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50 YEARS
ANKERHARTH
RH DegasserConcave
Bottom Lining Design
Highly Manoeuvrable
GEKKO Gunning Manipulator
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Contact: Ulla Kuttner
RHI AG, Technology Center
Magnesitstrasse 2
8700 Leoben, Austria
E-mail: ulla.kuttner@rhi-ag.com
Tel: +43 (0) 502 13-5323
Fax: +43 (0) 502 13-5237
www.rhi-ag.com
The products, processes, technologies, or tradenames in the
RHI Bulletin may be the subject of intellectual property rights
held by RHI AG or other companies.
2<
RHI worldwide
RHI Publishes Second
Sustainability Report
India >> In January 2013, RHI acquired 43.6% of the share capital
of Orient Refractories Ltd., (ORL) and a further 26% by the end of
April 2013 via an open offer. The transaction price for the 69.6%
totalled approximately 50 million.
ORL is an Indian producer of special refractories and monolithics
listed on the National Stock Exchange of India and Bombay Stock
Exchange. ORL develops and produces a wide range of shaped
and monolithic refractories for the iron and steel industry, serving
both domestic and international customers. Headquartered in New
Dehli, ORL has manufacturing as well as research and development facilities, along with eight sales offices located throughout
India.
For RHI the acquisition is key to pursuing its growth strategy
focused on emerging markets and strengthening its global market
position in the flow control business segment. With its strong
presence at Indian mini mills, ORLs business complements RHIs
current market position. In addition to the technical and service
know-how, ORLs production facility in India will further strengthen
RHIs service-oriented sales approach for the growing Indian and
Asian steel industry.
RHI worldwide
OMK Vyksa Steel Works
and RHI Sign the First FLS
Contract in Russia
USA >> AISTech 2013, the Iron and Steel Technology Conference and
Exposition, took place from May 69 at the David L. Lawrence Convention Center in Pittsburgh (USA). Key steel producers, suppliers, corporate executives and leaders, as well as academia gathered to exchange
technical information, network, and view new process and product
technologies.
This year 46 countries were represented at steels premier technology event by over 8000 attendees. Along with more than 500 companies, RHI and INTERSTOP shared a booth at the exposition, which provided a central information and meeting point for existing and potential customers.
RHI also participated in the technical sessions, presenting multiple
topics including BOF lining recommendations, EAF process optimizations, the latest developments in magnesia-carbon bricks for modern
EAFs, and flow control advances. Two of the technical sessions were
also chaired by RHI personnel.
AISTech 2014 will take place at the Indiana Convention Center, Indianapolis, from May 58.
Innovative Refractory
Solutions for Direct
Reduction Processes
USA >> A new direct reduction technology for iron ore in North America challenges existing refractory concepts. The
very demanding process conditions
require the development of innovative
refractory solutions. Typically, the furnace roof has been pump cast and the
walls shotcreted with high-grade alumina mixes.
During the April 2013 shutdown, RHIs
initiative was to install a trial brick
RESISTAL RK10-1in the furnace.
RESISTAL RK10-1 is a top brick grade
developed by RHI, giving extremely
high corrosion resistance together with
structural flexibility. The section lined
with RESISTAL RK10-1 included both
inboard and outboard walls and the corresponding roof section. Whilst the wall
sections are a fairly standard design, the
roof section is unique, requiring new
shapes. To reduce installation time and
further improve service life in the future,
development of a new brick/shape
design is under consideration.
50
YEARS
ANKERHARTH
One of the best-known refractory products for lining electric arc furnaces is celebrating an anniversary.
For more details please contact: RHI AG, 1100 Vienna, Wienerbergstrae 11, Austria
50 Phone:
years ago,
the502
foundation
was(0)laid
the successful
development
+43 (0)
13-0, Fax: +43
502for
13-6213,
E-mail: rhi@rhi-ag.com
Excellence
in Refractories
www.rhi-ag.com
Editorial
Contents
This year ANKERHARTH electric arc furnace ramming mixes celebrate 50 years of commercial production and RHI is very proud to
have reached this milestone with a pivotal product used for hearth
lining. Since its introduction back in September 1963, ANKERHARTH
has been continually optimized to provide customers with a range of
products suitable for all and ever-evolving EAF process conditions.
With more than 150000 tonnes sold in 2012, this brand is globally
recognized as the number one EAF bottom ramming mix solution; its
reliability and safety benefits are undisputed. Two main factors have
resulted in this success story: The special alpine magnesia composition available from RHI mines and a longstanding commitment to
research and development. The latter enables both incremental and
novel product advances tailored to customer requirements.
The first paper in this issue focuses on the chronological development of ANKERHARTH as well as the current product portfolio,
including the advantageous properties of this high-grade brand and
how they meet modern EAF hearth ramming mix requirements.
This is followed by the introduction of a new sol-bonded castable for
EAF delta applications. The easy drying and heat-up behaviour of
COMPAC SOL A100S-15, combined with outstanding material properties, generated very successful trial results at Acciaierie Bertoli Safau
(Italy), where top performance roof deltas are now routinely cast onsite with this brand. An additional energy-saving refractory application for EAFs, inert gas bottom purging, is the subject of the third
paper. Numerous case studies are provided, detailing various process improvements realized during diverse steel grade production
with this technology.
Postmortem investigations are essential to understand refractory
wear and develop strategies and new products to extend lining lifetimes. In this edition, one paper describes mineralogical investigations of water-damaged brickwork from an EAF and a second focuses
on the wear phenomena determined in a gunned tundish lining sample and measures that were subsequently recommended to extend
the casting sequence.
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Phone: +43 (0) 502 13-5323
Fax: +43 (0) 502 13-5237
Finally, I would like to express my appreciation to all those who contributed to this Steel Bulletin. Through your commitment we are able
to keep our valued readers abreast of RHIs developments, achievements, and services.
>7
Lining Developments
used for mixes that were applied with water. Initial trials
using liquid sodium silicate as a binder were not very successful due to the high shrinkage and resultant cracks during heating up. Improvements were realized with sulphate
and chromate bonded mixes; however, they required long
drying times. Therefore, as a result of their easier and
quicker application, doloma mixes became a strong competition to magnesia products.
Doloma Hearth (CRESPI System)
Due to its high sintering activity, it was possible to dry line
hearths with fired doloma. However, the use of oxygen and
intensive operating conditions led to an insufficient service
life in certain cases. Whilst the advantage of magnesia over
doloma was well known for EAF applications, the technology was not in place to produce an appropriate unshaped
In the subsequent years, EAFs became increasingly important for steel production because of the numerous productivity and technological improvements to the process. As a
result, the hearth ramming mixes had to be adapted to meet
the more demanding in-service requirements.
>9
Veitscher Hartherd
1960
1963
1967
1970
1973
1974
1980
1987
1990
2010
1999
2011
10 <
Fe2O3 level
Standard
Characteristic
Nomenclature
Application type
Standard mixes
NN
NB
SB
Chemical content
Low Fe2O3
Middle Fe2O3
High Fe2O3
Grain size
05 mm
5/0
08 mm
SiO2
(wt.%)
Fe2O3
(wt.%)
Al2O3
(wt.%)
Grain size
(mm)
ANKERHARTH NN18
71
26
0.5
2.4
0.1
08
ANKERHARTH NN15
71
26
0.7
2.0
0.1
05
ANKERHARTH NN28
69
26
0.9
3.8
0.3
08
ANKERHARTH NN25
72
23
0.8
3.4
0.4
05
ANKERHARTH NN98
72
22
0.5
5.0
0.4
08
ANKERHARTH NN95
73
21
0.4
5.2
0.4
05
ANKERHARTH NB18
71
26
0.5
2.4
0.1
08
ANKERHARTH NB28
69
26
0.9
3.8
0.3
08
ANKERHARTH NB20
74
20
0.6
3.6
0.3
05
High
ANKERHARTH NB90
73
21
0.4
5.2
0.4
05
Low
ANKERHARTH SB15
71
26
0.7
2.4
0.1
05
Middle
ANKERHARTH SB25
77
19
0.6
3.2
0.2
05
High
ANKERHARTH SB95
73
21
0.4
5.2
0.4
05
Middle
Low
Dust-free
application
CaO
(wt.%)
High
Steep banks
MgO
(wt.%)
Low
Middle
Brand
> 11
Fe2O3 Content
Standard banks
ANKERHARTH NN25
Slope angle ~ 40
(a)
Steep banks
ANKERHARTH SB25
Slope angle ~ 80
(b)
Figure 5. Comparison of the application characteristics of (a) standard ANKERHARTH NN and (b) ANKERHARTH SB, developed for
steep bank installations.
25
n High Fe2O3
n Middle Fe2O3
n Low Fe2O3
20
RH
KE
AN
25
ARTH
ERH
ANK
10
NN1
6
5
4
3
2
1
0
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
1700
12 <
N
HN
RT
RHA
KE
AN
15
N9
HN
T
AR
30
1150
1250
1350
1450
1550
1650
Temperature [C]
Figure 7. Temperature-dependent formation of liquid phases in
various ANKERHARTH mixes under oxidizing conditions calculated using FactSage.
Summary
Based on 50 years of experience, ANKERHARTH is still the
undisputed, leading EAF hearth ramming mix worldwide,
for all types of EAF processes. This was possible due to
decades of permanent further development of the product
portfolio, reacting to steadily increasing requirements from
the steel industry. The current ANKERHARTH portfolio covers all the prerequisites of EAF operators, providing specific
and customer tailored solutions. With a strong research and
development commitment as well as backward integration
providing secure high-quality magnesia sources, RHI is also
positioned to meet future demands from the electric steelmaking industry.
08 mm
During lining
+ Steeper banks possible
+ Easier deairing
In operation
Less resistance against hot erosion
References
[1] Jellinghaus, M. Stahlerzeugung im Lichtbogenofen (3rd Edition); Verlag Stahleisen: Dsseldorf, 1994.
