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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
Fundamental Design of Steelmaking Refractories Comprehensive up-to-date resource organizing fundamental aspects for the design and performance of steelmaking refractories Fundamental Design of Steelmaking Refractories provides a fundamental understanding in the design of steelmaking refractories, in detail and all in one source, enabling readers to understand various issues including how heat and mass transfer occurs throughout the refractory, how matrix impurity or their contact affects the phases, and how invisible defects form during refractory manufacturing that eventually facilitates to analyze wear, corrosion, and performance of different refractory linings for primary and secondary steelmaking vessels, tundish, and continuous casting refractories. Other specific sample topics covered in Fundamental Design of Steelmaking Refractories include: * Phase formations and correlation with impurity effects and refractory processing shortcomings * Stress, wear, and corrosion to design refractories and performance statistics of steelmaking refractories * Equilibrium and non-equilibrium phases, packing, stress and defects in compaction, and degree of ceramic bonding * Thermal and mechanical behavior, flow control mechanisms, continuous casting refractories, and premature refractory damage * Precast and purging system, consistent supply and time management, and preventive maintenance in operation With its complete coverage of the subject, Fundamental Design of Steelmaking Refractories fulfills the academic demand of undergraduate, postgraduate, and research scholars of ceramic engineering; metallurgical engineers and mechanical engineering outlets that want to nurture in the refractory and steel sectors will also find value in the text.
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Fundamental Design of Steelmaking Refractories
Debasish Sarkar National Institute of Technology, Odisha, India
This edition first published 2023
© 2023 John Wiley & Sons, Inc.
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Library of Congress Cataloging-in-Publication Data
Names: Sarkar, Debasish, 1972- author. | John Wiley & Sons, publisher.
Title: Fundamental design of steelmaking refractories / Debasish Sarkar.
Description: Hoboken, NJ : JW-Wiley, 2023. | Includes bibliographical references and index.
Identifiers: LCCN 2022057612 (print) | LCCN 2022057613 (ebook) | ISBN 9781119790730 (hardback) | ISBN 9781119790846 (pdf) | ISBN 9781119790853 (epub) | ISBN 9781119790860 (ebook)
Subjects: LCSH: Refractory materials. | Steel--Metallurgy.
Classification: LCC TN677.5 .S279 2023 (print) | LCC TN677.5 (ebook) | DDC 669/.82--dc23/eng/20230103
LC record available at https://lccn.loc.gov/2022057612
LC ebook record available at https://lccn.loc.gov/2022057613
Cover Image: © donatas1205/Shutterstock
Cover Design: Wiley
Set in 9.5/12.5pt STIXTwoText by Integra Software Services Pvt. Ltd, Pondicherry, India
Allocating to my Jovial and Eternal ‘Madhava’
Contents
Cover
Title page
Copyright
Dedication
Preface
Acknowledgment
About Author
1 Heat and Mass Transfer
1.1 Introduction
1.2 Energy Conservation
1.3 Conduction
1.3.1 Basic Concept and Properties
1.3.2 One-Dimensional Steady-state Conduction
1.3.3 Two-Dimensional Steady-state Conduction
1.4 Convection
1.4.1 Boundary Layers
1.4.2 Laminar and Turbulent Flow
1.4.3 Free and Forced Convection
1.4.4 Flow in Confined Region
1.5 Radiation
1.5.1 Basic Concepts
1.5.2 Emission from Real Surfaces
1.5.3 Absorption, Reflection, and Transmission by Real Surfaces
1.5.4 Exchange Radiation
