steel brochure

Refractories for Steelmaking

IncorporatIng ISI (EuropE) LImItEd

InduStrIaL SoLutIonS IntErnatIonaL

.

Industrial Solutions International (ISI) was founded in 1997 following the acquisition and merger of the three largest refractory companies in the United States. Our corporate goal at that time was to develop a supply chain for a full range of refractory materials utilizing small specialty manufacturers that could offer superior specialized products and technical services to the industry than our large competitors.

In 2006, after many years of managing sales and technical support to all industries in North America, ISl exclusively acquired the technology utilized by Dyson Refractories, based in the United Kingdom, for the manufacture of all basic refractories. The purchase included all magnesite chrome products including the internationally renowned Dymax® range of products.

Following an extensive review of manufacturing companies and plants throughout the world, ISl entered into a long term technology transfer/sharing agreement with Z. M. “ROPCZYCE” S.A. (ZMR) in Poland. Subsequently Industrial Solutions International also agreed to a long term exclusive distribution/management agreement to oversee and manage sales and distribution of all ZMR and ISI products to the non ferrous industry worldwide and specifically the copper and precious metals industry.

ZMR has a state of the art manufacturing plant and a highly advanced technical department. This group works closely with the ISI technical personnel in an effort to continue to develop new and improved products that, at times, are designed specifically to address individual clients operating conditions.

The ISl/ZMR joint philosophy involves working very closely with our clients to understand their specific process and operating parameters in order to select products and refractory designs that will maximize refractory life and value.

ISI/ZMR Services Offered• Engineering & Design/CAD Capabilities• Material Recommendation/Development and Supply• Finite Element Analysis/ Factsage• Installation and Demolition Supervision• Lining Thickness Reports and Recommendations• Post Mortem Analysis

INDUSTRIAL SOLUTIONS INTERNATIONAL

Knowledge and Expertise in the Refractory Industry.



.

QUALITY AND PERFORMANCE

Industrial Solutions International recognizes that the quality of products has a major impact upon the performance that can be achieved by their customers.

In order to fulfil this requirement, ISI has conducted a rigorous assessment of refractory manufacturers and are now satisfied that alliances formed are capable of delivering materials to ISI and customer requirements. All production is certified to ISO 9001, and ISO 14001 for the design, manufacture and supply of refractory materials.

Sourcing may follow differing routes dependent upon the application, product type, and manufacturing capabilities, but in all instances rigorous controls are applied.

Any data contained within this catalogue may be considered as representative of large production of a variety of sizes and shapes but cannot be considered as a specification.

TECHNICAL BACKUP

Technical support to the client is provided by the intensive research and development facilities of the associate companies and by the Technical Division of Industrial Solutions International. Selection of materials is made by reference to an extensive application database, which in conjunction with close liaisons with end users provides materials offering optimum performance in terms of cost and operation

!

a

Production

Production of refractory materials requires careful selection of raw materials, and attention to detail in further processing.

Further processing involves: Size reduction and separation to provide the components for a given • composition.Mixing in high intensity mixers to provide a homogeneous mass.• Pressing at high pressure to ensure maximum compaction - providing high • density and minimum porosity.Firing to high temperature by intermittent or tunnel kiln and allowing sufficient • time for optimum bond development.Further processing where necessary to exacting dimensional tolerance.•

2000 Tonne Laeis Press

3©2010

Eirich Mixer

Press Bay Tunnel Kiln

Intermittent Kiln

a

Product Development

In order to provide quality products, Industrial Solutions International, in collaboration with Zakłady Magnezytowe ”ROPCZYCE” S.A., deliver to their markets, materials of the highest quality consistent with a competitive price, backed by the expertise of application knowledge.

Industrial Solutions International operates a policy of continuous product development that from time to time results in the introduction of new products or modifications to existing products.

Product development is both proactive and reactive in that new materials and technologies are constantly reviewed, and where appropriate, incorporated into the manufacturing program. In parallel, cognizance is taken of material performance in the many and varied industries where Industrial Solutions International products are utilized. Wherever possible either material properties or design will be tailored to meet the requirements of a given application.