[2] Hdl, F. and Schmidt-Whitley, R. Die Geschichte der sterreichischen Magnesitindustrie und der RHI; RHI AG: Vienna, 2011.
[3] Eckstein, W., Kronthaler, A. and Silbernagl, M. ANKERHARTH Mixes for the Electric Arc Furnace Designed for the Future. RHI Bulletin. 2004,
No. 1, 1619.
Authors
Wilfried Eckstein, RHI AG, Technology Center, Leoben, Austria.
Karl-Michael Zettl, RHI AG, Steel Division, Vienna, Austria.
David Wappel, RHI AG, Technology Center, Leoben, Austria.
Corresponding author: Wilfried Eckstein, wilfried.eckstein@rhi-ag.com
> 13
Brand
Al2O3
SiO2
Figure 1 is a micrograph of COMPAC SOL A100S-15 showing the microporous matrix between the tabular alumina
CCS (N/mm2)
LTE (%)
TC (W/mK)
800 C 1200 C
ATL
SL
(C)
(Months)
Raw material
99.5
0.0
0.1
80
180
0.7
3.25
2.55
2.65
1850
24
Sintered alumina
99.5
0.0
0.1
80
180
0.7
3.05
2.45
2.40
1850
24
Sintered alumina
Table I. Chemical composition and physical properties of sol-bonded castables for EAF delta applications. Abbreviations include cold
crushing strength (CCS), linear thermal expansion (LTE), thermal conductivity (TC), application temperature limit (ATL), and shelf life (SL).
14 <
100
90
80
70
60
50
40
30
20
n Sol-gel
n Cement (8 wt.%)
10
0
0
Time [hours]
Figure 3. Drying behaviour of a cement-bonded castable (8 wt.%
cement) compared to a sol-bonded castable at 150 C. The amount
of water incorporated in both concretes was approximately the
same. In the case of sol-bonding, weight constancy was achieved
after a very short drying period at a constant temperature of only
150 C due to the high permeability at low temperatures.
100
0
-200
-400
-600
-800
-1000
-1200
n Sol-gel
n Cement
-1400
400 m
Figure 1. COMPAC SOL A100S-15 matrix after firing at 1500 C.
100
200
300
400
500
600
Temperature [C]
Figure 4. Determination of vaporization rates using thermal
gravimetric analysis illustrating that sol-bonded castables
release all the water at temperatures below 100 C.
> 15
Operation
start
Operation
end
Lifetime
(heats)
Casting
thickness
(mm)
Minimum
residual
thickness
(mm)
21.01.2012
09.02.2012
274
400
150
08.03.2012
22.03.2012
267
500
50
29.03.2012
15.04.2012
222
500
190
Table II. First three trial results casting EAF deltas with COMPAC
SOL A100S-15.
References
References and performance data have been obtained from
various steel plants where COMPAC SOL A100S-15 has
shown very impressive results in roof delta applications.
Furthermore, all the results have confirmed the advantageous properties of this castable in terms of drying and
heating up, as well as its uncomplicated installation. The
following sections describe trial results from Acciaierie
Bertoli Safau SpA (ABS) (taly) and provide a step-by-step
introduction regarding how to cast a roof delta on-site with
COMPAC SOL A100S-15.
(a)
(b)
Figure 6. (a) roof delta after 130 heats in operation with no problematic wear visible and (b) roof delta after 274 heats in operation showing a residual thickness between 100 mm and 300 mm.
(a)
moulds for the electrode mouths. Casting into the supporting ring requires a flat base plate that should be covered by
plastic film to facilitate lifting. All adjoining surfaces (e.g.,
Pyrostop board) that could absorb water from the mix have
to be impregnated or covered by some type of water-repelling material (e.g., oil or wax). Since the mix will shrink
slightly after casting, it is recommended that the electrode
mouths are coated with rubber material having a minimum
thickness of 10 mm (Figure 8) to avoid any crack formation.
A compulsory mixer (Figure 9) is recommended for mixing.
All the DIVASIL liquid binder should be added without any
interruption. The optimum mixing time is 23 minutes. To
determine if the mix consistency is in the intended range as
well as to get a better feeling regarding the optimum consistency, a consistency test should be performed (alternatively a ball-in-hand test) before the start of casting. The
amount of binder used must comply with the levels detailed
in the technical data sheets. Adding less binder than stipulated reduces the flowability and exceeding the recommended value can cause segregation and influences further
handling of the mix. The workability time is approximately
(b)
Figure 7. (a) supporting ring with base plate and electrode moulds and (b) mould construction.
(a)
(b)
Figure 8. (a) rubber coated electrode moulds positioned in a water-cooled supporting ring and (b) electrode mould prior to assembly
in a mould construction.
> 17
(a)
Drying
A simple heating pipe under the mould, consisting of steel
tubing with holes drilled into it for the gas flames (Figure
11a), is sufficient for the drying procedure. To avoid any
thermal losses the electrode mouths should be caped
(Figure 11b) and a simple heating vessel, which supports
and encloses the bottom of the roof delta should be used. It
is also recommended that the drying procedure is monitored
using thermocouples attached to the delta upper surface.
After 2448 hours, with a surface temperature of 110 C, the
roof delta should have finished drying and can go into
immediate operation. The drying period always depends on
the on-site conditions. For a fully automated drying procedure, using a preprogrammed thermal profile, RHI offers a
temperature-controlled (domestic) gas burner (Figure 12).
Conclusion
In the last years, a new generation of castables with solbonding (COMPAC SOL and CARSIT SOL) have provided
enormous advantages regarding processing and performance, especially in cement applications. These castables
were also the basis for further innovations in the field of
Figure 10. Standard hand vibrating units for de-airing the mix.
(b)
Figure 11. (a) simple heating pipe for the drying procedure and (b) delta with caped electrode mouths on the heating vessel.
18 <
1000 mm
Monolithic delta
350 mm
Heating vessel
Burner
Floor
(a)
(b)
Figure 12. RHIs heating appliance comprising a temperature-controlled gas burner and heating vessel. (a) schematic diagram and
(b) on-site equipment.
References
[1] Blajs, M., von der Heyde, R., Fritsch, P. and Krischanitz, R. COMPAC SOLThe New Generation of Easy, Safe, and Fast Heat-up No Cement
Castables. RHI Bulletin. 2010, No.1, 1317.
[2] Fritsch, P., von der Heyde, R. and Krischanitz, R. COMPAC SOLOperational Experiences With the Easy, Fast Heat-up No Cement Castable. RHI
Bulletin. 2011, No. 2, 4245.
[3] Von der Heyde, R., Krischanitz, R., Hall, D. and Zingraf, E. COMPAC SOLThe Success Story Continues With Gunning Mixes and New Product
Developments. RHI Bulletin. 2012, No. 2, 1216.
[4] Schtz, J., Maranitsch, A. and Blajs, M. New Oxycarbide Refractory Products Demonstrate Outstanding PropertiesFirst Practical Results. RHI
Bulletin. 2012, No. 1, 1619.
[5] http://www.absacciai.it
Authors
Markus Hochegger, RHI AG, Steel Division, Vienna, Austria.
Milo Blajs, RHI AG, Technology Center, Leoben, Austria.
Birger Nonnen, RHI AG, Steel Division, Mhlheim-Krlich, Germany.
Peter Zottler, RHI AG, Steel Division, Leoben, Austria.
Corresponding authors: M
arkus Hochegger, markus.hochegger@rhi-ag.com
Milo Blajs, milos-michael.blajs@rhi-ag.com
> 19
In addition, although a DC electric field is applied to the central steel bath above the bottom electrodes, by far the most
efficient movement of the entire steel melt is generated by
gas purging, where columns of bubbles rise from the bottom
to the top of the steel bath (Figure 1).
Bottom purging systems based on gas injection through a
single tube or multihole plugs have been developed that are
either buried in the EAF hearth ramming mix (i.e., indirect
purging) or are in contact with the steel melt (i.e., direct
purging). However, currently direct purging systems with a
multihole design represent the majority of bottom purging
systems in EAFs in the steel industry worldwide; for example
RHIs direct purging plug (DPP) series. Overall, approximately
9% of EAFs are equipped with bottom gas purging systems
today and with a common trend towards more cost-efficient
EAF operations in the steel industry, the tendency towards
bottom gas purging is increasing (Figure 2). Globally, RHI
delivers DPPs to more than 80 customers for EAFs with tap
weights between 6250 tonnes.
Safety
Gas purging plugs are installed into the EAF hearth
through a channel comprising surrounding blocks (Figure
3), thus (1) facilitating exchange of the purging plug in the
EAF hearth and (2) increasing safety standards as the
hearth ramming mix is installed, de-aired, compacted, and
sintered without interfering with the purging system.
100
Customer number
90
80
70
60
50
40
30
2000
2002
2004
2006
2008
2010
Year
Figure 1. Efficient steel melt mixing in the lower and upper bath
using 3 DPPs.
20 <
2012
Stirring gas
Wear indicator
Gas Injection
Typical DPP gas flow rates range from 10100 l/min or
higher if required (Table I). Nitrogen gas is applied in most
cases, although sometimes argon is used. The initial
momentum of the gas jet is dissipated into the steel melt a
few centimetres above the hot face of the plug and the gas
is divided among a large number of well-distributed gas
bubbles that rise to the steel surface. Consequently, the
impact of gas flow on melt movement depends primarily
on the gas volume applied and to a lesser degree on the
tube number, tube diameter, or tube arrangement.
Multihole design
Single-hole design
(DPP)
(DVS)
MgO-C brick
MgO-C brick
Tube configuration
Multiple tubes
Single tube
1 mm
2.55 mm
10100 l/min
100120 l/min
3070 l/min
Soft bubbling
Jetting
Soft bubbling
High
Medium
Low
Low
High
n.a.