1.6 Mass Transfer
1.6.1 Convection Mass Transfer
1.6.2 Multiphase Mass Transfer
1.6.3 Analogy—Heat, Mass, and Momentum Transfer
1.7 Heat Transfer in Refractory Lining
1.7.1 Tunnel Kiln
1.7.2 Ladle Lining
References
2 Equilibrium and Nonequilibrium Phases
2.1 Introduction
2.2 Basics of Phase Diagram
2.2.1 Gibb’s Phase Rule
2.2.2 Binary Phase Diagram and Crystallization
2.2.3 Ternary Phase Diagram and Crystallization
2.2.4 Alkemade Lines
2.3 One-Component Phase Diagrams
2.3.1 Water
2.3.2 Quartz
2.4 Two-Component Phase Diagrams
2.4.1 Fe–C
2.4.2 Two Oxides Phase Diagrams
2.5 Three-Component Phase Diagrams
2.5.1 Three Oxides Phase Diagrams
2.5.2 FeO–SiO
2
–C
2.6 Nucleation and Crystal Growth
2.6.1 Homogenous and Heterogeneous Nucleation
2.6.2 Crystal Growth Process
2.7 Nonequilibrium Phases
References
3 Packing, Stress, and Defects in Compaction
3.1 Introduction
3.2 Refractory Grading and Packing
3.2.1 Binary and Ternary System
3.2.2 Particle Morphology and Mechanical Response
3.2.3 Nanoscale Particles and Mechanical Response
3.2.4 Binder and Mixing on Packing
3.3 Stress–Strain during Compaction
3.4 Agglomeration and Compaction
3.5 Uniaxial Pressing
3.6 Cold Isostatic Pressing
3.7 Defects in Shaped Refractories
References
4 Degree of Ceramic Bonding
4.1 Introduction
4.2 Importance of Heating Compartment
4.2.1 Loading and Heating
4.2.2 Heat Distribution
4.2.3 Temperature Conformity
4.3 Initial Stage Sintering
4.3.1 Sintering Mechanisms of Two-particle Model
4.3.2 Atomic Diffusion
4.3.3 Sintering Kinetics
4.3.4 Sintering Variables
4.3.5 Limitations of Initial Stage of Sintering
4.4 Intermediate and Final Stage Sintering
4.4.1 Intermediate Stage Model
4.4.2 Final Stage Model
4.4.3 Influence of Entrapped Gases
4.5 Microstructure Alteration
4.5.1 Recrystallization and Grain Growth
4.5.2 Grain Growth: Normal and Abnormal
4.5.3 Pores and Secondary Crystallization
4.6 Sintering with Low Melting Constituents
4.7 Bonding Below 1000 °C
4.7.1 Organic Binder
4.7.2 Inorganic Binder
4.7.3 Carbonaceous Binder
References
5 Thermal and Mechanical Behavior
5.1 Introduction
5.2 Mechanical Properties
5.2.1 Elastic Modulus
5.2.2 Hardness
5.2.3 Fracture Toughness
5.2.4 Strength
5.2.5 Fatigue
5.3 Cracking
5.3.1 Theory of Brittle Fracture
5.3.2 Physics of Fracture
5.3.3 Spontaneous Microcracking
5.4 Thermal Properties
5.4.1 Stress Anisotropy and Magnitude
5.4.2 Thermal Conductivity
5.4.3 Thermal Expansion
5.4.4 Thermal Shock
5.4.5 Thermal Stress Distribution
5.5 Thermomechanical Response
5.5.1 Refractoriness under Load
5.5.2 Creep in Compression (CIC)
5.5.3 Hot Modulus of Rupture
5.6 Wear
5.6.1 System-dependent Phenomena
5.6.2 Adhesive
5.6.3 Abrasive
5.6.4 Erosive
5.6.5 Oxidative
References
6 High Temperature Refractory Corrosion
6.1 Introduction
6.2 Thermodynamic Perceptions
6.3 Effect of Temperature and Water Vapor
6.4 Slag–Refractory Interactions
6.4.1 Diffusion in Solids
6.4.2 Oxidation
6.4.3 Infiltration
6.4.4 Dissolution
6.4.5 Crystallite Alteration
6.4.6 Endell, Fehling, and Kley Model
6.5 Phenomenological Approach and Slag Design
6.5.1 Refractory Solubility
6.5.2 Slag Composition and Volume Optimization
References
7 Operation and Refractories for Primary Steel
7.1 Introduction
7.2 Operational Features in BOF
7.2.1 Charging and Blowing
7.2.2 Mode of Blowing
7.2.3 Physicochemical Change in BOF
7.2.4 Tapping
7.2.5 Slag Formation
7.3 Operational Features in EAF
7.4 Refractory Designing and Lining
7.4.1 Steel Chemistry and Slag Composition
7.4.2 Thermal and Mechanical Stress
7.4.3 Refractory Lining and Corrosive Wear
7.4.4 Refractory Composition and Properties
7.5 Refractory Maintenance Practice
7.6 Philosophy to Consider Raw Materials