By the judicious selection of material and there correct placement in the application zone dramatic improvements may be made to performance.

MOR Test

Service Simulation

Service Benefits

4

©2010

Rotary Slag Test

Electric Arc Furnaces

Electric Arc Furnace melting has been a feature of steel making since the early nineteenth century, when it was realized that advantage could be taken of the ease of transformation of furnace atmosphere from oxidizing to reducing.Developments in technology have been rapid from the early single phase two electrode four tonne capacity furnace to the current day three phase, three electrode, ultra high power 120 tonne plus furnaces.Development of furnace technology was most marked during the 1960’s with the advent of mini mills, and continuous casting, and the modern day furnace bears little resemblance to its forebears.Electric arc furnace design has evolved to such an extent that

melt down is achieved not only by the arc, but also by ancillary oxy - fuel burners, resulting in shorter tap to tap times, and a saving in primary energy.Tapping is now achieved with greater control owing to the bottom tapping regimes in place of the launder. Refining in the ladle has reduced refractory wear, particularly in the slag line and hot spots, owing to shorter residence times and lower temperatures. Refractory consumption both in the arc furnace body and roof has been reduced by the introduction of water cooled panels.Developments in electric arc furnace design continue, and recent changes have seen the use of slide gates to control the tapping stream, and the introduction of more favorable slag practices to reduce refractory wear and improve electrode consumption.

ELECTRIC ARC FURNACE OPERATIONThe charging process to the furnace is in itself damaging to the refractory lining by both impact and the chilling effect of the cold scrap. The aggressivity to the refractory lining is further increased by rapid temperature increase during melting, combined with the attack by slag fluidizers such as fluorspar.Preferential attack of the refractory lining occurs in the hot spot areas (opposite the electrodes) caused by flare, and at the slag line, owing to low basicity slags, and high FeO slags, often employed to aid phosphorous removal.Slag balance and slag control can have a major influence on refractory wear, particularly control of MgO content by Dolomite additions to prevent dissolution of MgO from the lining.Non water cooled electric arc furnaceThe ‘conventional ‘arc furnace where the whole of the furnace contains refractory materials in both the body and roof. In this type of furnace metal and slag are in contact with both metal and slag throughout the operation.Water cooled electric arc furnaceMany variants of this type of furnace are available, with water-cooled metal panels being incorporated in both the body and roof. The water cooled panels are protected from direct metal and slag contact by frozen slag adhering to the surface of the panels. There is only a minimal amount of refractory material in the lining, in the bottom, lower sidewall, slag line and roof delta section.Water cooled electric arc furnace with EBTA variant of the water cooled furnace where tapping does not take place via a ‘launder system but through an eccentric bottom taphole (EBT). The EBT system allows greater control to achieve slag free tapping, and is much preferred in those units operating with a ‘hot heel’ melting regime.

