FHS Ladle Installation Manual Incld OPI - 10.5.2018

Singapore, 10.5.
2018 STTF
Formosa Ha Tinh Steel
300 ton Steel Treatment Ladle
Refractory Lining Instruction

User guide
STEEL TREATMENT LADLE REFRACTORY LINING 2
1. STEEL LADLE LAYOUT

DESCRIPTION OF THE MAIN COMPONENTS
Top Rammig
Insulation
Working Lining
Slag line
Working Lining
Metal line/sidewall
Working Lining
Bottom Impact
Purging Well Block
Sidewall Safety Ramming
Brick Between bottom
and sidewall
Bottom Safety
Purging Plug unit Brick
Slide Gate Plates

2. LINING STATION
Line the Steel Ladle in a lining stand. It is situated in an area of the steel-works, where
Steel Ladle can be lined independently of the other activities in the plant.
2.1. General Equipment and Auxiliary Tools
The Lining stand should be equipped with:
Equipment on the bricking station
1 brick cutting machine for wet/dry cutting with moveable table as

well as blades for cutting (numbers depend on quality and diameter;
carborundum or diamond)
Sufficient storage space for the material required in order to ensure
short transport to the vessel
Normal supply of electric power,
Crane
water and compressed air
1 mortar box, steel or
1 horizontal mixer (min. 300 kg)
plastic, about 10 liters
1 portable light with
1 special ramming tool
extension cable
1 steel shear for cutting
1 vibrator (electric/pneumatic) the packing case steel
bands
1 fork lift truck Dust masks
1 mortar mixer Safety glasses
1 sledge hammer Brushes
1 shovel 1 bucket, about 10 liter
Required Media for lining
Water connections 3 bar Air connections 6 bar
Main power 220V and 380V

Personal equipment for each brick layers
1 trowel 1 tape measure
1 rubber hammer 1 hand brush
1 bricklayer hammer, preferably with an

1 crowbar
exchangeable cutting edge
1 spirit level, minimum length approx.
1 brick chisels
24”
1 hard chalk 1 graphite stick
3. STORAGE OF THE REFRACTORY MATERIAL
3.1. Protection against Moisture, Damages and shelf life
Even the best suitable packing can fulfil its purpose to protect the goods from
damage only, if the packing units are expertly handled when being loaded,
unloaded and transported.
When transporting our refractory materials the fact should be taken into account
that these are high quality furnace building materials the state of which is of
essential importance for the life of the components made from them.
It is advise able to remove the original packing of our products, if possible, only
immediately before installation on site, as unpacked material is to a high extent
exposed to the possibility of damage during intermediary transport and shifting.
Refractory products should generally be stored in dry (no dripping moisture), well
aired rooms. Any possibility of penetration of humidity, also from the ground,
should be avoided. Climatic high values of humidity are normally not problematic.
Some products which could be liable to damage under special climatic conditions
due to influence of humidity are specially protected by us.
The storage instructions given in the individual data sheets have to be strictly kept
especially with unshaped products (masses, mortars), as their shelf life is
generally limited.
In case refractory material gets wet in spite of all preventive measures, our
technicians should be consulted before using unshaped products (masses and
mortars).
Store refractory materials in an over-roofed room protected against moisture

ingress on all sides, well aired and on a solid ground. Protection against moisture
is essential for refractories.
Bricks and mixes are best protected against all kinds of damages in their original
packing. Open if possible the packing only at the bricking station. This practice
also simplifies the transport from the store to the bricking station.
Store any material left over on pallets in the stores. If you have to place bricks and
mixes on boards then provide wooden supports for better air circulation. It must be
guaranteed that the materials remain dry.
3.2. Maximum Piling Height
The floor of the ware house has to be even and rigid and the pallets stacked on
each other have to be placed with the entire pallet collar on the brick stack below.
Thus damages of the packed materials are avoided. As a maximum stacking

height we recommend:
> 4 pallets for masses and mortars
> 6 pallets (or cases) for bricks
> This leads to a maximum surface load of the warehouse floor of approx. 4,8
t/m² for mixes and/or 7,2 t/m² for bricks
4. INSTALLATION
4.1. General Remarks
Line the individual parts of the steel ladle very carefully. In operation the refractory
material is exposed to the highest and most multiple stresses and bad lining
immediately lead to low life times.
In the bottom, sidewall area tight brickwork is essential. Radial expansion is

