002. The structural problems of this blast furnace are cracks of the steel shell and thickness reductions of the stave and the refractory of hearth part caused by. Development and introduction of monitoring system of refractory lining wear in blast furnace hearth 562 fig. The refractory lining of every part should fit the parts thermal current intensity, so that the lining can maintain previous vertebral shape and stability under the impact of strong heat flux.
Adopt refractory materials with alkali refractory to resist furnace slag alkali erosion. The blast furnace body is a huge structure of 50m in height, 20m in width. A distinctive feature of the mechelmifibu coolers is the presence of three water inlets in the lower part of the cooler and three outlets in the upper part. The latest state of this type of lining in the lower part of the blast furnace is. Refractory lining rongsheng kiln refracotry materials. In the coreless furnace, a core induction furnace, as the if refractory material for induction furnace for melting gray cast iron, ductile iron, malleable cast iron, vermicular graphite cast iron and, as well as the use of refractory materials, ca. A study of the heat flow in the blast furnace hearth lining. In the experimental study, manual measurements were carried out on the outer surfaces of the furnace wall. In 2009 a second partial repair was conducted in order to repair the refractory hearth lining around the tap hole. How to choose refractory brick used for different parts of. Allied mineral products, formerly riverside refractories, offers a variety of mixes including, gunning, pumping, and shotcrete, for the blast furnace industry. The remaining refractory thickness assessment of hearth part in the blast furnace. My previous furnaces were all made from a clay form surrounded with regular concrete or mortar.
Showing or characterized by obstinate resistance to authority or control. Refractory linings of electric arc furnaces are made generally of resinbonded magnesiacarbon bricks. Sep 26, 2016 when choosing refractory brick used for different lining parts of blast furnace, we should follow some principles. They are typically composed of oxides of the following materials. New method revolutionizes furnace refractory installation. Blast furnace is generally refractory lined with ceramics materials such as fireclay bricks and high alumina bricks and carbon materials such as carbon brick and carbon graphite. In many ways, the production phase is similar to the iron and steel production. Recent studies show that furnace design, taphole position and refractory quality have profound effects on the furnace lining wear rate. This furnace has an historical rate production of 2. Refractory lining for induction furnace the bottom structural part of induction furnace figure with details published in a separate article on induction furnace on which main crucible lies is generally lined with bricks and do not require to be changed frequently. Allied mineral products, formerly riverside refractories, offers a variety of mixes including, gunning, pumping, and shotcrete, for the blast furnace. We also have our own refractory casting shop where various cast shapes can be produced for both new and existing equipment.
Differentiated use of refractories in blastfurnace hot. Measurement of blast furnace refractory lining thickness with a 3d laser scanning device and image registration method article pdf available in isij international 4810. The three dimensional model of heat transfer of cooling stave with refractory lining in a blast furnace are. The refractory lining consists of aluminium oxide and silica oxide. We are ready to codesign blast furnace lining projects. The charge, which consists of iron ore, coke and limestone etc. Castable refractories can be mixed with water, formed. The remaining refractory thickness assessment of hearth part.
We offer different variants of blastfurnace hearth and blastfurnace hearth bottom lining. Anchor selection can directly influence lining reliability and stability along with potential hotgas bypassing and hotspot development. Refractory materials are classified into three types based on fusion temperature melting point. Namho shin, sangwoo choi, yongrae roh, posco, pohang, korea. The three dimensional transient navierstocks equation associated with the volume of fluid vof was developed to describe the flow fields of air, molten iron and slag in the main trough of the blast furnace during tapping process. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally iron. The refractory lining can also resist thermal shocks, erosion, physical attack and chemical attack. A tribosystemic approach to refractory lining destruction in blast.
The observations of carbon deposition around zinc silicate as well as iron spots in the. Refractory linings build the service space for blast furnace to directly resist mechanical, high temperature and chemical erosion in the manufacturing process and insulate the. Used for blast furnace lining in castable refractory material. Refractory linings used in induction furnace are commonly made of acidic silica or basic magnesia compounds. Nowadays the campaign life of blast furnace is measured in terms of 10 15 yrs rather than 4 5 yrs while on the other hand, the trend is to replace smaller blast furnaces with large capacity blast furnaces. Pdf measurement of blast furnace refractory lining. However, working face of the main crucible is lined with a suitable ramming mass. In a blast furnace, fuel and ore are continuously supplied through the top of the furnace, while air sometimes with oxygen enrichment is blown into the bottom of the chamber, so that the chemical reactions take place throughout the furnace as the material moves downward. Dcarc, furnace, reverberatory, blast, copper, lead, slag, nickel laterite, chrome, magnesia. Refractory materials for blast furnaces north refractories. Fused magnesite grains and flake graphite are used as raw materials. For this emergency repair there was no time to reengineer the.