5©2010

Electric Arc FurnacesREFRACTORY APPLICATIONSRefractory selection for the lining of electric arc furnace is invariably built upon a combination of material qualities, and brick size to maximise the performance. Preferential wear in the hot spots and at the slag line is reduced by careful material selection, together with an understanding of the particular practice.SUB HEARTHThe sub hearth of the electric arc furnace has an extended lifetime in comparison with other components of the lining, and is only replaced after severe metal penetration through the working hearth or after major water leakage. Sub hearth linings are normally constructed with high quality magnesite bricks.WORKING HEARTHThe working hearth is required to withstand high temperature, temperature cycling, and impact from the scrap charge. Current furnace designs favour monolithic linings based upon high MgO powders rammed into placed and contoured into the sidewalls. Some furnace operations do however permit and prefer brick hearths, generally based upon pitch impregnated fired magnesite.SIDEWALLSWithin the sidewall area there are three main zones, the slagline, the hot spots and the remainder. Balanced lining wear is the main criteria in electric arc furnace refractory performance, and this requires zoning of the lining by both material quality and thickness. The majority of electric arc furnaces now incorporate magnesite carbon products into the sidewall, and their performance is influenced by both the base raw material, and graphite content. Performance is markedly increased as the crystal size of the magnesite increased to the ultimate by the use of fused magnesia. Increase of graphite content also follows the same pathway, although carbon retention is important, and this may be improved by the inclusion of finely divided metals.MAIN SIDEWALLThe areas in the sidewall that gives rise to least difficulty are those between the hot spots, the so called ‘cold spots’.The major factors influencing refractory performance are temperature, and slag splash, and in water cooled furnaces a magnesite carbon of at least 10% graphite content is preferred.HOT SPOTSThe wear mechanism in the hot spots is similar to that in the main sidewall, but is exacerbated by temperature owing to electrode flare. Higher quality magnesite carbon with a graphite content of 20%, and based upon either large crystal size or fused magnesia are preferred. Where oxy-fuel burners are employed, oxidation of the carbon can take placed, and this may be reduced by magnesite carbon materials incorporating finely divided metals.SLAGLINEThe aggressive nature of slag fluidizers such as fluorspar has a detrimental effect upon slag line performance, together with slags high in FeO. Materials based upon high quality magnesite, or in severe cases, large crystal size or fused magnesia are preferred. Where high iron oxide slags are encountered magnesite carbon materials incorporating metal additions are preferred.BURNER PORTS AND SLAG DOORThese areas of the furnace are subjected to wear by oxidation, and by impact of the slag door jambs. Magnesite carbon with metal additions are important in these areas.ROOFMany electric arc furnace roofs now have a high degree of water cooling, and as such require little refractory material. The Delta between the electrodes is invariably formed using a monolithic material or precast shape, but refractory bricks are often used to form the electrode ports. Materials in this area require good thermal shock and abrasion resistance, and high alumina materials are seen to advantage.

6

©2010

a

Electric Arc Furnace

Runcast BWA1M ARuncast BKT/EC ARuncast BMAL/TSW A

Normag M92 MNormag M92SU MThermag M965U M

Heartmix UR2 JHeartmix URF/C JHeartmix URBD JHeartmix URF/CT J

Thermag M965U QCarmag MWL832A QCarmag MWL743A Q

Carmag MWG735 DCarmag MW632 DCarmag MP732A DRunmag MCNSW ST4 DRunmag MCNR3 ST4 D

Runcast BMAL/MSW ORowmix MOR O

Carmag MW754A CCarmag MWHL7535 C

Carmag MP91AY NKonmix UMP1 S

Protmix ZO/M L

Normag M92 KNormag M92 I

Konmix MKNZ P

Runcast BMAL/TSW B

A Roof B Electrode Ring C Slag ZoneD Sidewal I Bottom Safety Lining J HearthK Safety Lining L Filling Mixes M Cold ZoneN Furnace Door O Tapping Spout P Repair MixesQ Taphole Block S Charging Door Repair

7©2010

a

Electric Arc Furnace Water Cooled Panels


Normag M92 MNormag M92SU MThermag M965U M


Thermag M965U QCarmag MWL832A QCarmag MWL743A Q

Carmag MWH7325 DCarmag MW632 DCarmag MG735 D

Runcast BMAL/MSW ORowmix MOR O

Carmag MP742A CCarmag MWH7425 CCarmag MW754A CCarmag MWHL7535 C


Protmix ZO/M L

Normag M92 KNormag M92 I

Konmix MKNZ P

Runcast BMAL/TSW B

A Roof B Electrode RingC Slag Zone D SidewallE Taphole Sealing Mix F Taphole SleevesG Taphole End Block H Taphole BackfillI Bottom Safety Lining J HearthK Safety Lining L Filling Mixes