7.7 Microstructure-dependent Properties of Refractories
7.7.1 Microstructure Deterioration Inhibition to Improve Slag Corrosion Resistance
7.7.2 Slag Coating to Protect the Working Surface
7.7.3 Microstructure Reinforcement by Evaporation-Condensation of Pitch
7.7.4 Whisker Insertion to Reinforce Microstructure
7.7.5 Fracture Toughness Enhancement and Crack Propagation Inhibition
References
8 Operation and Refractories for Secondary Steelmaking
8.1 Introduction
8.2 Steel Diversity, Nomenclature, and Use
8.3 Vessels for Different Grades of Steel
8.4 Operational Features of Vessels
8.4.1 Ladle Furnace (LF)
8.4.2 Argon Oxygen Decarburization (AOD)
8.4.3 Vacuum Ladle Degassing Process
8.4.4 Stirring and Refining Process in Degassing
8.4.5 Composition Adjustment by Sealed Ar Bubbling with Oxygen Blowing (CAS–OB)
8.4.6 RH Snorkel
8.5 Designing Aspects of Refractories
8.6 Refractories for Working Lining
8.6.1 Magnesia–Carbon Refractories
8.6.2 Alumina–Magnesia–Carbon Refractories
8.6.3 Dolo–Carbon Refractories
8.6.4 Magnesia–chrome (MgO-Cr
2
O
3
)
8.6.5 Spinel Bricks
References
9 Precast and Purging System
9.1 Introduction
9.2 Composition Design of Castables
9.2.1 Choice of Raw Materials and Properties
9.2.2 Choice of Binders
9.2.3 Aggregates Grading
9.2.4 On-site Castable Casting
9.3 Precast-Shape Design and Manufacturing
9.4 Precast Shapes and Casting
9.5 Purging Plugs
9.5.1 Plug Design and Refractory
9.5.2 Gas Purging
9.5.3 Installation and Maintenance
9.5.4 Clogging and Corrosion
References
10 Refractories for Flow Control
10.1 Introduction
10.2 First–Second–Third Generation Slide Gate
10.3 New Generation Ladle Slide Gate System
10.4 Ladle Slide Gate Plate
10.4.1 Critical Design Parameters
10.4.2 Selection of Slide Plate and Fixing
10.4.3 Materials and Fabrication of SGP
10.4.4 Mode of Failures
10.4.5 FEA for Stress and Cracking
10.5 Tundish Slide Gate and Plate
10.5.1 Modern Slide Gate and Refractory Assembly
10.5.2 Materials and Fabrication
10.5.3 Cracking and Corrosion Phenomena
10.6 Short Nozzles for Ladle and Tundish
10.7 Nozzle Diameter and Gate Opening in Flow
References
11 Refractories for Continuous Casting
11.1 Introduction
11.2 Importance of Long Nozzles in Steel Transfer
11.2.1 Furnace to Ladle Transfer
11.2.2 Ladle to Tundish Transfer
11.2.3 Tundish to Mold Transfer
11.3 Tundish Lining
11.3.1 Lining and Failure
11.3.2 Lining Improvement and Maintenance
11.4 Ladle Shroud (LS)
11.4.1 Design and Geometry
11.4.2 Failures, Materials and Processing
11.4.3 Operational Practice
11.4.4 Flow Pattern
11.5 Mono Block Stopper
11.5.1 Preheating Schedule
11.5.2 Installation
11.5.3 Failures
11.5.4 Glazing
11.6 Submerged-Entry Nozzle
11.6.1 Installation and Failures
11.6.2 SEN Fixing for Thin Slab Caster
11.6.3 SES Installation and Failures
11.6.4 Corrosion and Clogging
References
12 Premature Refractory Life by Other Parameters
12.1 Introduction
12.2 Refractory Manufacturing Defects
12.2.1 Consistence Raw Material
12.2.2 Processing Parameters
12.2.3 Pressing and Firing
12.3 Packing and Transport
12.3.1 Packaging and Packing Material
12.3.2 Vibration-free Packaging
12.3.3 Loading, Transporting, and Unloading
12.4 Procurement and Lining Failures
12.4.1 Total Cost of Ownership Concept
12.4.2 Preliminary Features of Lining
12.4.3 Workmanship
12.5 Preventive Maintenance in Operation
12.5.1 Professional Service
12.5.2 Slag Composition, Temperature, and Viscosity
12.5.3 Monitor and Maintenance of Lining
12.6 Consistent Supply and Time Management
12.6.1 Cycle Concept
12.6.2 Pull/Push Concept
References
Index
End User License Agreement
List of Tables
CHAPTER 01
Table 1.1 Thermal properties of...