Heat transfer through a refractory lining is a function of the materials thermal conductivity. Industry news refractory, refractories, refractory supplier. New generation refractory lining for coreless induction. Blast furnace refractories blast furnace lining refactory. The significance of improving the refractory configuration, the installation methods, and the short turnaround time for the repair will be discussed. Shortterm lining temperature changes during tapping in a blast furnace. The technique of definition of optimum quantity and arrangement of thermocouples in the blast furnace hearth lining is developed 5. The monitoring system of the firebrick lining state of the blast furnace devil is offered. Campaign life of furnca ehave increased from 5 yrs 1020ye and more these days. If you dont get the recipe just right, you could have the walls crumble at full temp, or melt into a pile of glass and clay. There are four main factors that affect the campaign life of a blast furnace. Furnaces and refractories fusion dust and slag or by the action of alkalies on fireclay refractories, to form alkalialumina silicates. The article presents the method of estimation of refractory lining inner profile of blast the furnace crucible and bottom of volume 1719 m3.
Solutions for hot blast stoves and blast furnace linings. It should be operated not less than 15 years during one campaign. Unlike other industrial furnaces, aluminum furnaces do not have an ignition system. If you are going to buy refractory lining in kilns, furnace or electric arc furnace, please contact rs kiln refractory company. Refractory lining definition of refractory lining by the.
The campaign duration of furnace refractory linings used in wrought steel production has been increasing dramatically over the past few decades. Up to today, lining materials have been supplied to about 50 blast furnaces in italy and. We engineered a new anchoring system for these elements for longer life. Business metals, metalworking and machinery foundries metallurgical plants equipment and supplies nonferrous metals foundries refractory coating innovations refractory coatings. Aluminum furnaces transform raw minerals into aluminum under high temperature. In the 1970s, a lining campaign of 2,000 heats was considered excellent while today more than 20,000 heats per lining can be achieved. Energy saving in walking beam furnaces by a new concept.
Refractories are inorganic, nonmetallic, porous, and heterogeneous. Choosing the right refractory material for a given melting or holding application. This study aims to numerically analyze the refractory wear of the blast furnace main trough. Our refractory mortar materials include heatsetting mortars which require high temperatures to allow the ceramic to set and airsetting mortars which set upon drying without a high heat chamber. A modern blast furnace bf is refractory lined to protect the furnace shell from the high temperatures and abrasive materials inside the furnace. Principles for blast furnace refractory lining inspection. Failure of refractory lining of a ferro chrome furnace the electric submerged arc furnace producing ferro alloys is a high temperature reaction vessel. Refractory materials for industrial furnaces onex, inc. Nowadays the campaign life of blast furnace is measured in terms of 10 15 yrs rather than 4 5 yrs. Numerical analysis on the refractory wear of the blast.
Apr 05, 2012 castable refractories can be mixed with water, formed, and solidified like cement, but the process of drying the solid before fulltemperature use is critical. Simple 3d geometry figure 3 shows the geometry that is used for setting up the 3d cfd model. Hot sale refractory lining materials in rongsheng manufacturer. How to choice refractory material for induction furnace. This page will detail some of the refractory formulas that i experiment with. Blast furnace is used to reduce the iron ore to iron. Refractory wear rate is evaluated by considering the fluid flow speed at the refractory walls. Refractory walls of a furnace interior with burner blocks bee, 2005 some of the important properties of refractories are. The refractory lining of every part should fit the parts thermal current intensity, so that the lining can maintain previous vertebr. In the service of blast furnace hot blast stoves the lining and checkerwork fail in individual zones as the result of deformation of the refractories, formation of cracks, and chemical corrosion of the lining under the action of lowmelting dust at high temperatures.
In a blast furnace, fuel and ore are continuously supplied through the top of the furnace, while air sometimes with oxygen enrichment is blown into the bottom of the chamber, so that the chemical reactions take place. Blast furnace refractory lining campaining life starting of blast furnace to shutting down of blast furnace depend on the life of refractory lining which liesa between the inside working volume to that of outer steel sheel, which protects the steel sheel. They are commonly used, for instance, to line kilns and other hightemperature furnaces. It was shown that the deformation of aluminosilicate refractories depends not only upon temperature, load, and hold but also to. It is a kind of containing silicon carbide and carbon of high alumina castable. Air heated in the blast furnace stoves, is applied from the bottom of the. A standard cooler has three pairs of drilled channels for inlet and outlet tubes. Differentiated use of refractories in blastfurnace hot blast. New monitoring system of the refractory lining wear in the. The furnace hearth is constructed by several refractory zones. Sanac started the production of refractories for blast furnaces since 1957. When working with castable refractory, be mindful of the hazard of heating trapped water too rapidly and causing a steam explosion. Considerable losses of production occur when largecapacity blast furnaces are shut down. Nondestructive testing ndt and inspection of the blast.
Bf has a complex refractory system to provide a long. The remaining refractory thickness assessment of hearth. Having over 80 years of experience in the iron and steel refractory product industry, our vast collection of blast furnace lining refractories are tailored to any application you may require. When the bricks are heated the bonding material is coked and turns into a carbon network binding the refractory grains, preventing wetting by the slag and protecting the lining the from erosion and chemical attack of the. Refractory lining of a furnace arch bee, 2005 figure 2b.