8

©2010

Electric Arc Furnace Water Cooled Panels Eccentric Bottom Tapping


Runcast BMAL/TSW B

Carmag MWH7325 DCarmag MW632 D

Konmix MPI EKonmix MKNZ E


Stertmix UZO H

Normag M92 INormag M92 I

Protmix ZO/M L

Algraf KG95A GNormag M92 MNormag M925U MThermag M965U M

Carmag MWL753AU FCarmag MWL744AY FCarmag MWL7145 R

Carmag MP742A CCarmag MWH7425 CCarmag MW754A CCarmag MWHL7535 C


9©2010

A Roof B Electrode RingC Slag Zone D SidewallE Taphole Sealing Mix F Taphole Sleeves

Product Data

Basic Refractories for Electric Arc Furnace Applications

Quality Chemical Analysis Aggregate Open

Porosity Bulk

Density CCS RULMgO AI2O3 Fe2O3 CaO SiO2 Cr2O3

% & g/cm3 MPa T0.6oCMagnesia bricksNormag M92 93.8 0.6 1.9 0.9 2.0 - 18 2.88 65 >1660Normag M92SU1 93.7 0.7 1.4 1.3 2.8 C – 4.40 4.5 2.96 77.5 >1660Thermag M92SU1 96.7 0.2 0.3 2.1 0.4 C – 3.95 4 3.00 70 >1700Magnesia chrome–bricksRunmag MCNR3 ST44 55.6 6.9 13.2 1.1 0.8 21.7 10 3.23 90 >1700Runmag MCNSW ST44 56.0 - 12.5 - 1.5 15.0 13 3.08 60 >1650Mixes and low–cement prefabricated castablesRuncast BWA1M - 73.5 0.45 0.6 24.6 - - - - -Runcast BMAL/MS2 4.5 92.5 0.1 1.6 - - 14 3.00 50 >1700Runcast BMAL/TS2 4.2 93.0 0.1 1.6 - - 15.5 3.05 50 >1700Runcast BKT/EC - 93.7 0.7 1.6 0.8 - 16.5 3.10 50 -

Mixes and Mortars

Quality Chemical Analysis [%] Open

PorosityBulk

Density CCS Grain SizeMgO AI2O3 Fe2O3 CaO SiO2 Cr2O3

% % g/cm3 MPa mmMixes and mortarsHeartmix URF/C 77.9 0.3 6.2 14.6 0.6 - - - - 0-7Heartmix URF/CT 76.9 0.4 6.2 14.7 1.04 - - - - 0-7Heartmix URBD 80 0.3 2.9 16 0.5 - - - - 0-7Heartmix UR2 95.5 0.7 1.6 0.6 1.3 10.5 - - - 0-6Konmix UMP1 69.5 4.8 8 1.6 3.2 - - - - 0-10Konmix MP1 80 17.8 0.2 - 0.15 - 22.53 2.73 12.53 0-6Konmix MKNZ 90 - 0.5 2 1.3 1.8 - - - 0-5Protmix ZO/M 91.5 1.2 1.3 1.5 3.9 - - - - 0-1Romix MOR 52.8 - 7.2 0.2 39.2 - - - - 0-3Startmix UZO 47 - 8 1.5 43 - - - - 2-7