Likely to reopen
Unlikely to reopen
n.a.
Main objective
Decreased wear
n.a.
As permanent lining
Table I. Characteristics of EAF bottom gas purging systems. Abbreviations include not applicable (n.a.).
> 21
Process-Related Benefits
The EAF process benefits realized using direct gas purging
systems are related to an overall increased steel bath movement as well as increased mixing between the lower and
upper steel melt volumes. The specific reported benefits of
DPP bottom gas purging systems can be subdivided into
three principal areas.
Increased thermal and temperature homogeneity in the steel
melt:
>> Decreased melting time of scrap and DRI.
>> Increased heat transfer during the superheating period.
>> Increased power transfer.
>> Decreased specific electrical energy demand.
>> Decreased deviation between the measured steel temperature in the EAF and the ladle furnace.
>> Avoidance of skull formation or debris in the EAF hearth
after tapping (i.e., clean furnace).
Increased chemical homogeneity in the steel melt:
>> Increased metal yield.
>> Increased use of secondary ferrous raw materials.
>> Decreased deviation between the measured carbon content in the EAF and the ladle furnace.
ga
in
in
St
irr
ea
W
at
c
di
Operation box
22 <
Argon
thernet
Nitrogen
MPI/Profibus/E
DPP stirrer 3
Conclusions
In the steel industry, DPP bottom gas stirring systems have
been installed in a variety of EAFs used to produce unalloyed
and low-alloyed steels as well as specialty and stainless steels,
for tap weights ranging between 6250 tonnes. Especially in
EAF steelmaking where metallurgical constraints exist, bottom
gas purging provides cost benefits by increasing the yield
from alloying elements, as well as decreasing electrical energy
demand and oxygen consumption. The additional advantage
of this technology includes a more homogeneous melt,
enabling improved process monitoring and control.
References
[1] Ricci, M., Waterfall, S. and Sun, S. Optimization of Bottom Stirring in the 165-Tonne Electric Arc Furnace at Arcelor Mittal Dofasco. RHI Bulletin.
2008, No. 1, 2228.
[2] De Santis, M. and Giavani, C. Bath Mixing in EAF Through Proper Lances-Plugs Gas Stirring Policies. Presented at Innovation in EAF and in
Steelmaking Processes, Milan, Italy, May 2728, 2009.
[3] Dong, K., Zhu, R. and Liu, W. Bottom-Blown Stirring Technology Application in Consteel EAF. Advanced Materials Research. 2012, Vols. 361363,
639643.
[4] Kazakov, S.V., Gulyaev, M.P. and Filippov, V.V. Hydrodynamics of Electric Arc Furnace Bath at Stirring With Inert Gases. Presented at 21st
International Conference on Metallurgy and Materials, Brno, Czech Republic, May 2325, 2012.
[5] Available and Emerging Technologies for Reducing Greenhouse Gas Emissions From the Iron and Steel Industry. Prepared by U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Sector Policies and Programs Division, North Carolina, Sept., 2012.
[6] Badr, K., Kirschen, M. and Cappel, J. Chemical Energy and Bottom Stirring Systems Cost Effective Solutions for a Better Performing EAF.
Presented at METEC InSteel-Con 2011, Dsseldorf, Germany, June 27July 1, 2011.
Reprinted with permission from the AISTech 2013 Conference Proceedings. Copyright 2013 Association for Iron & Steel Technology, Warrendale, PA, USA.
Authors
Marcus Kirschen, RHI AG, Steel Division, Vienna, Austria.
Ashraf Hanna, RHI Canada Inc., Steel Division, Burlington, Canada.
Karl-Michael Zettl, RHI AG, Steel Division, Vienna, Austria.
Corresponding author: Marcus Kirschen, marcus.kirschen@rhi-ag.com
24 <
Magnesia-Carbon BricksDetailed
Investigation of Water Damage
Recently, in the magnesia-carbon lined sidewalls of a 130tonne EAF, used for the direct reduced iron-based production of long products, the bricks showed partial signs of
binder coke decarburization and the entire residual brick
had a crumbly structure. In this investigated case, a leaking
water panel in the upper split shell was observed. The EAF
sidewall lining consisted of carbon-bonded high-quality sintered magnesia MgO-C bricks with 10 wt.% C (96.1 wt.%
Water-cooled
wall panel
MgO-C refractory
lining
Ramming mix
(a)
(b)
Figure 2. Typical refractory lining design of (a) EAF hearth and (b) sidewall with water-cooled wall panels in the upper region and
magnesia-carbon refractories below.
> 25
General information
Furnace
EAF
Brick type
Magnesia-carbon
Sampling position
Typical values
11.0
(1)
MgO
96.0
97.0
Al2O3
0.37
0.3
Investigation Methods
SiO2
0.75
1.2
P2O5
0.05
SO3
0.06
CaO
2.15
MnO
0.07
Fe2O3
0.46
1.7
0.8
(2)
10.8
12.0
Table I. Chemical analysis of MgO-C postmortem brick. On ignited sample (1050 C) by X-ray fluorescence analysis (1) and on
original sample (2).
Mineralogical Investigation
The mineralogical examination performed on polished sections from the brick and crumbly loose material gave indications of the wear mechanisms described below.
Carbon Whisker Formation
In a reducing atmosphere, a high CO partial pressure promotes the formation of new solid carbon precipitations at
temperatures of 600800 C [1]. Especially under the catalytic presence of iron, so-called carbon whiskers with typical
iron droplets at the end had formed (Figures 4 and 5). When
there is a certain level of whisker generation, cracks occur
resulting in the complete destruction of the refractory
material.
CA
1 m
Figure 3. Postmortem MgO-C brick with the cold face uppermost.
Sampling positions for the polished section (1) and chemical
analyses (CA) are indicated.
26 <
Figure 4. Example of carbon whisker formation detected by scanning electron microscopy. Newly formed carbon structures with
the typical bright iron drops at the whisker ends are visible.
Carbon Oxidation
10 m
H2 /H2O ratio
CO/CO2 ratio
1/108 1/107
+O 2
4Fe 3O 4
M
-40
-80
-140
-160
-180
-200
-220
-240
-260
2Cu2O A
4Cu+O2
C
-60
-120
1/106
1/105
1/106
1/105
1/104
S2+O2 SO2 B
+O 2
6FeO
2PbO
2Pb+O 2
2P 3O 4
6Fe 2O 3
B
M
2Ni+O 2
1/103
1/103
1/102
B
2NiO M
2CoO C
M M
2Co+O 2
M
C
O B
Sn+O2 Sn 2
O3 B
B
A
B
2/3Cr 2
2Fe 3O 4
1/
D
4/3Cr+O 2
O
B
2K 2O
3/2Fe+ 2
M
S
M
O C
4K+O 2
M
O C
2Na 2
M
B
2/5P 2 5
B 4Na+O 2
2MnO
+O 2
2ZnO
2Mn+O 2
M T
2/5P 2
O
2
+
n
2Z
B
M
O
Ti 2
Ti+O 2
T
O C
2/3V 2 3
4/3V+O 2
M
S
B
C
SiO 2
B
Si+O 2
B
2/3Al 2O 3
O
2
l+
4/3A
B
M
C
B
2MgO
O C
C
O
2Ca
iO
2Mg+ 2
A
2Ca+O 2
2L 2
O
2
i+
4L
M
M
M
2Fe+O2 2FeO
1/102
200
400
600
800
1000
1200
1400
M
M
D
C B
M
10-80
10-60
10-50
102/1
10-6
104/1
103/1
10-8
10 /1
6
2000
2200
2400
10 /1
7
108/1
109/1
1015/1
1014/1
H2 /H2O ratio
1014/1
10-42
10-38
10-34
104/1
105/1
106/1
1011/1
1012/1
10-12
10-14
10-16
108/1
10-18
109/1
1010/1
10-20
1011/1
10-22
1012/1
10-24
1013/1
10-30
10-10
107/1
1010/1
1013/1
CO/CO2 ratio
10-100
103/1
105/1
Suggested Accuracies
A +/- 1 kcal
B +/- 3 kcal
C +/- 10 kcal
D +/- > 10 kcal
Change of state Element Oxide
M
Melting point
M
B
Boiling point
B
S
Sublimation point
S
T
Transition point
T
1800
10/1
102/1
1600
1/1
10/1
Temperature [C]
Absolute zero
10-200
2CO 2
2H O
2H2+O2 2
M
2C+O
2
2CO
-300
0
2CO+O 2
1
10-1
10-2
10-3
10-4
1/10
1/1
C+O2 CO2
M
-280
PO2 [bar]
1/104
H2 /H2O ratio
-100
1/107
1/10
-20
H2 /H2O
CO/CO2
1/108
CO/CO2 ratio
PO2 [bar]
10-26
10-28
Figure 7. Richardson-Ellingham diagram [1,2]. The free energy of the reaction 2H + O2 2H2O (green line) is at > ~ 670 C, considerably higher than for 2C + O2 2CO (red line), so that carbon is oxidized by steam.
> 27
Conclusions
This postmortem study of a worn MgO-C brick from the
sidewall cold face of a 130-tonne EAF indicated three main
wear factors:
>> Brick decomposition by carbon bursting (carbon whisker
formation).
>> Hydration and decomposition of periclase (possibly
starting during the furnace heat up).
>> Oxidation of the carbon binder.
The three wear mechanisms are only possible at this particular position in the sidewall lining because of the varying
temperature profile, beginning with the lining heat up during production start and the temperature changes during
operation (e.g., the significant influence of the cooling elements as well as differing cooling rates depending on production cycles and idle times).