sufficiently absorbed by the backfill material. Therefore no radial expansion gaps
are required. The vertical expansion is taken up by horizontal joints and ramming
below the retainer supporting flanges.
All mechanical maintenance must be finished before starting the installation of

refractory material. Prepare the ladle shell by repairing the retainer steel flanges
and any other damages to the shell.
If steam holes are present, the steel shell must be swept clean and the steam
holes cleaned. Steam holes are located in the bottom and sidewall and must be
re-drilled if they are blocked. A grid pattern of 400 mm with a diameter for each
hole of 8-12 mm is recommended.
This lining guide illustrates all steps of a ladle lining procedure, from the empty
steel shell to the fully installed ladle lining in bottom and sidewall.
However, in many cases the installation of an entire ladle lining is not necessary in
daily routine. Most of the time, the ladle working lining in sidewall bottom
and/or slag zone will only be subject to reinstallation with the currently installed
permanent lining of bottom and sidewall remaining in place for another campaign.
For this working lining installation procedure, the following actions must be
executed:
Demolition of worn sidewall, slag zone and/or bottom working lining bricks.
Removal of demolished bricks and cleaning of ladle.
Repair of damaged permanent lining.
Installation of new working lining.
4.2. Bottom Safety Lining
Start the bottom safety lining at any position using RESISTAL B80 V, shape-1.
Install the bricks in tight contact with each other and stagger the cross joints from
row to row.
Install the bricks as close as possible to the side-wall shell. The gap between the
brick to the steel shell has to be rammed or casted by castable – COMPRIT B81-5
V.
For second layer, the bricks of the second layer must be placed at an angle of 30°
- 90° to the previous layer to avoid continuous brick joints. Any unevenness from
layer below to be leveled by wet mortar – RESIMUT B73V-03 V.
Castable, COMPRIT B81-5 V
RESISTAL B80 V, 1
When having finished the second layer, cast or ram the remaining gap to the steel
shell as done for the previous layer!
When the entire permanent lining (i.e. insulation(s) and safety lining) in the bottom
has been installed, the lining of the sidewalls can be started.
4.3. Installation of Insulation & Safety at Sidewall
For lining the sidewalls, the insulation boards (PYROSTOP CARTO 125), the and
the safety lining are installed simultaneously.
Depending on shape, the insulation should be installed two or three layers ahead
of the safety lining.
Start with cleaning the steam holes in the ladle shell!

Clean the shell from any remaining material (steel remnants or slag)!
To install the insulation boards, apply mortar only to the corners and
center. This is to keep the boards in position until the insulation and safety
lining bricks secure the boards. Applying mortar full board will close the
weep holes and reduce the insulation properties.
PYROSTOP CARTO 125
RESISTAL B80 V, SL476

(one layer)
When having installed a row of insulation boards, start with the installation of the
safety bricks tightly to the previously installed insulation boards.
> The closing brick in every row must be cut!
> Make sure no closing brick is smaller than 50 mm. If so, remove
another brick and cut two closing bricks!
> Always put at least two uncut bricks between two cut bricks.
Continue the lining of each layer simultaneously up to the lip ring. The last row of
insulation boards and safety lining must be cut to fit into the remaining gap
beneath the lip ring. The last layer to touch the lip ring (one inch gap or 25mm can
be allowed and to be filled with castable COMPRIT B81-5 V).
Cut each of the final layers tight to the lip ring to ensure the stability of the wall
lining as shown in below picture. Lack of mechanical stability has a negative
influence on the lifetime of the ladle!
Cutting of the last layer