1 Vacuum pitch impregnated bricks2 Steel fibres added3 After forming and firing 1680oC4 Steel clad

10

©2010

Product Data

Magnesite Carbon Products for Electric Arc Furnace Applications

Quality Chemical Analysis Aggregate Open

PorosityBulk

Density CCSMgO AI2O3 Fe3O3 CaO/ SiO2

C % % g/ml MPaBricks with 6 – 10% CarbonAlgraf KG95A C+SiC>27 - >75 - - 4 2.85 27Carmag MWL714S 6 97.7 0.05 0.16 >2 3 3.12 85Carmag MP91AY 7 99.0 0.08 0.15 >2 2.25 3.00 85Carmag MWH732S 10 97.0 - 0.70 >2 3.5 3.00 28Carmag MG73S 10 97.0 0.07 0.20 >2 2.0 3.00 32Carmag MP732A 10 97.5 0.15 0.35 >2 4.0 3.00 40Carmag MW632 10 96.9 0.07 0.30 >3.8 2.0 3.00 40Carmag MWL832A 10 98.0 0.05 0.20 >2 5.0 3.00 37Bricks with 12 – 13% CarbonCarmag MP742A 12 97.5 0.15 0.35 >2 4.0 3.00 37Carmag MWL743A 12 97.0 - 0.30 >2 1.7 2.96 34Carmag MWH742S 12.5 97.0 - 0.80 >2 4.0 2.91 25Carmag MWL744AY 13 >97.5 - 0.20 >2 2.5 3.00 37Bricks with 14 – 16% CarbonCarmag MW754A 14.5 97.5 - 0.50 >2 2.0 3.00 40Carmag MWL753AU 15 97.5 - 0.20 >2 3.0 2.94 31Carmag MWHL753S 16 97.0 - 0.50 >2 3.0 2.96 22

11©2010

Standard Brick Shapes

Shape Dimensions [mm]a b h

2-40 250 124 402-76 250 124 764 375 150 76

25/0 250 150 10030/0 300 150 10035/0 350 150 10040/0 400 150 10045/0 450 150 10055/0 550 150 10070/0 700 150 10090/0 900 150 10090/0-160 900 160 100

Shape Dimensions [mm]

a b l h1P10 119 109 230 641P14 121 107 230 641P28 128 100 230 642Q14 132 118 250 652Q20 135 115 250 652Q28 139 111 250 654P6 126 120 375 764P10 130 120 375 764P15 135 120 375 764P26 146 120 375 764P34 184 150 375 764P50 170 120 375 764P70 170 100 375 7625/8 154 146 250 10025/30 165 135 250 10035/40 170 130 350 10035/60 180 120 350 10035/8 154 146 350 10035/80 190 110 350 10040/10 155 146 350 10040/20 160 140 400 10040/40 170 130 400 10040/80 190 110 400 10045/20 160 140 450 10045/40 170 130 450 10045/8 154 146 450 100

The tables illustrate some common brick shapes which cover most applications. Many other shapes are available and others may be manufactured to their customer’s specification.

12

©2010

Steel Ladles

13©2010

Ladles in the steel plant environment are primarily required to contain and transport molten steel from the melting unit to the casting facility. In the recent past this was the sole purpose of the ladle, and the refractory requirements were undemanding, allowing the use of low alumina bloating fireclay as the working lining. Backing linings were also built using fireclay materials, and the low thermal conductivity, and heat capacity allowed the ladles to be used without preheating.

Modern day steel ladles operate in harsher conditions, where temperatures are higher, steel is stirred in the ladle, slag chemistries are more variable, and residence times are longer. All these factors have caused a radical change in ladle design, with great dependence on zoning either by quality or thickness to overcome preferential wear and achieve a balanced life at the lowest possible cost per tonne.

Future designs for ladles will follow the current trends, with greater reliance upon the ladle for refining, deoxidation and degassing. Residence times will be long owing to the treatment, and electrode heating in the ladle will be necessary to maintain the temperatures required for casting. Demands upon the refractory will continue to be high requiring continuous development to maintain and improve performance.

LADLE REFINING FURNACES

Ladle refining furnaces have become increasingly common in both EAF and BOS shops, where primary melting is carried out in either the arc furnace or converter, and further heating and treatment in the ladle. Refining in the ladle may comprise deoxidation, desulphurisation and alloy trimming using a variety of calcium aluminate synthetic slags. All ladle refining furnace provide heat to the steel by electrode heating usually with stirring using either electromagnetism or gas plugs. After final heating in the ladle, most ladles are subjected to degassing using either RH or DH degassers, and a common feature of the ladle refining furnace is one of long residence and high temperature. Refractory applications vary widely depending upon both the operation and practice, and each may show individuality.