Table 1.2 One-dimensional steady...
Table 1.3 Conduction shape factors...
Table 1.4 Dimensionless number...
CHAPTER 03
Table 3.1 Typical composition of...
CHAPTER 04
Table 4.1 Variables affecting sintering...
Table 4.2 Dimensional characteristics of...
Table 4.3 Material transport mechanism...
CHAPTER 06
Table 6.1 Oxide composition of...
CHAPTER 07
Table 7.1 Several operational parameters...
Table 7.2 Characteristic features of...
Table 7.3 Chemical analysis of...
Table 7.4 Essential material selection...
CHAPTER 08
Table 8.1 An overview of...
Table 8.2 Steel nomenclature...
Table 8.4 Lower limits of...
Table 8.5 Represents the advantages...
Table 8.6 The operational parameters...
Table 8.7 The variation of...
Table 8.8 Selection of MgO...
Table 8.9 Mixing practice of...
Table 8.10 Mixing practice of...
Table 8.11 Classification of commercial...
CHAPTER 09
Table 9.1 Different quality of...
Table 9.2 Thermal shock resistance...
Table 9.3 Standard LCC castable...
Table 9.4 Bauxite-based LCC...
Table 9.5 Precast and on...
Table 9.6 Different operational and...
Table 9.7 Purging plug life...
CHAPTER 10
Table 10.1 An interactive analysis...
Table 10.2 Matrix refractory selection...
Table 10.3 Quality selection based...
Table 10.4 Quality selection based...
Table 10.5 Quality selection based...
Table 10.6 The parameters of...
Table 10.7 Type of sliding...
CHAPTER 11
Table 11.1 Competitive properties of...
Table 11.2 Chemical composition of...
Table 11.3 Different zones for...
Table 11.4 Competitive operational...
Table 11.5 Effect of preheating...
Table 11.6 Main features of...
Table 11.7 Main process conditions...
Table 11.8 An interactive analysis...
Table 11.9 Chemical composition and...
CHAPTER 12
Table 12.1 Chemical analyses of...
Table 12.2 Different critical...
Table 12.3 Typical composition of...
Table 12.4 Typical composition of...
Table 12.5 Typical composition of...
List of Illustrations
CHAPTER 01
Figure 1.1 A schematic representation...
Figure 1.2 (a) Closed system with...
Figure 1.3 The energy balance...
Figure 1.4 Schematic representation of...
Figure 1.5 (a) Heat flow...
Figure 1.6 Heat transfer through...
Figure 1.7 Heat transfer through...
Figure 1.8 Schematic representation of...
Figure 1.9 Schematic representation of...
Figure 1.10 Schematic representation for...
Figure 1.11 Velocity boundary layer...
Figure 1.12 Thermal boundary layer...
Figure 1.13 Species concentration boundary...
Figure 1.14 (a) Development of...
Figure 1.15 Variation of velocity...
