Refractories and Industrial Ceramics Vol. 50, No.

2, 2009

IMPROVEMENT IN THE STEEL-POURING LADLE LINING LIFE

IN OPEN-HEARTH PRODUCTION OF ZAO METALLURGICAL PLANT
PETROSTAL’

V. A. Kononov,1 N. V. Kononov,1 S. N. Skrobov,2 and O. A. Salomakhin2

Translated from Novye Ogneupory, No. 4, pp. 66 – 72, April 2009.

Original article submitted September 22, 2008.

Basic principles are considered for the development of refractory linings for steel-pouring ladles operating un-
der severe conditions using a furnace-ladle unit. Joint action of personnel of the metallurgical enterprise and
refractory supplier makes it possible to determine the local area of lining wear and to adopt timely measures
for improving life. The effect of the main factors governing wear is determined. The order of selecting the re-
quired standard sizes and quality indices for objects taking account of the type of metal smelted is determined.
Keywords: refractory lining, slag belt, local wear.

As a result of technical progress in the field of refractory
production the possibility has developed not only of improv-
ing metal quality, but also reducing expenditure connected
with steel-pouring ladle lining operation, in particular those
operating under conditions of furnace-ladle installations and
metal evacuation.
Refractory consumption for lining ladles in metallurgical
enterprises with a complete cycle is about one quarter of all
refractory consumption (in absolute value and cost) [1]. The
overall expenditure for traditional ladle refractories in the
cots of Russian metal was previously 1.5 – 2.0%, and there-
fore a insufficient attention has been devoted used to saving
refractories. A long life for a lining has a marked effect the
non-metallic inclusion content in metal.
Currently the expenditure on acquiring contemporary
refractories is 4 – 7% of metal cost. An increase in metal cost
may be balanced by a reduction in specific refractory con-
sumption due to the use of modern methods for lining opera-
tion and new standard sizes for refractory objects.
For effective operation of carbon-containing refractories
it is necessary to have a high-temperature unit for warming
up refractories. A lining warm-up unit may be horizontal or
vertical. Expenditure in installing a high-temperature unit is
repaid in 6 – 8 months. Each uint is equipped with a heat-pro-
tective cover in order to avoid heat loss during pouring.
The carbon-containing composition refractories used in
contemporary linings do not exhibit high heat resistance and
during operation they should not be cooled to lower than
1 Russian metallurgists mainly use imported refractories.
Company Shiber, Moscow, Russia.
2
ZAO MZ Petrostal’, St. Petersburg, Russia.
800°C. With presence in some cycles of cooling below
800°C there may be some reduction in lining life.
The life of refractory linings used in furnace-ladle de-
vices is determined by a group of factors, each of which
should be considered in lining operation. These are factors
connected with refractory properties, lining construction, and
pouring technology.
In the presence of high quality refractories it is not al-
ways possible to achieve maximum lining life. Even insignif-
icant changes in metal smelting technology and pouring may
lead to a reduction in refractory life.
EFFECT OF REFRACTORY QUALITY
ON LINING LIFE
Refractories used
In contemporary linings there is mainly use of car-
bon-containing refractories based on periclase-carbon or
aluminopericlase-carbon composition. Some Russian enter-
prises manufacture these refractories based on imported Chi-
nese raw material. In principle the production technology for
domestic refractories provides the required specifications.
There are small deviations with respect to ecology, con-
nected with the release of free phenol from the binder.
Studies performed by the enterprises make it possible to hope
for a reduction of harmful discharges into the atmosphere [2].
In the first stage supplies were produced by European firms