References
[1] http://www.industrialheating.com/articles/85273-nitrogen-on-site-generation-for-heat-treatment-of-aluminum
[2] White, J. Refractories Research IV, the Thermodynamic Stability of Oxide Refractories. Journal of the Australian Ceramic Society. 1974, Vol. 10,
No. 1, 14.
Authors
Erna Hausner, RHI AG, Technology Center, Leoben, Austria.
Johann Eder, RHI AG, Technology Center, Leoben, Austria.
Marcus Kirschen, RHI AG, Steel Division, Vienna, Austria.
Corresponding author: Erna Hausner, erna.hausner@rhi-ag.com
28 <
Principally, BOF slag has two essential functions: Metallurgical and maintenance, the latter including slag splashing,
washing, or foaming. For an efficient slag maintenance
practice, a (MgO) oversaturated slag with good adherence
to the lining is required. To minimize the wear rate during
the initial stage of slag formation, it is necessary to charge
or rather provide a MgO carrier in the form of fluxes and
avoid <MgO> dissolution from the lining. (MgO) saturation
in the slag is limited by the sequence and amount of lime
addition and hence the slag basicity and tapping temperature. Rising (MgO) levels in the slag result in increased viscosity and lower metallurgical slag activity. The (MgO) slag
level also has an essential influence on the [P]/(P2O5) ratio.
A considerable impact on the [P] levels is noticeable when
the (MgO) content in the slag exceeds more than 6% (Figure
2). As a result, a compromise between refractory wear stabilization and metallurgical requirements has to be found.
Top only
Oxygen lance
Top-blown
(BOF) process
Soft
Strong
Oxygen lance
Combined
Oxygen lance
Bottom only
Oxygen lance
N2
N2
Hydrocarbon
Hydrocarbon
Ar
Ar
Oxygen
Oxygen
Bottom-blown
(OBM or Q-BOP) process
Figure 1. Oxygen steelmaking processes [2]. Abbreviations include oxygen bottom Maxhtte (OBM), which is equivalent to Q-BOP [3].
> 29
0.018
0.014
0.012
Based on visual controls and vessel profile laser measurements, different maintenance methods can be selected
depending on the vessels wear situation. The efficiency of
available maintenance options have been evaluated for the
specific BOF regions in terms of suitability as well as the
machinery investment costs, physical stress on the operator, and metallurgical influence (Table I).
0.010
0.008
0.006
0.004
0.002
0.000
0
10
12
14
16
The differences and similarities between two globally wellestablished BOF operating philosophies are summarized in
Table II. Whilst the top blowing process is characterized by
a higher refractory lifetime, achieved by excessive slag
maintenance using slag splashing, the combined blowing
process focuses on rapid slag formation, increased yield,
higher refining flexibility, and precise process control.
Both processes cause lining wear in similar areas (i.e., slag
line, slag crosses, trunnions, charge pad, and tap pad), with
the exception that combined blowing causes additional
wear to the bottom area. However, slag splashing is performed in a completely different manner for the two processes: Whilst shops running the top blowing process
splash for an extended period of time after almost every
heat, the combined blowing practice requires a much lower
splashing frequency of limited duration.
None
Slag foaming
Manual gunning
Slag
maintenance
Maintenance using
refractory material
Manipulator gunning
++
High
++
+++
++
++
++
None
Intermediate
++
++
++
++
None
None
Intermediate
++
++
++
Low
High
Low
+++
+++
Intermediate
Intermediate
Low
++
++
++
++
++
++
++
++
++
Lip ring
Lower cone
Slag washing
Trunnion
None
Tap pad
High
Slag splashing
Intermediate
Bottom joint
None
Charge pad
Metallurgical influence
None
Upper cone
Method
+
+
+++
+++
Automated gunning
High
Low
Low
+++
+++
+++
+++
++
+++
None
Low
Low
+++
++
++
+++
++
None
Low
Intermediate
+++
++
Appropriate (+), good (++), ideal (+++), and the specific area cannot be maintained with the method (blank)
Table I. BOF maintenance matrix [4] including the investment cost, operator stress, and metallurgical influence.
30 <
Taphole replacement
0.016
O2
O2
(Ar/N2)
System
Oxygen top blowing onto the liquid metal bath combined with
bottom purging elements through which N2 or Ar are injected
Characteristics
Charge pad
Tap pad
Slag line and slag crosses
Trunnions
Charge pad
Tap pad
Slag line and slag crosses
Trunnions
Bottom
80100%
1020%
Up to 5 minutes
13 minutes
Gas/control box
Rotary union
Piping
Bottom purging elements
Key parameter
Combined blowing
process
(%)
10000
4000
- 60
Linings
(no.)
1.0
2.5
+150
0.7
0.3
-57
Yield
(%)
88
92
+5
Re-blow rate
(%)
23
18
-22
Slag weight
(tonne)
14
12
-14
Flux requirement
(kg/tonne crude steel)
63
56
-11
Shorter and quicker reaction pathways between the slag and steel bath
Better slag formation and conditions for flux addition and melting
900
680
-24
0.037
0.034
-8
100%
83%
-17
0.012
0.008
-38
More effective movement of [P] into slag caused by quicker lime dissolution and lower refining temperatures
2[P] + 5[O] + (CaO) (CaO.P2O5)
Lifetime
(heats per campaign)
Explanation
> 31
100
40
35
30
25
20
15
10
5
0
500
1000
1500
2000
2500
3000
3500
4000
(a)
40
20
16
17
18
19
20
21
22
40
35
60
0
0
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
(b)
40
35
80
Conclusion
30
25
20
15
10
5
0
0
500
(c)
1000
1500
2000
2500
3000
3500
4000
References
[1] PLANTFACTS Stahlinstitut VDEh. http://www.stahl-online.de/Deutsch/Stahlinstitut_VDEh/Technische_Fachinformation/Anlagendatenbank.php?Z_
highmain=2&Z_highsub=9&Z_highsubsub=3
[2] Kollmann, T. Influence of Bottom Purging on the Metallurgical Results, Masters Thesis, University of Leoben, Austria, 2010.
[3] Fruehan, R. (Ed) The Making, Shaping and Treating of Steel: Volume 1 - Steelmaking and Refining. 11th edition; AIST Publications: Warrendale, 1998.
[4] Lammer, G., Jandl, C. and Zettl, K. Maintenance MatricesOverview of Common Refractory Maintenance Methods for BOFs and EAFs. RHI
Bulletin. 2011, No. 1, 1217.
[5] Schoeman, E., Wagner, A., Ebner, W. and Berger, M. Implementation of Basic Oxygen Furnace Bottom Purging at Mittal Steel Newcastle. RHI
Bulletin. 2006, No. 2, 711.
[6] Kollmann, T., Jandl, C., Schenk, J., Mizelli, H., Hfer, W., Viertauer, A. and Hiebler, M. Comparison of Basic Oxygen Furnace Bottom Gas Purging
Options. RHI Bulletin. 2012, No. 1, 815.
Reprinted with permission from the Fifth Baosteel Biennial Academic Conference, June 46, 2013.
Authors
Thomas Kollmann, RHI AG, Steel Division, Vienna, Austria.
Christoph Jandl, RHI AG, Steel Division, Vienna, Austria.
Corresponding author: Thomas Kollmann, thomas.kollmann@rhi-ag.com
32 <
form Al2O3. Together with MgO, magnesium aluminate spinel is then generated [2]. These newly formed reaction
products increase the hot strength, thereby having a positive effect on abrasion resistance. Furthermore, oxidation
resistance is increased due to the reduced apparent porosity. However, a disadvantage is the susceptibility of Al4C3 to
hydration (equation 1). This reaction with water (also from
ambient air) can destroy the microstructure and as a consequence the entire brick. As a result, problems can occur
when the vessel is out of operation and has cooled down
for a long period of time.
Aluminium
Aluminium is a very effective antioxidant. It melts at 660 C
and forms Al4C3 and AlN at approximately 800 C. At higher
temperatures Al4C3 decomposes and reacts with O2 or CO to
> 33
High
n Oxidation resistance
n Brittleness
n Chemical durability
Optimum
Low
Antioxidant level
Figure 3. Relationship between the amount of antioxidant and
various brick properties. There is an optimal range of antioxidant
that can be added.
Brick properties
Controlled Expansion
3.0
1800
2.5
1500
2.0
1200
1.5
900
1.0
600
0.5
0.0
Temperature [C]
Silicon
300
0
0
10
15
20
25
30
Time [hours]
Figure 2. Ladle lining showing the disadvantages of antioxidantcontaining MgO-C bricks. (a) standard MgO-C grade and (b)
high-grade antioxidant-containing MgO-C bricks with greater
wear due to spalling.
34 <
Boron Carbide
6010 m
1 mm
(a)
4104 m
(a)
1 mm
(b)
2786 m
1 mm
(b)
Figure 5. Beneficial effect of controlled expansion on brick performance. MgO-C grade (a) without controlled expansion and
(b) with controlled expansion.
(c)
Figure 6. Comparison of the oxidation depth in MgO-C bricks.
Oxidation of carbonaceous components results in increased
matrix porosity at the hot face. The decarburization depth is
indicated (arrows). (a) without antioxidants, (b) with standard
antioxidants, and (c) B4C addition in combination with Al and Si.
> 35
(a)
(b)
Residual lining
thickness [mm]
900 - 950
800 - 850
700 - 750
600 - 650
500 - 550
400 - 450
300 350
200 - 250
100 - 150
0 - 50
Figure 8. Converter wear lining thickness profile. The newly developed ANCARBON F1Q14B (resin-bonded, high-quality fused MgO
brick containing B4C) was tested in large areas at the trunnions and slag line (areas 13 within the red delineated region).