to tight joint to ring
4.4. Lining Sidewall or Metal Line
Since it is the insert or Island bottom, we will start with sidewall lining first (ANKO
65M&C7A). Use mortar or ramming mix if the permanent lining presents an
uneven surface.
Use as little mix as possible for leveling, but as much as necessary.
The bricks have to be installed exactly vertical to avoid steps and open joints!. Use
spirit level to check.
Put the first brick of the working lining on the leveling mix at the correct distance to
the already installed safety lining of the sidewall ~10-15mm for bakfill. Continue
the brick laying and use differently tapered bricks to be able to follow the safety
lining at the correct distance (ANKO 65MRC7A, MK8/30 & MK8/8 s per the ratio in
the drawing).
When installing the wear lining, there must not be any gaps between the bricks!.
Use rubber hammer to tighten the bricks. If any gap keep within 2mm which can
close by expansion.
Fill the remaining gap between wear lining and permanent lining with backfilling
mix (PERFILL KL T) after closing the ring, densify it with trowel or rod.
Each ring must be tightly closed with suitably sized bricks. Usually one or two
bricks have to be cut in order to close the ring of one layer of bricks.
> The wedging of the closing brick must be measured and cut according to
the remaining gap.
> Closing bricks must neither be installed in the trunion area nor in the area of
tilting.
> Closing bricks must not be next to purging plug and slide gate.
Closing Bricks
> Shift the closing bricks from one layer to the next one: Do not install them
directly above each other!
> Fit the brick tightly into the remaining gap by means of a rubber hammer
(inserting only by hand is not enough).
> If the remaining gap is smaller than 50 mm, two closing bricks must be cut
and inserted with at least two uncut bricks between them
When installing the inserted or Island Bottom bottom, continue the lining of the
sidewall up to the height before an elevated working platform is necessary and
then proceed to Installation of blocks.
The current state of installation after completing Installation of working lining lower
part in sidewall” is shown in below
4.5. Installation of Blocks
The pocket block or purging well block and slide gate well block can be installed
directly to steel shell or as directed by the supplier (below picture is only example).
Usually it has contour for shelf cantering.
Fill the gap between permanent lining and block with casting mix – COMPRIT
B81-5 V.
4.6. Installation of Bottom Brick
If the permanent lining presents an uneven surface, leveling with a thin layer of
leveling mix or ramming mix must be performed. Continuing the lining on an
uneven permanent lining would result in an uneven working lining and must be
avoided!
> Carry out the bottom leveling with a maximum layer of 15 mm of mix for
proper brick lining.
> Use a spirit level for leveling (see Figure below)
Start with the center row parallel to the pocket / purging well blocks.
Take time for first row and do it accurately! If first row is not straight, installing all
other rows will cause problems! Use auxiliaries like a spirit level (may be3m); or
other devices shown in below Figure to ensure a straight first line.
To save time and avoid brick cutting around the blocks already installed, observe
the following instructions for installing the first row:
> Measure the rectangular distance from the block’s surfaces.
> Consider a ramming joint > 50 mm and < 100 mm around the blocks.
> Determine the distance to the blocks where to place the first row of bricks in
order to have an even number to both blocks.
> An uneven number of bricks between the blocks means increased lining
time due to the cutting bricks around the blocks and should be avoided.
> Ensure fully closed, tight joints between the bricks. Absolutely no gaps are
allowed!
Install the first row and fix the ends of the row with wooden wedges!
Install a second row at an angle of 90° to the first row as show in below Figure.
Each quarter of the bottom lining can then be installed with the bricks tight to each
other. Refer to the lining drawing as impact area is RADEX SMAC5-21, 30/0 & rest
with RADEX SMAC5-2, 25/0. This need to be followed. Secure the rows with
wooden wedges!
> Ensure full tight joints between the bricks. Absolutely no gaps are allowed!
> Keep a ramming gap of 70 – 100 mm to the sidewall! This prevents
bulging of the bottom due to thermal expansion during operation!
> Any bricks that need to be adapted must be cut, not hammered (chipped).
> Keep a ramming/casting gap of > 50 and < 100 mm around the pocket
block and well block as shown in below Figure. This prevents bulging of
the bottom and crack formation to the block due to thermal expansion
during operation
> Any bricks that need to be adapted must be cut, not hammered.
> Pocket block/set has to be flush with the ladle refractory bottom floor, or
exceed the bottom max. 50 mm in height (see Figure 56).
> The well block for the slide gate must be flush or lower than the surface of
the working lining.
50-100mm
prepare the recommended high grade mix COMPRIT A95-6 or customer given mix
with required amount of water. Mixing time is 1 minute dry and 5 minutes in wet
condition or according to recommendation, advisable to be in ramming
consistency.
> After proper mixing, the mix has to be put inside the gaps in layers of
max. 100 mm and rammed thoroughly with a pneumatic hammer.
> Remove the wooden wedges when filling the gap!
> The ramming with the pneumatic hammer must be done carefully! Take
care not to lift up the blocks by excessive ramming!
> After ramming, roughen the surface and fill in the next 100 mm layer and
ram it. Repeat until the bottom joint is filled entirely.
> Do not exceed the recommended maximum amount of water for mixing
as this would cause extensive premature wear
When all joints from the bottom to the sidewall and the gaps around the blocks
have been filled and densified, the bottom lining is completed.
4.7. Installation of remaining sidewall
Continue the lining of the sidewall working lining up to the height before an
elevated working platform is necessary and then proceed to next step
Installation of working lining upper part in sidewall & slag zone”.
After placing an elevated working platform in the ladle, the lining of the sidewall
can now be completed.
> Continue the installation of the working lining of the sidewall up to the
slag zone.
> The slag zone is to be installed with ANCARBON F3T14, MK9/8 &
MK9/30.
> Besides that, the installation of the slag zone bricks does not differ from
the installation of the other bricks of the sidewall.
> When all layers of the slag zone have been installed, the lining of the
free board is to be done using ANCARBON F3T14, 5P8, 5P16 and the
filling of the lip ring are the final step to complete the lining procedure.
Comprit A95-6
Free Board (5P..)
one layer
Slag line,
ANCARBON F3T14
The installation procedure of the free board bricks is the same as for all other
bricks in the sidewall. For correct installation refer to the lining drawing.
The vertical ramming gap for the closing ring (area between lip ring and last row of
bricks) has to be 50-100 mm. If the gap is larger than 100 mm, another layer of
bricks must be installed.
Make sure only material with sufficient mechanical stability is used for lip
rings.
Welded segments must be thoroughly welded to guarantee mechanical
stability.
For good clamping the lip ring should cover the bricked lining beneath it by
a minimum of 2/3 of the width.
steel frame) and the temperature inside the furnace outgrow 50 °C, the heat-up
process has to be reduced until both temperatures converge again.
5. DRY OUT or PREHEATING
After finishing the lining of a bricked ladle, it must be heated up to be ready for
operation. The heating-up procedure is an important process with respect to
lifetime of ladle and performance of the lining bricks.
Important: Heating up the ladle allows the bricks to expand and tense up. Tilting
a ladle before that will most likely result in the loss of bricks and imminent danger
to operating personnel due to falling bricks.
> As the newly installed bricks need to expand and tense up, only vertical
preheating is allowed until the brick wall temperature reaches 750 °C.
> The ladle may be turned upside down only after it has been entirely
heated-up (≥ 1100 °C)!
The following facts are crucial to ensure maximum lifetime of the bricks and to best
prepare a ladle for operation:
The recommended heating-up period for the ladle is at least 11 hours and
at most 18 hours.
The heating-up curve should be linear.
Ideally, after approx. 14 hours the brick wall temperature should be at the
target temperature of 1100 °C.
This requires a heating-up rate of between 75 and 80 °C/h.
> Up to 300 °C the burner flame should be kept slightly oxidizing.
> From 300-800 °C the burner flame should have an air surplus of 15-
25%, facilitating a so-called “post combustion” of the volatile contents
to prevent smoke development.
> From 800-1100 °C the burner flame should be only very slightly
oxidizing (1-2% excess air) to avoid a deeper penetrating
decarburization of the brick surface.
Up to 2 h holding time at 1100 °C are acceptable.
Longer holding times at this temperature will irreversibly damage the bricks due to
carbon burn-out.
If ladle operation is delayed, the ladle must be kept at significantly
lower temperature during standby times in order to prevent
decarburization of bricks.
Standby temperature is at 750 °C and should only be kept for a
maximum of 24 hours.
The heat-up curve based on these facts is shown in below Figure.
The curve relates to the surface temperature of the bricks and illustrates different
possible paths to heat up a ladle in terms of heat rates and standby times.
When the final temperature of 1100 °C has been reached and the heating-up
process has been completed, the first heat should be tapped into the ladle with
minimal delay.
It might become necessary to have longer preheating or standby times if the ladle
is not immediately needed. In such a case, the ladle should be kept under the
burner with minimal excess air at 750 °C.
Heating to 1100 °C again should be started just in time before the next heat.
Note: The ladle can be kept at 750 °C for maximum 24 hours.
At FHS we will follow below graph for heat up for complete new ladle including
safety & one for only complete working lining. Other instructions for holding or
standby incase of delay are as above only.
1200 Hold at 1,100°C