BOTTOM

The ladle bottom is invariably constructed from either fired alumina, carbon bonded dolomite or magnesite with the provision of an impact or tapping pad, in carbon bonded alumina graphite with metal additions. The severity of the operation in terms of residence times often sees the replacement of the bottom at mid campaign, usually coinciding with a slag line repair.

SIDEWALLS

Sidewalls of ladle refining furnaces sometimes exhibit preferential wear associated with the method of stirring, requiring either increased thickness panels, or improved refractory quality. The ladle sidewalls may be constructed using either carbon bonded dolomite, carbon bonded magnesite or carbon bonded magnesite carbon. All basic ladle linings however have very high thermal conductivity and heat capacity and thorough and effective preheat with sufficient soak time is essential.

SLAGLINES

Slags associated with ladle refining furnaces are usually high in calcium aluminate, and contain fluxing agents such as fluorspar, making them particularly aggressive. Slag line refractory materials are usually magnesite carbon with at least 10% flake graphite and containing metal additions. In particularly severe applications recourse is made to magnesite carbon based upon large crystal size magnesite, and in the most arduous conditions magnesite carbon based upon fused magnesia.

The action of bubblers in the ladle bottom may also have a profound effect at the slagline particularly if the gas stream is close to the sidewall. In these cases severe localised erosion may occur giving rise to premature failure of the slagline.

Steel Ladles

Izomix UZKI/M R

Izomix UZKI/MK R

Izomix UZI/L R

Izomix UZI/W R

14

©2010

Slagmix UZRA P

Slagmix UZRA/SU P

Slagmix UZRA/KP P

Slagmix UZRA/S P

Slagmix UZRA/SSO P

Slagmix UZRA/SWO P

Slagmix UZRA/KPG P

Slagmix UZRA/O P

Algraf AMG01A K

Algraf AMG01A2 K

Algraf AMGN02A K

Carmal MSP610A K

Runcast BMAL/M K

Kromex MC1 L

Normag M87 L

Konmix SMKB21 L

Konmix SMKC31 L

Topan ALMA L

Topan ALMK L

Runcast BMAL/MM G

Algraf AMG01A G

Algraf AMGN02A G

Carmal MSP601A G

Algraf AMG01A2 G

Startmix UZS O

Startmix UZS/W O

Startmix MS1 O

Startmix UZS2 O

Runcast BMAL/M55 C

Runcast BMAL/T C

Altop SUW55URC F

Altop SUW035URC F

Thermag M96F3RC F

Sealmix MKX/W S

Runcast BKW E

Runcast BMAL/M55 C

Runcast BMAL/T C

Nitral KSIAL E

Runcast BKW E

Algraf AMG01 B

Algraf AMG01A B

Algraf AMG02 B

Carmag MG63 B

Carmag MW714 B

Carmag MWH01 B

Carmag MWH04 B

Carmag MWH01D B

Carmag MWH01DM B

Carmag MWH63U B

Carmag MWH712U B

Topkrom MCW22/K B

Carmag MW643A A

Carmag MW744A A

Carmag MW764A A

Carmag MWH643 A

Carmag MWL734 A

Carmag MWHL743U A

Carmag MWHN754U A

Carmag MWHN764A A

Topkrom MCV A

Konmix MKX2 J

Runcast BMAL/L3M J

Normag M87 H

Normag M90 H

Ksztahkagazoprzepuszczalna(Purging Plug)

I

Konmix MKX3 D

Protmix ZOK M

Gunmix MTMW N

A Slag Zone B Bath Zone C Well BlocksD Lip E Nozzles F Sliding GatesG Bottom H Distance Ring I Gas Purging PlugJ Well Block Mix K Impact Zone L Safety LiningM Filling Mixes N Gunning Mix O Starting MixP Slag Forming Mix R Insulating Mix S Sealing Mix