36 <
Other Applications
Apart from resin-bonded MgO-C bricks, antioxidant addition
has also proved to be beneficial for alumina-magnesia-carbon (AMC) bricks. AMC bricks, developed mainly for ladle
bath areas, are characterized by in situ spinel formation
with MgO and demonstrate higher strength compared to
MgO-C. However, they are more brittle and show significantly lower slag resistance. Especially in the impact area of
ladles, deep decarburization and steel infiltration of antioxidant-free AMC bricks have been observed (Figure 9).
The first trials with antioxidant-containing carbon-bonded
MgO-C bricks in EAF taphole and sidewall applications were
successful.
Conclusion
Whilst metal powder additives in carbon-bonded bricks can
have very beneficial effects, the disadvantages must not be
ignored. It is essential to identify the type of primary wear
occurring in the refractory lining and assess if and what
type of antioxidants would be the best countermeasure,
since the wrong application can even reduce performance.
The commonly applied combination of Al and Si is a wellstudied technology and widely used in steel plants. Further
developments including controlled expansion and metal
ceramic bonding are also highly successful for certain applications. However, they must be applied appropriately, taking into account their drawbacks.
References
[1] Routschka, G. and Wuthnow, H. (Eds) Praxishandbuch Feuerfeste Werkstoffe. 5th Edition; Vulkan-Verlag: Essen, 2011.
[2] Baudin, C., Alvarez, C. and Moore, R. Influence of Chemical Reactions in Magnesia-Graphite Refractories: II, Effects of Aluminum and Graphite
Content in Generic Products. J. Am. Ceram. Soc. 1999, 82, No. 12, 35393548.
[3] Watanabe, K., Yabuta, K., Okamoto, H. and Yamamoto, H. Oxidation Behaviour of MgO-C Bricks With Various Additives. Presented at UNITECR
95, Kyoto, Japan, Nov., 1922, Vol. 2, pp. 100107.
[4] Zhang, S., Marriott, N.J. and Lee, W.E. Thermochemistry and Microstructures of MgO-C Refractories Containing Various Antioxidants. J. Euro.
Ceram. Soc. 2001, 21, 10371047.
[5] Majcenovic, C., Eder, J. and Rotsch, J. Microscopic Examination of Premature Wear Caused by Joint Opening and Vertical Crack Formation in
Magnesia-Carbon Steel Treatment Ladle Linings. RHI Bulletin. 2012, No. 1, 3438.
Acknowledgement
The authors would like to express their gratitude to Mr Sizov at NTMK (Russia) for providing Figure 8.
Authors
Andreas Rief, RHI AG, Technology Center, Leoben, Austria.
Stefan Heid, RHI AG, Technology Center, Leoben, Austria.
Matthias Hck, RHI AG, Steel Division, Vienna, Austria.
Corresponding author: Andreas Rief, andreas.rief@rhi-ag.com
> 37
In its most basic form, refractory mix gunning can be performed by plant personnel operating a manual gunning
lance. However, this task in front of a metallurgical vessel at
elevated temperature puts considerable physical and mental stress on the operator. Furthermore, the performance
and accuracy of manual gunning can be problematic, and
due to the limited length of a manual gunning lance, certain
converter areas can be inaccessible.
CONREP
Super
gunning
TERMINATOR
500
SHOOTER
ANKERTWIN
GEKKO
Manipulator
gunning
Hand lance
25
Machine-Assisted Gunning
To overcome these difficulties, specialized machines have
been developed for the purpose of minimizing or even completely eliminating human influence and physical effort. At
the moment, RHI offers a wide range of different manipulators for gunning maintenance and the investment costs are
compared to the gunning equipment performance in Figure 1.
The smallest and most affordable gunning manipulator
TERMINATOR XL
2000
40
150
(a)
(b)
Figure 2. (a) standard ladle and (b) BOF versions of GEKKO. The differences between both versions are detailed in Table I.
38 <
450
Ladle A (standard)
Ladle B
Maximum reach
4.1 m*
4.1 m*
8 m*
Telescopic boom
None
None
Lance movement
Lance height
Water and refractory mixing position
BOF
Nontiltable
Tiltable
Fixed
Fixed
Front end
Front end
Rear end
Table I. Main differences between the individual lance types available for GEKKO. The length from the heat shield to lance tip is indicated (*) and can be extended by 1 m with a different lance type.
692.6 C
96.5 C
97.3 C
117.9 C
88.1 C
80.0 C
Figure 3. Infrared image of GEKKO during a gunning operation.
Lance temperatures are indicated.
> 39
Summary
GEKKO is a cost-effective, highly manoeuvrable gunning
manipulator for both BOF and ladle applications. It enables
the targeted maintenance of prewear areas whilst minimizing physical operator stress. Following its market introduction in 2011, GEKKO has been a continual maintenance
method at ArcelorMittal Bremen and additional European
steel plants are benefiting from its compact, reliable capabilities.
Authors
Gregor Lammer, RHI AG, Steel Division, Vienna, Austria.
Christian Spiel, RHI AG, Steel Division, Vienna, Austria.
Alexander Ratz, RHI AG, Steel Division, Vienna, Austria.
Corresponding author: Gregor Lammer, gregor.lammer@rhi-ag.com
40 <
RH Degassing Process
Steel grade/application
Characteristics
Rail steel
Tube steel
Electrical steel
Interstitial-free steel
Vacuum chamber
Burner
opening
Leg
Recirculating steel
Alloy
chute
Bottom
Vacuum
Upper
vessel
Inert gas
injection
Inlet snorkel
Lower
vessel
Leg
Bottom
Snorkel
Outlet snorkel
Ladle
Figure 1. RH degasser.
> 41
RH Degasser Lining
The RH degasser is lined with various types of magnesiachromite bricks, selected to meet the specific wear mechanisms occurring in different areas of the reaction vessel. For
example, the snorkel is subjected to thermal shock, erosion,
and corrosion, whilst bricks in the lower and upper vessel
must withstand redox reactions.
During operation, thermal expansion of the wear lining
bricks in the bottom area can cause the bricks to lift, since
they are constrained by the external metal shell (Figure 3).
In addition, stresses resulting from brick expansion in the
Centre piece
Steel infiltration at
damaged throat bricks
Steel shell
Bricks constrained
at knuckle
Lifting bricks
(a)
(b)
Figure 3. Schematic diagram of the brick lining in the bottom region of a RH degasser. Section through (a) legs and centre piece and
(b) bottom region perpendicular to the legs. Potential steel infiltration is indicated in red.
42 <
Knuckle Region
The brick shape and bricklaying in the knuckle region were
also modified (see Figures 4b and 7). This dissipates any
(a)
thermomechanical stress up into the lower vessel wall lining, providing additional benefits. The new vessel bottom
and lower wall working lining design is depicted in Figure 8.
(b)
Figure 4. Schematic diagram of the bottom wear lining. Sections through the (a) old and (b) new lining designs.
> 43
(a)
(b)
Figure 7. (a) knuckle brick installation and (b) completed knuckle brick ring.
Summary
References
[1] http://www.millennium-steel.com/articles/pdf/2008/pp104-108%20MS08.pdf
[2] Marschall, H.U. and Jandl, C. Design Evaluation of BOF Linings With the Aid of Thermomechanical Simulation. RHI Bulletin. 2010, No. 2, 1519.
Authors
Alain St-Jacques, RHI Canada Inc., Burlington, Canada.
Michael Heiligenbrunner, RHI AG, Technology Center, Leoben, Austria.
Corresponding author: Alain St-Jacques, alain.st-jacques@rhi-ag.com
44 <
Bernd Trummer, Leopold Kneis, Michael Pellegrino, Michael Klikovich and Martin Kresadlo
(a)
(b)
Introduction
The introduction of bottom gas purging into ladle metallurgy was a major step in steel secondary metallurgy. Purging plugs were integrated into the ladle bottom in order to
feed purging gas into the liquid steel. From a refractory
standpoint, two major design families were established:
Plugs for cold exchange and plugs for hot exchange. Bottom
gas purging started with cold exchangeable purging ceramics, which were considered to be maximally safe in operation. Their design allows plug exchange only when the ladle
is taken out of circulation and completely cooled down.
Therefore, numerous ladles are necessary to keep productivity at a high level. The implementation of hot exchangeable
plugs was a revolution that significantly improved productivity. The time necessary to get the ladle back into circulation
after plug exchange dropped dramatically from a minimum
of two days to about half an hour. However, major safety
concerns had to be resolved. The closing system was introduced into the ladle bottom to guarantee high productivity
and high safety during operation.
(c)
(d)
Figure 1. Overview of RHI closing systems for ladle purging
ceramics (a) wedge gate closing system where the purging plug
is held in position by a removable closing plate locked with
wedges, (b) bayonet hinged cover where the purging plug is
held in position by a hinged cover that is bayonet locked and
secured by a bolt, (c) bayonet system where the purging plug is
held in position by a bayonet locked closing plate that is secured
by a bolt, and (d) SOC-System where the purging plug is held in
position by a removable cover that is secured by four bolts.
> 45
Wedge gate
Bayonet hinged
cover
Bayonet
SOC-System
SOC-H System
Safety level
++
+++
+++
Operator handling
++
+++
++
++
+++
+++
++
++
+++
Operational safety
+++
+++
++
+++
Implementation time
++
+++
+++
++
++
System costs
+++
+++
+++
++
++
Maintenance efforts
+++
++
++
++
++
Main features
Additional features
Gas
Gas seal
Interlocking device
Spindle
Locked position
Holding ring
with hinge
Locking plate
Base plate
46 <
prevents any steel infiltration into the plug caused by pressure fluctuations in the gas supply. The purging gas is fed
via the check valve into this configuration.