for 2-3hr
1000
Hold at 1,100°C
New working lining for 2-3hr
800
- heating @ 85°C/hr
New full lining
600 including safety -
heating @ 70°C/hr
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
6. Maintain or Repairs
Ladles after some life time needs repair partially to continue safe operation. During
these repairs ladle would cooled for approximately 2days for safe access for
people to repair.
Change of Block: if the blocks wear faster, it needs to be changed. The block and
ramming mix around the block need to be removed and cleaned. New block need
to be brought and positioned as described in page#9 & 10. Then ramming to be
done as in page#12. During the repair try not to keep ladle in horizontal position
and maintain vertical position.
Slag line change: At middle of the campaign the ladle slag line need to be
dismantled after cooling down. The slag line can be removed when thickness is
about 40-50mm. Then check the base of the metal line and make a leveling with
castable COMPRIT A95-6 V or COMPRIT B81-5 V. Then slag lien to be line and
top gap to be rammed as per page #13. After repair ladle need to be kept vertical
and taken for heating under vertical burner. This slag lien change would take
about 1day.
Heat up after repair: During steel contact, a slight infiltration of the hot face brick
surface occurs as well as an adhesion of a thin slag layer, which reduces further
decarburization of the brick surface. Therefore the regulations for used ladles
should be somewhat similar as for newly lined ones, but less strict.
1200
1000
Hold at 1,100°C
for 2-3hrs
800 Heat up rate
100°C/hr
600
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
7. Operational Conditions to Achieve good Life time
Average heat-size of 300T.