Figure 1.16 (a) Laminar, hydrodynamic...
Figure 1.17 Control volume for...
Figure 1.18 Axial temperature variation...
Figure 1.19 Comparison of a...
Figure 1.20 (a) Spectral dependence...
Figure 1.21 Absorption, reflection, and...
Figure 1.22 Spectral dependence of...
Figure 1.23 Schematic representation of...
Figure 1.24 Schematic of two...
Figure 1.25 A typical representation...
Figure 1.26 A typical schematic...
CHAPTER 02
Figure 2.1 Major working lining...
Figure 2.2 (a) Indication of...
Figure 2.3 Schematic representation of...
Figure 2.4 Congruent melting of...
Figure 2.5 Incongruent melting of...
Figure 2.6 (a) Solid solutions...
Figure 2.7 (a) Gibbs Triangle...
Figure 2.8 (a) Three solid...
Figure 2.9 Isothermal section at...
Figure 2.10 (a) 3D representation...
Figure 2.11 (a) ABC congruently...
Figure 2.12 (a) Border lines...
Figure 2.13 Phase diagram of...
Figure 2.14 Phase diagram of...
Figure 2.15 Fe–C...
Figure 2.16 SiO2–Al2O3...
Figure 2.17 MgO–Al2O3...
Figure 2.18 MgO–CaO...
Figure 2.19 MgO–FeO...
Figure 2.20 MgO–SiO2...
Figure 2.21 CaO–SiO2...
Figure 2.22 Ternary phase diagram...
Figure 2.23 Ternary phase diagram...
Figure 2.24 Ternary phase diagram...
Figure 2.25 Ternary phase diagram...
Figure 2.26 Ternary phase diagram...
Figure 2.27 Pseudoternary phase diagram...
Figure 2.28 Free energy of...
Figure 2.29 Spherical cap model...
Figure 2.30 Illustration of energy...
Figure 2.31 Nonequilibrium crystallization path...
CHAPTER 03
Figure 3.1 Particle packing in...
Figure 3.2 Particle shape determination...
Figure 3.3 (a) H and...
Figure 3.4 Loading and stress...
Figure 3.5 Liquid distribution in...
Figure 3.6 Typical density distribution...
Figure 3.7 Pressure variations in...
Figure 3.8 Schematic presentation of...
Figure 3.9 Schematic representation of...
Figure 3.10 Flow control refractorie...
CHAPTER 04
Figure 4.1 A typical loading...
Figure 4.2 Mean emissivity of...
Figure 4.3 Two particles (a...
Figure 4.4 Coble model for...
Figure 4.5 The mean diffusion...
Figure 4.6 The change in...
Figure 4.7 Effect of pH...
CHAPTER 05
Figure 5.1 Figure of impulse...
Figure 5.2 Load–displacement...
Figure 5.3 SENB tests for...
Figure 5.4 (a) Schematic representation...
Figure 5.5 Weibull schematic showing...
Figure 5.6 A brittle ceramic...
Figure 5.7 (a) Three-point...
Figure 5.8 Schematic showing the...
Figure 5.9 (a) The diagram...
Figure 5.10 (a) Diagram showing...
Figure 5.11 Anisotropic thermal expansion...
Figure 5.12 Temperature-dependent Thermal...
Figure 5.13 The effect of...
Figure 5.14 Thermal expansion behaviour...
Figure 5.15 A typical RUL...
Figure 5.16 A typical RUL...
Figure 5.17 RUL behavior of...
Figure 5.18 a) Nabarro-Herring...
Figure 5.19 (a) Standard curves...
Figure 5.20 A typical creep...
Figure 5.21 Creep behavior of...
Figure 5.22 (a) Schematic representation...
Figure 5.23 Three hypothetical wear...
Figure 5.24 Schematic showing two...
Figure 5.25 (a) Rough, hard...
Figure 5.26 A diagram of...
Figure 5.27 Erosive wear rate...
CHAPTER 06
Figure 6.1 A quick scheme...
Figure 6.2 Standard free energy...
Figure 6.3 Equilibrium partial pressures...