Purging Plug With Refractory Distance Ring and Safety
Check Valve With Standard Gas Connection
Safety pad
Safety pad
(c)
Gas connection
with internal check valve
(b)
Distance ring
Exchangeable safety
check valve
(d)
Distance ring
Figure 3. (a) purging plug with a safety pad and gas connection without a check valve, (b) purging plug with a safety pad and gas
connection with an internal check valve, (c) purging plug with a distance ring and safety check valve with a standard gas connection,
and (d) purging plug with a distance ring and exchangeable safety check valve with a standard gas connection.
> 47
(a)
(b)
(c)
(d)
(e)
(f)
Figure 5. Schematic demonstration of plug installation using the SOC-H setting device. (a) install RHI plug in centreline of SOC-H,
(b) shut closure plate, (c) turn locking device to keep locking plate closed, (d) tighten spindle clockwise to secure plug into position,
(e) tighten gas connection, with threaded gas seal, using hook wrench, and (f) mount interlocking device to secure locking device.
48 <
(a)
(b)
(c)
(d)
(e)
(e)
(f)
Figure 7. Schematic demonstration of plug removal with the SOC-H extraction device. (a) open threaded gas seal with a hook wrench,
(b) turn spindle counterclockwise to release gas connection, (c) remove interlocking device, (d) unlock locking device by turning,
(e) open closing plate, and (f) remove plug with RHI extraction device.
> 49
(a)
Summary
SOC-H is the new state of the art ladle gas purging system
from RHI, which has recently been introduced into the market. It consists of purging ceramics, a safety closing system,
a gas connection with internal check valve, plug setting and
plug extraction devices, with additional tools and equipment necessary for a safe, reliable, and easy to handle ladle
purging system. SOC-H has proven its efficiency in tests in
several steel mills and has been installed on all ladles at the
brand new Outokumpu Americas steel mill in Alabama.
Since the startup of this new steel mill in November 2012,
SOC-H has demonstrated its reliability.
(b)
Figure 8. Purging plugs with SOC-H gas connection adaptor. (a) SOC-H purging plug for use with a safety pad or exchangeable check
valve and (b) SOC-H with fixed check valve.
Authors
Bernd Trummer, RHI AG, Steel Division, Vienna, Austria.
Leopold Kneis, RHI AG, Steel Division, Vienna, Austria.
Michael Pellegrino, Veitsch-Radex America Inc., Steel Division, Hammond, USA.
Michael Klikovich, RHI AG, Steel Division, Vienna, Austria.
Martin Kresadlo, RHI US Ltd., Steel Division, Pittsburgh, USA.
Corresponding author: Bernd Trummer, bernd.trummer@rhi-ag.com
50 <
SiO2
Depending on the precise composition of the coating material, the typical reactions occurring with corundum or magnesia are given in the sections below.
1698
Two liquids
52 <
1698
1470
Mullite
Trd
0
140 1210 1205 Fe2Al4Si5O18
1083
1380
Iron cordierite
1470
1178
1088
1200 Fa
Fe2SiO4 (1205 )
1150
1177
0
1200
150
1148
Wustite
Hercynite
170
0
(1369 )
0
FeO
20
40
wt.%
Al6Si2O13
(~1850 )
~1840
Corundum
190
Crs
160
0
Corundum
(1723 )
~1590
FeAl2O4
(~1780 )
~1750
80
(~2020 )
100
Al2O3
Figure 2. Phase diagram of FeO, Al2O3, SiO2 showing the influence of iron oxide on the melting temperature [2].
(a)
(b)
Figure 3. Surface detail of a purging plug with (a) standard polished steel cone and (b) refractory coating on the cone.
(a)
(b)
Figure 4. Mortar application to (a) the standard stainless steel cone and (b) a cone with refractory coating.
Summary
Repairing a worn well block by gunning or casting is mandatory to achieve high purging ceramic lifetimes. Tight
bonding between the repair mix and plug surface assures
proper support and results in low wear of the replacement
plug. Otherwise a gap between the gunning repair and
plug forms that will speed up wear of the repair at a later
stage.
References
[1] Kneis, L., Trummer, B. and Knabl, B. The Hybrid Plug An Innovative Purging Plug for Steel Ladles. RHI Bulletin. 2004, No. 1, 3438.
[2] Osborn, E.F. and Muan, A. Oxide Phases in Equilibrium with Metallic Iron, Phase Equilibrium Diagrams of Oxide Systems, Plate 9; The American
Ceramic Society and the Edward Orton, Jr., Ceramic Foundation; Columbus, Ohio, 1960.
Authors
Bernd Trummer, RHI AG, Steel Division, Vienna, Austria.
Michael Pellegrino, Veitsch-Radex America Inc., Steel Division, Hammond, USA.
Leopold Kneis, RHI AG, Steel Division, Vienna, Austria.
Corresponding author: Bernd Trummer, bernd.trummer@rhi-ag.com
> 53
v2
Fr = .
gl
(1)
Parameter
Symbol
Description
tMIN (sec)
MIN (-)
Peak time
tPEAK (sec)
PEAK (-)
Time at which the peak concentration of the tracer occurs at the outlet.
AV (-)
tAV (sec)
Weighted average of the RTD curve. The value for the mean residence time, up to twice the theoretical
residence time, is important to calculate the dead flow fraction.
VP (%)
Flow with the same residence time. No longitudinal mixing exists (back mixing effect).
VM (%)
VD (%)
Corresponds to the volume in a tundish that is moving very slowly and therefore nearly stagnant.
54 <
The Model
Comprising all the aforementioned phenomena, a state of
the art tundish water model was established at the Technology Center Leoben (Austria). The model is setup in such a
manner that any specific tundish geometry, ranging from a
single strand slab up to an eight strand billet tundish, can
be investigated. This provides the basis for tailored product
development. Each process variable, such as the water temperature, the throughput of incoming water through the
ladle shroud, the throughput exiting each individual strand
as well as the level in the tundish are accurately controlled
by a PC. The highly automated setup guarantees an accurate operation and is indispensable for reproducing any
result. A front view of the model during a dye injection test
and the PC control interface can be seen in Figure 1.
(a)
Modelling Examples
Typical examples of modelling results for steady-state and
transient casting conditions are described in the following
sections.
Dye Injection
The method of measuring the residence time distribution
(RTD) is a very common practice to assess tundish performance during steady-state conditions. In such studies a
tracer (e.g., dye) is injected into the incoming water stream
and its concentration at the exit is recorded as a function of
time. Besides the concentration measurement, a video is
recorded synchronously to generate a visual impression of
the general flow characteristics. Using this approach, differences between furniture configurations can be efficiently
studied. As an example, the comparative setup and general
flow in a bare and TUNFLOW-equipped single strand
tundish are shown in Figure 2. The corresponding RTD
(b)
Figure 1. (a) snap shot during a dye injection test and (b) PC control interface.
(a)
(b)
Figure 2. Snap shot during a dye injection test. (a) bare tundish and (b) tundish equipped with TUNFLOW.
> 55
n Bare
n TUNFLOW
Dimensionless concentration
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
VD
(b)
0.5
1.0
1.5
2.0
2.5
3.0
3.5
Dimensionless time
(a)
Bare
TUNFLOW
34.3
21.4
VP
8.4
31.6
VM
57.2
47.0
MIN
0.08
0.13
AV
0.73
0.88
VP/VD
0.24
1.48
(a)
(a)
(b)
56 <
(b)
Figure 5. Top view showing the tundish surface above the impact
zone. (a) competitor impact pot and (b) optimized TUNFLOW
design.
Vortex Formation
Slag carryover is an issue especially when the tundish level
decreases during a ladle change or at the end of casting.
However, improper installation of tundish furniture can also
lead to vortex formation and consequently slag transfer
down to the mould during steady-state operating conditions.
With the aid of water modelling such unfavourable flow conditions can be revealed and measures to minimize the detrimental effects can be undertaken. Figure 7 shows the behaviour during tundish draining. The formation of strong swirling and the onset of vortex formation above the strand exit
could be visualized following dye injection (Figure 7a). When
the tundish level was further reduced, strong vortex development was seen during the video footage. It caused
entrainment of the lightweight particles initially floating on
(a)
(b)
Figure 6. The impact on emulsified slag transport in the (a) bare
tundish and (b) tundish equipped with TUNFLOW.
Conclusions
As a global partner for the steel industry, RHI is always
striving to offer the best customer solutions, based on individual conditions and needs. Technology in the steel industry is constantly developing and topics such as clean steel
are becoming ever more important. This is affecting all metallurgical vessels including the tundish. Simulation techniques can help further develop existing products or invent
new solutions in an efficient way. Not only do they save
costs, but also time. With the aid of a water modelling facility at the Technology Center Leoben, as well as extensive
experience with CFD simulation, RHI is in the best position
to develop the most appropriate and tailored technological
solutions for steel customers worldwide.
(a)
(b)
Figure 7. (a) vortex formation during draining and (b) entrainment of lightweight particle.
References
[1] Sahai, Y. and Emi, T. Melt Flow Characterization in Continuous Casting Tundishes. ISIJ International. 1996, 36 No. 6, 667672.
[2] Ahuja, R. and Sahai, Y. Fluid Flow and Mixing of Melt in Steelmaking Tundishes. Ironmaking and Steelmaking. 1986, 13, 241247.
[3] Mazumdar, D. and Gutherie, R. I. L. The Physical and Mathematical Modelling of Continuous Casting Tundish Systems. ISIJ International. 1999,
39, No. 6, 524547.
Authors
Gernot Hackl, RHI AG, Technology Center, Leoben, Austria.
Wolfgang Fellner, RHI AG, Technology Center, Leoben, Austria.
Bernd Petritz, RHI AG, Technology Center, Leoben, Austria.