Continuous running of Ladles. Lining should not be exposed to extreme
temperature changes (Temperature of ladles before tapping should be
≥1000°C). No circulation ladles will be allowed to cool down to less than
600 °C.
Number of heats/ladle/day should be > 6.
Maximum Tapping temp 1650°C. Limit high temperature tapping.
Flux addition during tapping is must (5-8 kg/T lime, 1.5-3.0 kg/t pre-
fused synthetic slag, along with de-oxidizer), balance lime( 3.0-3.5
Kg/ton) to be added at LF. Slag volume should be such that it
completely covers the ‘100mm’ arc length at LF.
De-oxidant addition (Al/Si/C) during tapping to have total [O] ≤100 ppm
at LF-in.
Carry-over slag from BOF should be avoided.
Input materials should be selected so as to have ‘S’ opening ≤0.05% at
LF.
Ladle life is based on total purging time and total holding time. If total
treatment time, if time exceeds 120 minutes, count as 1.5 heats and
180min (heat in ladle 3hr), count as 3 heats.
RH heats should be considered as 2 normal heats. (As less pressure
inside the ladles initiates self-degeneration of magnesia carbon bricks).
Re-processed heats will be considered as two normal heats.
Maximum temperature at LF should be less than 1650°C. If for any
purpose temp increased to more than 1650°C, dolo-lime should be
added to take care of slag basicity & MgO saturation.
All the logical unit of ladle refractory should be from one single source.
Retainer plates should be maintained campaign-wise & if necessary in