Figure 6.4 (a) Fraction of...
Figure 6.5 (a) Direct interstitial...
Figure 6.6 a) Comparison of...
Figure 6.7 Schematic illustration of...
Figure 6.8 Schematic diagram of...
Figure 6.9 The concentration distribution...
Figure 6.10 Dissolution and rede...
Figure 6.11 Illustration of the...
Figure 6.12 (a) Cross-section...
Figure 6.13 Definition of refractory...
Figure 6.14 The composition ranges...
Figure 6.15 Dependence of FeO...
Figure 6.16 Isocarbon curves in...
Figure 6.17 Solubility of MgO...
CHAPTER 07
Figure 7.1 Schematic representation of...
Figure 7.2 A competitive analysis...
Figure 7.3 A schematic representation...
Figure 7.4 Schematic representation of...
Figure 7.5 The top-blown...
Figure 7.6 Schematic presentation of...
Figure 7.7 Ternary phase diagram...
Figure 7.8 Evolution of composition...
Figure 7.9 Simplified diagram showing...
Figure 7.10 Simplified diagram showing...
Figure 7.11 Finite element analysis...
Figure 7.12 Cross-sectional view...
Figure 7.13 All critical zones...
Figure 7.14 Lining thickness after...
Figure 7.15 Effect of desilication...
Figure 7.16 MgO-C refractory...
Figure 7.17 Different shaped Mg...
Figure 7.18 Red color represents...
Figure 7.19 RHI reported an...
Figure 7.20 Different class of...
Figure 7.21 Influence of graphite...
Figure 7.22 Type of additives...
Figure 7.23 (a) Variation of...
CHAPTER 08
Figure 8.1 (a) Ladle furnace...
Figure 8.2 Influence of nonmetallic...
Figure 8.3 Schematic view of...
Figure 8.4 Ladle desulfurizing by...
Figure 8.5 Scheme of AOD...
Figure 8.6 Ladle degassing unit...
Figure 8.7 Vacuum oxygen decarburization...
Figure 8.8 Vacuum arc degassing...
Figure 8.9 (a) Recirculating degassing...
Figure 8.10 Ladle to mold...
Figure 8.11 Porous plug assembly...
Figure 8.12 Typical examples of...
Figure 8.13 Calculated mixing times...
Figure 8.14 Schematic representation of...
Figure 8.15 Schemtic representation of...
Figure 8.16 A typical ladle...
Figure 8.17 Stresses at different...
Figure 8.18 Crack in lining...
Figure 8.19 (a) MgO-C...
Figure 8.20 The effect of...
Figure 8.21 A typical temperature...
Figure 8.22 Zones of flow...
Figure 8.23 Conventional refractory...
Figure 8.24 Refractory lining...
Figure 8.25 Process flow diagram...
Figure 8.26 Process flow diagram...
Figure 8.27 Process flow diagram...
CHAPTER 09
Figure 9.1 Self-flow of...
Figure 9.2 (a) Effect of...
Figure 9.3 Exothermic reaction in...
Figure 9.4 Classification of refractory...
Figure 9.5 (a) Refractoriness under...
Figure 9.6 Andreasen and Dinger...
Figure 9.7 A typical shape...
Figure 9.8 (a) CAD view...
Figure 9.9 (a) Impact pad...
Figure 9.10 (a) A schematic...
Figure 9.11 (a) Different design...
Figure 9.12 (a) Effect of...
Figure 9.13 (a) The slag...
Figure 9.14 (a) Schematic representation...
Figure 9.15 (a) Wear mechanisms...
CHAPTER 10
Figure 10.1 Different refractories during...
Figure 10.2 Slide gate assembly...
Figure 10.3 Tundish slide system...
Figure 10.4 Slide gate assembly...
Figure 10.5 Schematic representation of...
Figure 10.6 (a) Refractory in...
Figure 10.7 Configuration of slide...
Figure 10.8 (a) Typical wear...
Figure 10.9 Relationship between plate...
Figure 10.10 Damage of Al2O3...