Corresponding author: Gernot Hackl, gernot.hackl@rhi-ag.com
> 57
Aida Mahmutovi, Johann Eder, Maid Henjakovi, Izet Kari and Omer Kablar
Nominal/unbending radius
9 m/16 m
1100 mm
Productivity
140 tonne/hour
120 mm x 120 mm
130 mm x 130 mm
Billet length
612 m
Casting method
Open stream
Submerged casting
Casting speed
45 m/min
Lubrication
Oil
Ladle capacity
120 tonne
Anchors
Tundish capacity
26.3 tonne
Steel shell
800 mm
Mould
Curved 1000 mm
58 <
150
200
300
150
300
Investigation Methods
Several areas of the postmortem sample were investigated
by chemical and mineralogical test methods [2]. Chemical
analyses were performed on areas CA1 and CA2 using
X-ray fluorescence (XRF) after dissolution of the sample in
Li2B4O7.
CA2
1
2
CA1
The mineralogical investigations were carried out on polished sections, prepared from areas 1 and 2, using an optical light microscope and scanning electron microscopy
(SEM), combined with an energy dispersive X-ray (EDX)
analyser to provide chemical microanalyses.
Chemical Analyses
The chemical analyses carried out on areas CA1 and CA2
(see Figure 3) are detailed in Table III. In region CA1, just
Figure 3. Postmortem sample of the ANKERTUN 217 working lining after 19 casting sequences [2]. The hot face is uppermost
and the slag line position is at area 1.
General information
Brand/raw materials
Sampling position
Determination
by XRF
ANKERTUN 217
Olivine, dead burned magnesia
CA1
(below slag line)
CA2
(above slag line)
Typical values
(wt.%)
(wt.%)
(wt.%)
0.12
0.24
Na2O
TERMEX B
Tundish slag
SiO2
CaO
MgO
31.036.0
0.6
45.049.0
29.6
42.6
21.48
MnO
MgO
51.0
66.9
78.8
Al2O3
7.25
1.81
0.5
SiO2
24.1
20.1
16.0
P2O5
0.05
0.04
SO3
0.29
0.19
CaO
14.1
7.13
TiO2
0.21
0.06
Cr2O3
0.13
0.15
MnO
0.25
0.06
Fe2O3
2.37
3.06
NiO
0.06
0.09
2.2
2.5
Table III. Chemical analyses of the ANKERTUN 217 working lining below and above the slag line. The X-ray fluorescence analysis was performed on an ignited sample (1050 C).
FeO
Al2O3
P2O5
Fe
1.5
1.65
1.44
3.02
Fe2O3
7.08.0
0.087
0.098
1.12
Table II. Chemical composition (wt.%) of the TERMEX B tundish cover powder [1] and tundish slag.
> 59
Mineralogical Investigation
Polished sections from areas 1 and 2 (see Figure 3) were
examined by light microscopy (Figures 4 and 7). SEM-EDX
analyses were performed on areas A and B (Figures 5 and 6)
at the slag line, and area C (Figure 8) above the slag line.
At the slag line, infiltration by CaO-rich slag was evident,
resulting in corrosion of MgO grains (see Figure 5). The formation of magnesium aluminate (MA) spinel (MgAl2O4) was
also detected. The dominant phase was the lower melting
point monticellite (CaMgSiO4), following reaction of the forsterite (Mg2SiO4) with infiltrating slag components; relics of forsterite were clearly visible. At discrete positions the appearance of fluoride-containing calcium silicate was detected
(Table IV). In the phase system periclase-forsterite-monticellite-MA spinel, the melting point of the quaternary eutectic
mixture is 1425 C. However, in the presence of fluoride, the
first melting phases can occur at even lower temperatures.
Rounded pores were evident, due to the high chemothermal
load, which would negatively impact on the matrix stability.
In area B (Figure 6), densification of the matrix due to slag
infiltration was clearly visible, in addition to the dominating
monticellite phase (Table V).
By comparison, the ANKERTUN 217 above the slag line
showed a more uniform structure, with a lower level of slag
infiltration (Figure 7). Whilst the start of olivine and MgO
corrosion was visible (Figure 8), the amount of monticellite
formation was lower and no fluorine-containing compounds
were detected (Table VI).
5
6
11
Figure 5. Scanning electron micrograph showing the microstructural detail of area A (see Figure 4). Several rounded pores are
visible, caused by chemothermal load due to infiltration by CaOrich slag. Monticellite (1) is the dominating phase in this area.
The relic of a magnesia grain (2), fluoride-containing calcium silicate (3), a forsterite relic (4), and MA spinel (5) are indicated.
6
3
5
4
Figure 6. Scanning electron micrograph showing the microstructural detail of area B (see Figure 4). A high level of matrix densification is evident, caused by infiltration of the CaO-rich slag.
Monticellite (2) is the dominating phase in this area. Forsterite
(3), single periclase (MgO) crystals after corrosion (4), fluoridecontaining calcium silicate (5), MA spinel (6), and the relic of an
olivine grain (7) are indicated.
60 <
1
2
Therefore, the following process modifications were performed or suggested to increase the lining durability.
Spot or area
MgO
28.8
93.3
SiO2
CaO
40.1
29.4
TiO2
MnO
Fe2O3
2.0
4.7
32.7
51.6
0.7
50.8
42.7
3.7
2.1
0.7
28.1
68.7
1.0
0.7
17.5
23.5
36.7
18.1
1.3
1.2
27
4.3
35.4
28.2
1.9
0.9
2.2
Cr2O3
1.7
4.3
Area A
10.7
Al2O3
Figure 8. Scanning electron micrograph showing the microstructural detail of a region in area C (see Figure 7). The start of magnesia (2) and olivine (3 and 5) corrosion is evident. The formation of monticellite (1) is indicated.
1.6
1.4
Table IV. SEM-EDX microanalyses (wt.%) of the area and spots in Figure 5. The fluorine results are semiquantitative and the total iron
was calculated as Fe2O3.
Spot or area
Area B
MgO
Al2O3
SiO2
CaO
2.5
42.7
3.2
30.6
TiO2
MnO
Fe2O3
17.6
1.8
1.6
26.8
39.8
30.9
1.8
0.7
51.6
42.4
3.7
1.5
0.9
93.8
1.7
4.5
1.3
1.5
1.5
1.1
5.0
13.8
28.0
49.6
35.4
45.8
68.5
0.8
40.5
7.3
Table V. SEM-EDX microanalyses (wt.%) of the area and spots in Figure 6. The fluorine results are semiquantitative and the total iron
was calculated as Fe2O3.
Spot or area
MgO
Al2O3
SiO2
CaO
TiO2
MnO
Fe2O3
28.2
40.1
31.7
93.6
0.9
0.6
4.9
53.4
43.0
3.0
0.6
23.7
5.5
2.9
53.9
43.1
1.8
1.2
Area
53.7
30.6
12.9
2.9
23.6
0.8
0.4
42.5
Cr2O3
0.6
Table VI. SEM-EDX microanalyses (wt.%) of the area and spots in Figure 8. The fluorine results are semiquantitative and the total iron
was calculated as Fe2O3.
> 61
Summary
A postmortem evaluation of the ANKERTUN 217 slurry gunning mix was performed to examine potential processes
affecting the tundish working lining durability. The results
of both chemical and mineralogical analyses indicated that
the casting sequence and steel cleanliness at AMZ can be
improved by:
>> Changing the tundish cover powder composition to
minimize the slag corrosivity.
>> Installing an ANKOFORM S90 0-6 protection plate to
reduce erosion of the tundish front wall.
>> Using an alternative wet slurry gunning mix with no
forsteritic component.
>> Installing an electromagnetic slag detection device at
the ladle.
Adopting the listed measures should lead to future productivity and quality improvements.
References
[1] TERMEX B data sheet. EXOTERM-IT d.o.o., Kranj, Slovenia. http://www.exoterm-it.si/prospekti/eng/TERMEX_B.pdf
[2] Eder, J. Postmortem Investigation of an ANKERTUN 217 Sample, Out of a Tundish at Arcelor Mittal Zenica, Bosnia-Herzegovina, October 2011.
Internal Report. RHI AG, Technology Center, Leoben, Austria.
[3] http://www.amepa.de/
Acknowledgement
The authors would like to express their appreciation to Termomatik-Toplotehnika Zenica (Bosnia and Herzegovina) for their technical assistance.
Authors
Aida Mahmutovi, Faculty of Metallurgy and Materials Science, University of Zenica, Bosnia and Herzegovina.
Johann Eder, RHI AG, Technology Center, Leoben, Austria.
Maid Henjakovi, Termomatik-Toplotehnika d.o.o., Zenica, Bosnia and Herzegovina.
Izet Kari, amoter d.o.o., Zenica, Bosnia and Herzegovina.
Omer Kablar, ArcelorMittal Zenica, Bosnia and Herzegovina.
Corresponding author: Aida Mahmutovi, aida.mahmutovic@famm.unze.ba
62 <
Flavio Campagnoli, Daniel Merigo, Veniero Mori, Massimiliano Di Cosmo and Angelo Zingre
Concept
Carrier
Parallel drive
Hydraulic cylinder
> 63
(a)
(b)
(c)
(d)
Figure 3. (a) casting position, (b) new nozzle inserted prior to change, (c) nozzle change, and (d) temporary strand closing/end of cast.
Grade
Remark
Well Block
JUSTAL DS1028
Standard
JUSTAL DS6028
JUSTAL DS7028
JUSTAL DS1015
Standard
JUSTAL DS6015
Exchangeable Nozzle
Gasket
Annual production
500000 tonnes
2 x 5 strand Danieli
8 x 90 tonnes
INTERSTOP CS 60-R
9 x 20 tonnes
MNC
(a)
Well block
Gasket
Exchangeable nozzle
(b)
Figure 4. (a) parallel drive arrangement and (b) clear view to the
nozzle.
(a)
Figure 7. MNC-RSP mounted on the tundish using the preexisting mounting car.