mid-campaign also (slag-zone change).
Preferable LF slag should be – CaO-53-58%, MgO-6-8%, SiO2-10%
(max), Al2O3-25-30%, FeO+MnO≤2%.
Fluorspar addition at LF and during tapping should be NIL.
Correct pre-heating of ladles, as per preheating curve (depicted above).
Ladle has to be covered during casting and slag has to be drained out
immediately after casting finished.
Mechanical damage to the brickwork due to de-skulling has to be
repaired.
Damaged permanent lining has to be repaired as and when required.
Well block hot repair after changing inner nozzle.
Seating block hot repair when change PP.
8. Wear Out Measurement
During slag line change and after campaign wear out measurement to be taken for
record and study.
This will be used to optimize the future supplies to achieve good cost performance.
(below is an example similar will be designed for FHS)
Customer
o
Plant N
Date Customer Logo
Residual thickness protocol
Ladle Nr. Total Heats Steel contact time Steel casted Ladle in production
[min]
5 89 Total = Total= from:
Average = Average= to:
Repair at wear rate per heat Temperature Measurements done by
Tapping
45 SZ= T max =
SW= Average =
Slagzone repair prewear area at

Layer Material Initial length 12 o'clock 3 o'clock 6 o'clock 9 o'clock x-o'clock
14 AC-F3T10S 187 110 110 110 110 70
13 AC-F3T10S 187 100 100 100 100 70
Slagzone
12 AC-F3T10S 187 90 90 90 90 65
11 AC-F3T10S 187 85 85 85 85 60
10 AC-F3T10S 187 85 90 85 90 55
9 AC-F3T10S 187 80 90 90 80 50
Side-
8 RX-SMAC5-21 187 85 90 85 85 60
wall
7 RX-SMAC5-21 187 100 100 100 100 65
Final prewear area at

Layer Material Initial length 12 o'clock 3 o'clock 6 o'clock 9 o'clock 5-o'clock
14 AC-F3T10S 187 120 120 120 120 70
13 AC-F3T10S 187 110 110 110 110 70
Slagzone
12 AC-F3T10S 187 100 100 100 100 70

11 AC-F3T10S 187 90 90 90 90 55
10 AC-F3T10S 187 85 85 85 85 50
9 AC-F3T10S 187 70 70 70 70 65
8 RX-SMAC5-21 187 75 75 75 75 140
7 RX-SMAC5-21 187 80 80 80 80 140
6 RX-SMAC5-21 187 110 110 110 110 115
Sidewall
5 RX-SMAC5-21 187 120 120 120 120 110

4 RX-SMAC5-21 187 130 130 130 130 100
3 RX-SMAC5-21 187 150 150 150 150 105
2 RX-SMAC5-21 187 155 155 150 150 110
1 RX-SMAC5-21 187 155 155 150 150 100
Repair Mixes kg total Type

Gunning
Wellblock
100
100
100 100
100
100
100
Comments
Operating instruction
COMPRIT A95-6 V
Classification Refractory concrete, conventional DIN EN ISO 1927-1
Bonding type Hydraulic
Safety and health

Pay attention to the Material Safety Data Sheet (MSDS) before installing this product. In the MSDS all relevant
information regarding potential health, safety and environmental hazards and protective measures for these
hazards can be found. The MSDS also specifies the appropriate personal protective equipment to be used
when installing this product.
Storage and shelf life

The optimum storage temperature for goods in their original, unopened packaging ranges from 15 to 25 °C.
Keep in a dry place away from sunlight. The goods should be utilised within 12 months.
Inappropriate storage may lead to the formation of lumps, in which case the material must no longer be used
since parts of the binder have already reacted.
Do not stack more than 2 pallets on top of each other.
Processing
Processing below 5 °C is not recommended !!
Optimum processing temperature of the material: 15 to 25 °C
If the recommended temperatures cannot be kept, corresponding measures have to be taken.

Mixing liquid: drinking water (temperature: 15 °C to 25 °C)
8,0-9,0 l/100kg
Mixing device: clean high intensity mixer, free from impurities
Date: 2018-05-10 Page: 1 / 3 OPI_COMPRIT_A95_6_V_ISO_en.pdf