Figure 10.11 The zirconia insert...
Figure 10.12 Typical damages in...
Figure 10.13 Shape variation clearly...
Figure 10.14 Surface damage of...
Figure 10.15 (a) 2-dimensional...
Figure 10.16 Design alteration to...
Figure 10.17 Schematic view of...
Figure 10.18 Different 5, 4...
Figure 10.19 Latest technology of...
Figure 10.20 Type of cracks...
Figure 10.21 Predicted temperature and...
Figure 10.22 (a) Working surface...
Figure 10.23 Different shapes, assembly...
Figure 10.24 (a) The dimension...
CHAPTER 11
Figure 11.1 Refractories to synchronize...
Figure 11.2 (a) A typical...
Figure 11.3 On-site tundish...
Figure 11.4 Evolution of the...
Figure 11.5 Stress–strain...
Figure 11.6 (a) Change in...
Figure 11.7 Design of bell...
Figure 11.8 Schematic representation of...
Figure 11.9 Schematic representation of...
Figure 11.10 Support ring assisted...
Figure 11.11 Canned flange (a...
Figure 11.12 Tapering of ladle...
Figure 11.13 Argon injected ladle...
Figure 11.14 Position of permeable...
Figure 11.15 Argon sealing management...
Figure 11.16 Effect of air...
Figure 11.17 Details overview of...
Figure 11.18 (a) Critical area...
Figure 11.19 Process and planning...
Figure 11.20 (a) Vertical position...
Figure 11.21 (a) Manual and...
Figure 11.22 (a) The meshing...
Figure 11.23 A typical design...
Figure 11.24 Preheating schedule of...
Figure 11.25 Installation practice of...
Figure 11.26 Schematic representation of...
Figure 11.27 Schematic representation of...
Figure 11.28 (a) Tundish well...
Figure 11.29 Online heating of...
Figure 11.30 Off-line heating...
Figure 11.31 Type of failure...
Figure 11.32 Shape and size...
Figure 11.33 Preheating curve of...
Figure 11.34 Characterization of nozzle...
Figure 11.35 (a) Wear profile...
CHAPTER 12
Figure 12.1 Schematic representation...
Figure 12.2 Brief about natural...
Figure 12.3 Effect of...
Figure 12.4 (a) Variation of...
Figure 12.5 Variation of green...
Figure 12.6 Different important symbols...
Figure 12.7 Fundamental aspects to...
Figure 12.8 Temperature variation during...
Figure 12.9 Representation of the...
Figure 12.10 Shear stress–...
Figure 12.11 Schematic representation of...
Figure 12.12 Viscosities of CaO...
Figure 12.13 Calculated viscosity values...
Figure 12.14 Calculated viscosities of...
Figure 12.15 (a) Detailed temperature...
Figure 12.16 Schematic diagram of...
Guide
Cover
Title page
Copyright
Dedication
Table of Contents
Preface
Acknowledgment
About Author
Begin Reading
Index
End User License Agreement
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Preface
The first part of the book accentuates the valuable basics of “Heat and Mass Transfer,” “Equilibrium and Nonequilibrium Phases,” “Packing, Stress, and Defects in Compaction,” “Degree of Ceramic Bonding,” “Thermal and Mechanical Behavior,” and “High-Temperature Refractory Corrosion,” including relevant finite element analysis in the perception of composition design, manufacturing, and failure mechanism of steelmaking refractories. While considering the steelmaking refractories, detailed “Operation and Refractories for Primary Steelmaking,” “Operation and Refractories for Secondary Steelmaking,” “Precast and Purging System,” “Refractories for Flow Control,” “Refractories for Continuous Casting,” and “Premature Refractory Life by Other Parameters” are essential to acme. These issues have been discussed in the second half of the book to fulfill the academic demand of undergraduate, postgraduate, and research scholars of ceramic engineering, metallurgical engineering, and mechanical engineering outlets who want to nurture in the refractory and steel sectors. The description of such cumulative basic knowledge, collective shop floor data, and relevant failure analysis criteria makes sense and eventually stimulates the awareness of how to grasp and analyze a particular class of refractory for steelmaking.