(b)
> 65
Conclusion
The new INTERSTOP MNC-RSP, with its innovative features,
successfully passed the initial hot operation at Ferriera
Valsabbia. As a result the customer decided to operate the
MNC-RSP on a larger scale. The MNC-RSP system has been
running on a fully equipped tundish since March 2013.
(a)
(b)
(c)
Figure 9. Tundish at the continuous casting machine.
Authors
Flavio Campagnoli, Ferriera Valsabbia SpA, Odolo, Italy.
Daniel Merigo, Ferriera Valsabbia, SpA, Odolo, Italy.
Veniero Mori, RHI Italiana, Steel Division, Brescia, Italy.
Massimiliano Di Cosmo, Stopinc AG, Hnenberg, Switzerland.
Angelo Zingre, Stopinc AG, Hnenberg, Switzerland.
Corresponding author: Angelo Zingre, angelo.zingre@rhi-ag.com
66 <
Low Frequency
Typically, refractories are heterogeneous, comprising various raw materials with a range of grain sizes (i.e., macro to
microscopic). The materials are highly attenuative, excessively scattering frequencies above 300 kHz. Therefore, very
low frequency ultrasound is required (i.e., 50200 kHz) to
test refractories.
Testing Methods
The main testing method used for refractories is direct
transmission. The ultrasonic pulse signal is emitted from a
transducer on one side of the sample and a second transducer, positioned on the opposite side, detects the transmitted signal. The transmission time (t), calculated by the ultrasonic device, provides information about the material properties and any abnormalities in the signal path (Figures 1
and 2). A limitation of this technique is that if the path
length is long but the defect is very short it can be difficult
to detect the flaw because there is insufficient difference
between the original (t) and altered (t1) transit times. The
ultrasonic signal amplitude determined at the receiver indicates energy consumption of the ultrasonic pulse after it
has travelled along the path through the refractory material.
Transmission
Pulse echo
Pulse time
Pulse-echo time
Ultrasonic velocity
Elastic material properties
Ultrasonic velocity
Elastic material properties
2 transducers
(a)
1 transducer as
sender/receiver
(b)
Figure 1. Comparison of the (a) transmission and (b) pulse-echo ultrasound equipment setup.
> 67
t
v=
L
(m/s)
(1)
Receiver
Transmitter
wave) transducer, whilst a shear wave transducer is necessary for the shear modulus. The Poissons ratio is calculated
using:
= E 1
2G
(2)
E = v2l . r .
(1+ )(1 2)
(3)
(1 )
(a)
Input signal
Received signal
Ultrasonic data can be detected and displayed using a number of different methods (Figure 3) [4]. The most commonly
used are:
>> A-scan: One position.
>> B-scan: Consecutive positions along a line.
>> C-scan: Multiple positions covering an entire planar
surface.
Transmitter
Receiver
(a)
(b)
(b)
Input signal
Received signal
68 <
(c)
Figure 3. Ultrasonic detection and display methods. (a) A-scan,
(b) B-scan, and (c) C-scan. Arrows indicate the position of signal
transmission. The receiver is positioned at an appropriate position either on the opposite surface for transmission or on the
same surface for pulse echo.
dH[mm]
17
0,04
L [mm 385
365
24,3
Publikation:
The magnesia chromite brick was examined using C-scan
Figure 4. Magnesia chromite brick sample showing grid mea
transmission ultrasound with dry contact coupling. The
surement positions.
results presented are measurements taken using a 6 x 16
point grid positioned on the largest brick face, namely in the
pressing direction (Figure 4). The ultrasonic velocity measureLength
Length 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 1010 1111 1212 1313 1414 1515 1616
ments for the 96 positions are presented two-dimensionally in
Figure 5, with colour coding indicating lower (red) to higher
Row
Row1 1 2687 2780 2778 2750 2813 2748 2672 2787 2711 2769 2807 2872 2789 2812 2661 2583
(green) velocities. The lower velocities are indicative of cracks
Row 2 2 2676 2692 2641 2617 2723 2697 2620 2771 2687 2730 2802 2776 2824 2732 2648 2563
or inhomogeneities. The data is visualized as a map in Figure
Row 3 3 2634 2661 2729 2723 2585 2712 2742 2802 2843 2739 2705 2682 2761 2732 2648 2422
6. An ~ 400 m/s decrease in the ultrasonic velocity along the
region in row 6 was clearly evident. This region was further
Row 4 4 2579 2552 2592 2667 2623 2672 2697 2771 2720 2856 2763 2612 2723 2665 2623 2458
investigated by cutting the brick along the white line indicated
Row 5 5 2619 2671 2697 2713 2618 2692 2653 2663 2750 2696 2580 2607 2669 2626 2614 2483
in Figure 6. Optical inspection confirmed a conspicuous
region (Figure 7) in the area where lower velocities had been
Row 6 6 2342 2447 2455 2501 2453 2477 2505 2343 2410 2337 2330 2431 2427 2548 2558 2465
recorded. In this region the fine grain content was reduced
compared to the neighbouring brick structure.
Testing Equipment
Figure
Figure5.
6: Ultrasonic velocity measurements (m/s) recorded in the
pressing direction. The colour coding indicates lower (red) to
higher velocities (green).
Length 1
Row 1
10
11
12
13
14
15
16
Width Pos.1
Row 2
Pos. 2
Row 3
Pos. 3
Row 4
Pos. 4
Row 5
Pos. 5
Row 6
Pos. 6
1
10
11
12
13
14
15
16
Testing Procedures
The following ultrasonic testing procedures were examined,
and in certain cases compared:
>> C-scan dry contact coupling using the transmission
technique.
>> C-scan noncontact air coupling using the transmission
technique.
> 69
y [mm]
220
200
t [s]
180
(a)
80
100
120
140
180
100
80
60
y [mm]
40
20
160
100
200
250
300
x [mm]
50
100
150
200
x [mm]
60
t [s]
150
100
140
180
(b)
100
80
60
y [mm]
40
20
50
100
150
200
x [mm]
70 <
shown in Figure 14 was submerged in a water-filled container. A 2-MHz pressure wave (longitudinal wave) transducer was used that provided high structural resolution.
The sample was rotated about its axis and the transducer/
receiver remained stationary.
300
600
650
350
700
750
t [s]
t [s]
400
450
800
850
500
900
550
600
-150
950
-100
-50
50
100
x [mm]
(a)
1000
-150
150
-100
-50
50
100
150
50
100
150
x [mm]
(a)
300
600
650
350
700
750
t [s]
t [s]
400
450
800
850
500
900
550
600
-150
(b)
950
-100
-50
50
100
1000
-150
150
x [mm]
Figure 11. B-scans of two cement rotary kiln bricks. The measurements were obtained using air-coupled ultrasound with the transmission technique. The y axis represents the transit time (t) and the
x axis shows the lateral position of the measurement points along
the brick. The grey scale indicates the ultrasonic signal amplitude.
Red circles mark positions in the bricks containing inhomogeneities.
(b)
-100
-50
x [mm]
Figure 13. B-scans of two cement rotary kiln bricks. The measurements were obtained using air-coupled ultrasound with the pulseecho technique. The transit time measurements start where the
black/white contrast regions (i.e., amplitude) are depicted in the
images. The red circles (b) mark positions in the brick containing
inhomogeneities.
> 71
350
300
250
y [mm]
200
150
100
50
0
50
100
150
200
250
300
350
x [mm]
Figure 16. Cross section image of a slide gate plate. Point-like
and line-shaped structures are visible.
Figure 17. Cut section through the slide gate plate in a region
where a line-shaped structure was detected using ultrasound. On
close examination the structure was not a crack.
z [mm]
80
90
100
100
y [m
m]
80
50
100
150
200
250
3000
350
x [mm]
Figure 15. C-scan depicting the 3D data as a flat projection of the cylindrical stopper nose. The arrows mark positions where accumulations of inhomogeneities were detected.
72 <
Future Perspectives
The comprehensive analyses of multiple ultrasound testing
setups and coupling techniques indicated the following:
>> Dry contact coupling provides the possibility for very
fast C-scan analysis of refractory shapes. This advantageous property will be developed in further collaborations with MFPA Weimar.
>> Whilst air coupling generates useful results, automation
of this technique is more difficult because the distance
between the sample and transducer requires optimization.
>> Water coupling produces the highest resolution and the
option for 3D imaging, therefore this technique will also
be explored in future studies.
In conclusion, ultrasonic testing of refractories provides
information about both the material properties and material
structure in one step. It is therefore an invaluable tool for
refractory development as well as quality assurance in the
production plant and will continue to be a focus of nondestructive testing at RHI.
References
[1] Samokrutov, A.A., Shevaldykin, V.G., Bishko, A.V., Pluzhnikov, A.I. and Lobachev, A.S. Testing Technology of Fire-Resistant Objects Using
Ultrasonic Low-Frequency Antenna Arrays. Presented at 9th European Conference on NDT (ECNDT), Berlin, Germany, 2529 Sept., 2006. Berlin:
Deutsche Gesellschaft fr Zerstrungsfreie Prfung (DGZfP), CD-ROM, 2006, 15.
[2] http://www.ndtint.com/Basic%20UT%20Principles.PDF
[3] Royer, D. and Dieulesaint, E. Elastic Waves in Solids I; Springer: New York, 2000.
[4] http://www.ndt-ed.org/EducationResources/CommunityCollege/Ultrasonics/EquipmentTrans/DataPres.htm
[5] http://www.dr-hillger.de/PDF/Flexus_e.pdf
Authors
Christian Manhart, RHI AG, Technology Center, Leoben, Austria.
Martin Schickert, Institute of Materials Research and Testing (MFPA Weimar), Bauhaus Universitt Weimar, Germany.
Gerhard Urbanek, RHI AG, Technology Center, Leoben, Austria.
Corresponding author: Christian Manhart, christian.manhart@rhi-ag.com
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