Fundamental Design of Steelmaking Refractories

Debasish Sarkar, PhD, is currently Professor of the Department of Ceramic Engineering, National Institute of Technology, Rourkela, India. Prof. Sarkar has been working in the subject area of nanostructured ceramics, ceramic processing, iron and steel making refractories. process optimization and finite element analysis of structural ceramics for 26 years. He has published numerous peer-review articles, national and international patents, prototype developments, and books on the projected topics.

• Preface xvAcknowledgment xviiAbout Author xix1 Heat and Mass Transfer 11.1 Introduction 11.2 Energy Conservation 21.3 Conduction 61.4 Convection 161.5 Radiation 291.6 Mass Transfer 341.7 Heat Transfer in Refractory Lining 39References 432 Equilibrium and Nonequilibrium Phases 452.1 Introduction 452.2 Basics of Phase Diagram 452.3 One-Component Phase Diagrams 622.4 Two-Component Phase Diagrams 642.5 Three-Component Phase Diagrams 722.6 Nucleation and Crystal Growth 792.7 Nonequilibrium Phases 83References 853 Packing, Stress, and Defects in Compaction 873.1 Introduction 873.2 Refractory Grading and Packing 883.3 Stress–Strain during Compaction 983.4 Agglomeration and Compaction 993.5 Uniaxial Pressing 1023.6 Cold Isostatic Pressing 1043.7 Defects in Shaped Refractories 107References 1114 Degree of Ceramic Bonding 1134.1 Introduction 1134.2 Importance of Heating Compartment 1144.3 Initial Stage Sintering 1184.4 Intermediate and Final Stage Sintering 1264.5 Microstructure Alteration 1304.6 Sintering with Low Melting Constituents 1374.7 Bonding Below 1000°C 138References 1425 Thermal and Mechanical Behavior 1435.1 Introduction 1435.2 Mechanical Properties 1445.3 Cracking 1545.4 Thermal Properties 1605.5 Thermomechanical Response 1685.6 Wear 176References 1826 High Temperature Refractory Corrosion 1836.1 Introduction 1836.2 Thermodynamic Perceptions 1846.3 Effect of Temperature and Water Vapor 1876.4 Slag–Refractory Interactions 1916.5 Phenomenological Approach and Slag Design 206References 2157 Operation and Refractories for Primary Steel 2177.1 Introduction 2177.2 Operational Features in BOF 2217.3 Operational Features in EAF 2327.4 Refractory Designing and Lining 2367.5 Refractory Maintenance Practice 2527.6 Philosophy to Consider Raw Materials 2547.7 Microstructure-dependent Properties of Refractories 257References 2608 Operation and Refractories for Secondary Steelmaking 2638.1 Introduction 2638.2 Steel Diversity, Nomenclature, and Use 2678.3 Vessels for Different Grades of Steel 2708.4 Operational Features of Vessels 2728.5 Designing Aspects of Refractories 2918.6 Refractories for Working Lining 303References 3159 Precast and Purging System 3199.1 Introduction 3199.2 Composition Design of Castables 3209.3 Precast-Shape Design and Manufacturing 3379.4 Precast Shapes and Casting 3379.5 Purging Plugs 341References 35010 Refractories for Flow Control 35310.1 Introduction 35310.2 First–Second–Third Generation Slide Gate 35510.3 New Generation Ladle Slide Gate System 35910.4 Ladle Slide Gate Plate 36010.5 Tundish Slide Gate and Plate 38010.6 Short Nozzles for Ladle and Tundish 38910.7 Nozzle Diameter and Gate Opening in Flow 390References 39311 Refractories for Continuous Casting 39511.1 Introduction 39511.2 Importance of Long Nozzles in Steel Transfer 39711.3 Tundish Lining 40011.4 Ladle Shroud (LS) 40911.5 Mono Block Stopper 42711.6 Submerged-Entry Nozzle 430References 44412 Premature Refractory Life by Other Parameters 44512.1 Introduction 44512.2 Refractory Manufacturing Defects 44612.3 Packing and Transport 45312.4 Procurement and Lining Failures 45612.5 Preventive Maintenance in Operation 46312.6 Consistent Supply and Time Management 47512.6.1 Cycle Concept 47612.6.2 Pull/Push Concept 476References 477Index 479