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(RHI, etc.). European refractories, in spite of comparatively
long life properties, have a high cost and therefore the major-
ity of refractory users have transferred purchasing to China.
Some Russian refractory enterprises have created in-house
production in China (OOO Gruppa Magnezit, OAO Boro-
vich Refractory Combine, etc.).
Accuracy of refractory object preparation
The life of refractories is determined to a considerable
extent by the thickness of vertical and horizontal joints. The
size of a joint mainly depends on deviations with respect to
object thickness. In a lining made from refractory objects,
having the minimum deviations in thickness, joint-free lining
assembly is provided. The accuracy of manufacture with re-
spect to thickness is at the level of ±0.5 mm. This index is
determined by modern press equipment. Currently in the ma-
jority of Russian enterprises there is imported press equip-
ment that makes it possible to provide the required tolerance
with respect to object dimensions.
Standard sizes of objects used
In Russia many metallurgical enterprises provide tech-
nology of ageing helical laying of a lining in 2 – 3 standard
sizes of objects. In world practice there is mainly use of cir-
cular laying of a ring of lining of made of objects of one stan-
dard size. In order to provide joint reliability in a ring no
fewer than two key bricks are used, that are cut from a nor-
mal object by means of a diamond tool. The key bricks pro-
vide wedging of the lining and guarantee exclusion of metal
penetration over a vertical joint of a lining.
The leading producers for laying objects use bricks of
trapezoidal shape. Some firms make linings with objects
150 – 200 mm thick having the shape of a trapezoidal
wedge. This makes it possible to reduce the number of hori-
zontal joints that has a favorable effect on lining life. How-
ever, object of considerable thickness have different density
during manufacture. Their central part has a lower density
than the periphery, and this has a deleterious effect on the life
of the whole lining.
Recently in world practice of laying a lining there has
been use of trapezoidal objects of smaller thickness (up to
100 mm). These objects are manufactured in presses with a
lower force, the objects have a more uniform density
throughout the whole cross section and this promotes uni-
form wear. There is a tendency to use ladle objects of small
dimensions, so-called mini-keys [3].
The small size of objects and their high quality makes it
possible to increase lining life by 15 – 20% in spite of an in-
crease in the number of horizontal joints. The uniform den-
sity of each object and their high strength properties also
makes it possible to increase lining life.
V. A. Kononov et al.
EFFECT OF REFRACTORY LINING
CONSTRUCTION ON ITS LIFE
Lining construction features
In service there is wear of the refractories in the lining of
a steel-pouring ladle, connected with the specific nature of
ladle operation by the user. In the slag belt zone there is in-
tense breakdown of the lining as a result of chemical reaction
of slag with refractory. Therefore in the slag belt zone use of
basic composition refractories is recommended based on
fuzed or sintered periclase. Objects made from fuzed materi-
als have the best have the best structure and exhibit the lon-
gest life. In order to reduce the wettability of refractory with
slag high purity graphite is added to its composition. The
amount of graphite in the refractory is determined from pour-
ing conditions. The content of impurities (SiO2, Fe2O3, etc.)
in refractory objects should be at a minimum.
In the area of impact of the metal stream in a ladle there
is erosion breakdown of refractory. Depending on pouring
conditions the stream of molten metal may hit the side of the
ladle or a specific area of the bottom. In order to overcome
this effect it is necessary to reinforce the ladle lining in the
area of molten metal impact. Reinforcement of the so-called
striking zone is performed as a result of both improving ma-
terial composition, and also increasing the refractory contact
area. With metal blowing through channel blowing tuyeres
there is erosive wear of the lining in the zone where bubbles
pass, and therefore it is also desirable to strengthen this area.
Types of lining
Several types of modern lining are widespread: from
piecewise objects, poured, rammed, vibration based on
low-cement mixes, etc. Sometimes different combinations
are used: poured at the bottom and piecewise in the walls, vi-
bration mixes in the bottom and walls and piecewise in the
slag belt. The method of an “infinite lining” has been intro-
duced where as the lining elements wear there is restoration
by a special template that is installed within the ladle. A
low-cement thixotropic mix is poured between the wall and
template. The life of linings of this type exceed 1000 melts.
According to experience in the OAO O. A. Serov Metallurgi-
cal Plant it is not profitable to use a lining of this type up to a
life of 500 melts, but after a life of 1000 melts production ef-
ficiency increases. The refractory mix used is raw material
components based on special grades of tabular and reactive
alumina, that are only produced abroad, and the cots of the
mix is considerably higher than for piecewise objects. Effi-
cient use of these mixes is only possible with special equip-
ment produced mainly by European firms.
Lining laying technology
Assembly of a lining without mortar requires highly
qualified layers and special attachments and equipment.
There is considerable importance in laying technology for
heat insulation, reinforcing and the working layers of walls.