Volume of mixing compound needed: 8,0-9,0 litres /100 kg dry material
Mixing process
Dry mixing time: 1 minute
Addition of mixing compound
Wet mixing: 6 minutes, depending on mixing device
8,0-9,0 l/100kg
To set the correct dosing of the mixing compound, a consistency test ("ball-in-hand" test) is recommended!
Material is proper material is too wet material is too dry

mixed.
Preparation of adjoining areas

Contact surfaces that could draw water from the concrete (insulation, brickwork) must be free from dust and
made to be water-repellent. Suitable ways to achieve this are: coating with liquid sodiumsilicate, forming oil,
grease or paraffin and/or covering with film.
Preparation of templates
The entire surface of the template must be treated with a suitable form release agent.
Lining
Do not mix more material than can be used up within 20 minutes! (Take transportation into account!)
Lining of the individual components must be done continuously and without interruption. Layer formation must
be avoided!
Compacting
Compacting is done by vibration.
A smooth, shiny surface indicates good compacting.
Removing the template

The template may only be pulled out after dimensional stability has been reached.

Air drying
After stripping, the components have to be exposed to air for a minimum of 24 hours to set. During this time,
the elements have to be kept moist or covered with film. Do not start heating before this minimum period of 24
hours is over.
Installed material needs to be protected from frost until it is heated.
Drying and heating

To prevent structural damage, the drying and heating recommendations enclosed must be strictly observed for
newly lined components.
The heating curve depends on the geometry of the unit and on the wall thickness.
The given temperatures are furnace chamber temperatures, resp. surface temperatures.
Enclosed find the standard heating curves for different wall thicknesses.
For thicker walls, the heating time is correspondingly longer.
Heating curves for deviating conditions will be provided upon request.
For precise monitoring of the temperature curve we recommend using thermal elements in several areas (hot
and cold side).
Should the temperature difference during heat-up between the measured value of the thermocouple between
the working lining and the insulation (respectively the steelframe) and the temperature inside the furnace
outgrow 50 °C, the heat-up process has to be reduced until both temperatures converge again.

COMPRIT B81-5 V
Classification Refractory concrete, conventional DIN EN ISO 1927-1
Bonding type Hydraulic
Safety and health


The optimum storage temperature for goods in their original, unopened packaging ranges from 15 to 25 °C.
Keep in a dry place away from sunlight. The goods should be utilised within 12 months.
Do not stack more than 2 pallets on top of each other.
Processing
Processing below 5 °C is not recommended !!
Optimum processing temperature of the material: 15 to 25 °C
If the recommended temperatures cannot be kept, corresponding measures have to be taken.

Mixing liquid: drinking water (temperature: 15 °C to 25 °C)
8,5-9,5 l/100kg
Mixing device: clean high intensity mixer, free from impurities
Date: 2018-05-10 Page: 1 / 3 OPI_COMPRIT_B81_5_V_ISO_en.pdf

Volume of mixing compound needed: 8,5-9,5 litres /100 kg dry material
Mixing process
Dry mixing time: 1 minute
Addition of mixing compound
Wet mixing: 6 minutes, depending on mixing device
8,5-9,5 l/100kg
To set the correct dosing of the mixing compound, a consistency test ("ball-in-hand" test) is recommended!
Material is proper material is too wet material is too dry

mixed.
Preparation of adjoining areas

Contact surfaces that could draw water from the concrete (insulation, brickwork) must be free from dust and
made to be water-repellent. Suitable ways to achieve this are: coating with liquid sodiumsilicate, forming oil,
grease or paraffin and/or covering with film.
Preparation of templates
The entire surface of the template must be treated with a suitable form release agent.
Lining
Do not mix more material than can be used up within 20 minutes! (Take transportation into account!)
Lining of the individual components must be done continuously and without interruption. Layer formation must
be avoided!
Compacting
Compacting is done by vibration.
A smooth, shiny surface indicates good compacting.
Removing the template

The template may only be pulled out after dimensional stability has been reached.

Air drying
After stripping, the components have to be exposed to air for a minimum of 24 hours to set. During this time,
the elements have to be kept moist or covered with film. Do not start heating before this minimum period of 24
hours is over.
Installed material needs to be protected from frost until it is heated.
Drying and heating

To prevent structural damage, the drying and heating recommendations enclosed must be strictly observed for
newly lined components.
The heating curve depends on the geometry of the unit and on the wall thickness.
The given temperatures are furnace chamber temperatures, resp. surface temperatures.
Enclosed find the standard heating curves for different wall thicknesses.
For thicker walls, the heating time is correspondingly longer.
Heating curves for deviating conditions will be provided upon request.
For precise monitoring of the temperature curve we recommend using thermal elements in several areas (hot
and cold side).
Should the temperature difference during heat-up between the measured value of the thermocouple between
the working lining and the insulation (respectively the steelframe) and the temperature inside the furnace
outgrow 50 °C, the heat-up process has to be reduced until both temperatures converge again.