Refractory production, as fighting fit as their consumption, includes a certain degree of heat and mass transfer. Preliminary from the thermodynamics, heat and mass transfer mechanisms are being described, and eventually, an analogy is drawn in Chapter 1. In-situ phase formation during manufacturing and transformation in the presence of impurities are common phenomena in refractory; thus fundamentals of binary and ternary equilibrium phases and non-equilibrium phases are described in Chapter 2. Optimum compaction and load are a prerequisite to press organic-bonded refractories. A low load regime results in low green density, whether high load beyond critical stress consequences spring back and expedite lamination that eventually produces defect and early stage failure during the maneuver. Such phenomena are deliberated in Chapter 3. Industrial-scale production demands a uniform temperature distribution throughout the kiln to form adequate ceramic bonding or sintering of compact mass otherwise results in premature refractory failure. In this regard, Chapter 4 describes the initial and final stages of sintering, densification, grain growth, and their shape in the matrix. Even with refractory processing failure, meticulous thermal and mechanical stress cracking, severe wear aggravated by abrasion, and corrosion are unavoidable in refractory practice and applications. For these concerns, Chapter 5 highlights the thermal and mechanical behavior, and Chapter 6 underscores the high temperature corrosion mechanism with a relevant model.
In the face of refractory consumption in iron production and transportation, billions of tons of refractories are used for primary steelmaking, secondary steelmaking, and continuous casting around the rondure. Several classic oxides and non-oxide shaped or unshaped refractories are needed because of their operational features, steel and slag chemistry, and tailor-made demand. In this context, how the MgO-C refractory protects by slag, failure due to thermal gradient, slag-refractory corrosion, and eventually their maintenance practice by monolithic is illustrated in Chapter 7. Steel ladle transports molten steel from BOF to tundish through secondary steelmaking processes. The different working lining is evident in the account of different steel grades, and this refractory manufacturing to the mode of failure is discussed in Chapter 8. Processing and probable failure of monolithic either as a back-up lining of ladle, the roof of EAF, or different precast shapes including tundish dam, impact pad, and well-block is discussed in Chapter 9. Continuous gas purging through monolithic porous plug maintain homogenized steel chemistry; thus an exhaustive performance and failure analysis of a different class of porous plug are also deliberated. The flow control mechanism has been discussed in Chapter 10 before an elaborate analysis of the continuous casting refractories in Chapter 11. Occasionally, premature refractory failure depends on several unknown and invisible factors encountered and discussed in Chapter 12.
Acknowledgment
I earnestly acknowledge all academicians, researchers, students, and industry personalities who have contributed to this field. Considerably chosen are several classic pieces of work, including industry practice data, and I have prepared the manuscript with all relevant references and probable copyright permissions. Special thanks to my dearest family members, fellow friends, students, and colleagues who have allowed the discussion and space to prepare the manuscript.
About Author
Debasish Sarkar is a Professor at the Department of Ceramic Engineering, National Institute of Technology, Rourkela, Odisha, India. By 2007 Prof. Sarkar had finished his PhD and held a visiting researcher position at the Korea Research Institute of Standards and Science, Daejeon, South Korea. Gaining adequate experience in research, he received the Materials Research Society of India (MRSI) Medal in 2016. He is avid about research, and his publications number more than a hundred, including peer-reviewed international journals, book chapters, books, and national and international patents.
Debasish has a wide horizon of collaboration with refractory and steel sectors around the Globe that eventually aligns the content according to industry demand. Refractory development with life assessment and performance monitoring are his recent time interests. Professor Sarkar is consistently engaged as an advisor for the industry sponsored project on ‘Steelmaking Refractories and Flow Control’.
He was designated head of the “Centre for Nanomaterials” at NIT Rourkela and established an excellent team to accomplish high-end research and products. As an experienced researcher in nanostructured ceramics and ceramic processing, he is also a mentor for the ‘Miniaturization of Ceramic Components’ to support the industry in every way viable.