Refractory material heat protection of furnace youtube. We offer different variants of blast furnace hearth and blast furnace hearth bottom lining. Pure substances melt instantly at a specific temperature. Blast furnace an introduction blast furnace is the focus of any integrated steel plant. Projections are welded on the outside surface of the. The refractory lining thickness of the blast furnace is in use as 650 mm. Refractory castable for blast furnace trough 123yilong. Refractory repairs and total relining furnace rebuilders. Rs can provide you all the needed refractories materials for. Jul 20, 2017 in the coreless furnace, a core induction furnace, as the if refractory material for induction furnace for melting gray cast iron, ductile iron, malleable cast iron, vermicular graphite cast iron and, as well as the use of refractory materials, ca. Monitoring the wear of the refractory lining in the blast. In additionto the temperatures, the furnaces are subjected to other factors that command the life of refractory lining. Refractory lining failures in fecr furnaces refractory. Refractory lining is a layer of material which can resist high heat temperature in the kiln or furnace.
Home our products refractory materials and refractory repairs we have stocks of many types, sizes and grades of refractory materials. They are also finding more applications in blast furnace linings, although this use is still rare. In the steel industry, the blast furnace is a process for making molten iron by melting iron ore. Wikipedia quotes astm c71 on the definition of refractory. Refractory lining synonyms, refractory lining pronunciation, refractory lining translation, english dictionary definition of refractory lining. Iron ore is smelted in the blast furnace in order to remove unwanted impurities such as rocks, clay and sand, and also to seperate the iron from the oxygen. Refractory materials and refractory repairs furnace.
These furnaces are lined with copper pipe units filled. Principles for blast furnace refractory lining inspection and. This paper summarises the experiences with the new light weight material and lining concept for the water cooled skid pipe system in walking beam furnaces no. New generation refractory lining for coreless induction furnace. Im hope in the next few weeks to have all the pages written to go along with. Furnace reline refractory lining ceramic technology. Pdf estimation of state of the blast furnace crucible.
This refractory lining reflects the heat bach into the furnace. If using a commercial mixture, follow the manufacturer. The 2 bucks furnace was my first use of an actual refractory formula. If an emergency economic repair to a monolithic lining in a furnace is needed, onex offers plastic. Refractory cement for your foundry furnace can be a real btch. Trough the castable lining was developed in the late twentieth century 70 a new unshaped refractory materials, with the iron quantity, long service life, low consumption of refractory material, convenient construction etc. Typical blast furnace internal hearth 3d geometry no refractory. When the change reaches the limit what refractory lining material can resist, the furnace lining will be damaged.
Considerable losses of production occur when largecapacity blast furnaces are shut down for lining repair, which may take 23 months. How do i choice refractory material for induction furnace lining. Refractory brick lining is normally used in conjunction with refractory concrete lining. Jet refractory, regardless of the spraying repatching or build new lining body, accept the spray on the working plane jet material status can be divided into. Within this line of work, analyses of refractory materials. Ceramic refractory coating of inner hot face lining to resist carbon and oil penetration and increase the life of refractory lining. Cti removed the existing refractory lining of a bell annealing furnace and installed a new lining of insulation board and ceramic fiber, along with installing new heating elements for the furnace. High temperature and thermal shock in the melting process of blast furnace, there will be a large change in high temperature and heat conductivity. In addition to the expected wearing of the lining, incidents such as gas leakage, water attacks, premature furnace shut downs, and thermal fluctuations can cause severe damage to local areas of the refractory. Brick refractories are used for refractory lining of floors and burner areas of boilers and furnaces, and where refractory concrete lining alone is unsuitable. The paper applies tribological principles to the study of blast furnaces lining destruction processes. Aug 15, 2014 a modern blast furnace bf is refractory lined to protect the furnace shell from the high temperatures and abrasive materials inside the furnace. Refractory lining an overview sciencedirect topics. Up to today, lining materials have been supplied to about 50 blast furnaces in italy and abroad always achieving excellent results and acquiring a solid reputation among the users.
The refractory lining of blast furnaces and modernization of. Any material expands when heat ed, and contracts when cooled. Emz blast furnace of 15 m3 in volume dmkd blast furnace of 15 m3 in volume zsmk blast furnace of 3000 m3 in volume. Investigation of accretion formation in blast furnace shaft. A refractory material or refractory is a material that is resistant to decomposition by heat, pressure, or chemical attack, and retains strength and form at high temperatures. Refractories for lining of blast furnaces and its auxiliary. When choosing refractory brick used for different lining parts of blast furnace, we should follow some principles. Consequently, a balanced ratio of sic to carbon is just as important in a successful material as selecting the. The mathematical description, algorithm and program of calculation the temperature fields in any vertical and horizontal crosssection of the devil lining are developed with use of the indications of the temperature sensing transducer to in the oven lining.
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