PERFILL KL T
Classification Back filling mix
Bonding type organic
Safety and health


The material must be stored in the original packing on a dry place protected from weather.
Shelf life under these conditions is approx 12 months.
To avoid prehardening of product don't stack pallets.
Instructions for use

The product must not be mixed with water!
Lining
Direct placement
The ready to process mass is processed directly from the packaging and is usually compacted using a
pneumatic hammer or similar devices.
Apply the dry product with a shovel or trowel to fill up brick joints and seams.
Compacting with a hand rammer
Fill the material in layers of up to a max. height of 80 mm and compact thoroughly with pegging rammers.
Roughen up the surface of the previous layer before applying the next layer.
Date: 2018-05-10 Page: 1 / 2 OPI_PERFILL_KL_T_ISO_en.pdf

Date: 2018-05-10 Page: 2 / 2 OPI_PERFILL_KL_T_ISO_en.pdf

FHS Ladle Installation Manual Incld OPI - 10.5.2018

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FHS Ladle Installation Manual Incld OPI - 10.5.2018

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Singapore, 10.5.

Formosa Ha Tinh Steel

300 ton Steel Treatment Ladle

Refractory Lining Instruction

1. STEEL LADLE LAYOUT

Slide Gate Plates

2.1. General Equipment and Auxiliary Tools

The Lining stand should be equipped with:

Equipment on the bricking station

1 brick cutting machine for wet/dry cutting with moveable table as

1 shovel 1 bucket, about 10 liter

Required Media for lining

Water connections 3 bar Air connections 6 bar

Main power 220V and 380V

Personal equipment for each brick layers

1 trowel 1 tape measure

1 rubber hammer 1 hand brush

1 bricklayer hammer, preferably with an

1 hard chalk 1 graphite stick

3. STORAGE OF THE REFRACTORY MATERIAL

3.1. Protection against Moisture, Damages and shelf life

Store refractory materials in an over-roofed room protected against moisture

3.2. Maximum Piling Height

Thus damages of the packed materials are avoided. As a maximum stacking

4.1. General Remarks

In the bottom, sidewall area tight brickwork is essential. Radial expansion is

All mechanical maintenance must be finished before starting the installation of

4.2. Bottom Safety Lining

Castable, COMPRIT B81-5 V

4.3. Installation of Insulation & Safety at Sidewall

Start with cleaning the steam holes in the ladle shell!

PYROSTOP CARTO 125

RESISTAL B80 V, SL476

Cutting of the last layer

4.4. Lining Sidewall or Metal Line

4.5. Installation of Blocks

4.6. Installation of Bottom Brick

4.7. Installation of remaining sidewall

5. DRY OUT or PREHEATING

1200 Hold at 1,100°C

7. Operational Conditions to Achieve good Life time

Average heat-size of 300T.

Retainer plates should be maintained campaign-wise & if necessary in

8. Wear Out Measurement

Residual thickness protocol

Slagzone repair prewear area at

7 RX-SMAC5-21 187 100 100 100 100 65

Final prewear area at

12 AC-F3T10S 187 100 100 100 100 70

5 RX-SMAC5-21 187 120 120 120 120 110

Repair Mixes kg total Type

Safety and health

Storage and shelf life

If the recommended temperatures cannot be kept, corresponding measures have to be taken.

Mixing device: clean high intensity mixer, free from impurities

Date: 2018-05-10 Page: 1 / 3 OPI_COMPRIT_A95_6_V_ISO_en.pdf

Material is proper material is too wet material is too dry

Preparation of adjoining areas

Removing the template

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Drying and heating

Date: 2018-05-10 Page: 3 / 3 OPI_COMPRIT_A95_6_V_ISO_en.pdf