Product Data

Refractories for Steel Ladles

Quality Chemical analysis aggregate Open

Porosity Bulk

Density CCSMgO AI2O3 Fe3O3 CaO SiO2

C % % g/ml MPaBricks with 4 - 7 % carbonAlgraf AMG01 6.0 8.0 84 0.3 - 1.0 5 3.20 50Algraf AMG01A 6.5 14.0 81 0.8 0.4 1.2 3 3.20 60Algraf AMG01A2 6.0 8.0 89 0.2 0.3 2.5 3 3.15 80Carmal MSP601A 6.0 42.5 55.5 0.5 0.5 0.5 5 2.98 65Carmag MW714 6.0 96.5 0.15 0.7 1.45 0.7 4.5 3.08 65Carmag MWH712U 6.0 97.0 0.2 0.4 1.7 00.6 4 3.15 50Carmag MWH01 7.0 76.0 0.7 5.4 15 0.9 3 3.05 35Carmag MWH01D 4.5 55.0 0.3 1.4 40 1.1 4 2.95 35Carmag MWH01DM 4.5 50.0 0.6 3.5 40 1.9 3 2.90 45Bricks with 8 - 11 % carbonAlgraf AMG02 11.5 8.0 80 1.6 - 4.5 9.0 2.95 25Algraf AMGN02A 8.0 7.0 80 1.0 0.8 7.6 6.0 2.95 55Carmag MG63 10.0 95.5 1.0 0.7 1.6 0.8 6.5 2.95 40Carmag MWL734 10.5 97.0 0.2 0.4 1.7 0.6 4.0 3.01 45Carmag MWH04 11.0 78.0 0.3 5.4 14 0.7 3.5 2.97 25Carmag MWH63U 8.5 96.0 0.2 0.4 1.9 0.7 6.0 3.00 30Bricks with 12 - 18 % carbonCarmag MW643A 12.0 95.8 0.6 0.9 1.4 1.0 5.0 2.94 35Carmag MW744A 13.0 97.0 0.1 0.6 1.8 0.7 4.0 2.94 35Carmag MW764A 16.0 97.0 0.2 0.7 1.4 0.7 3.5 2.94 30Carmag MWH643 15.0 96.0 0.6 0.7 1.47 0.7 6.0 2.92 27Carmag MWHL743U 12.5 97.0 0.15 0.6 1.4 0.7 4.5 3.00 30Carmag MWHN754U 14.0 97.0 0.1 0.5 1.8 0.7 5.0 2.95 28Carmag MWHN764A 17.5 97.0 0.2 0.7 1.4 0.7 4.0 2.90 24

15©2010

Quality Chemical Analysis [%] Open

Porosity Bulk


% % g/cm3 MPa T0.6oCMagnesia bricksNormag M87 90.6 0.8 2.3 0.6 4.5 - 19.0 2.82 55 >1650Normag M90 91.0 2.2 2.0 0.7 3.1 - 19.0 2.82 60 >1650Thermag M96F3RC 96.5 0.2 0.6 1.6 0.6 - 14.0 2.99 110 -Magnesia chrome–bricksTopkrom MCV 53.0 7.0 13.1 1.0 1.1 23.3 16.0 3.29 80 >1700Kromex MC1 76.9 3.7 6.4 1.2 2.4 8.5 20.0 2.91 45 >1560Topkrom MCW22/K 57.5 6.4 11.1 0.7 1.3 23.1 17.0 3.15 60 >1700

Product Data

16

©2010

Sialon bonded alumina bricksNitral KSIAL - 74.0 - - - - 18.0 3.00 100 -Altop SUW03SURC - 79.5 - - 10.6 - 4.0 3.17 220 -Altop SUW5SURC 4.0 93.5 0.2 - 0.3 - 7.0 3.18 230 -High–alumina bricksTopan ALMA 0.3 65 0.9 - 32 - 14.5 2.61 90 1680Topan ALMK - 61.3 0.98 - 35.4 - 15.5 2.43 50 1550Mixes and low–cement prefabricated castablesRuncast BMAL/T 4.5 94 0.1 1.3 - - 15.0 3.05 60 >1700Runcast BMAL/M 5.0 93 0.1 1.4 - - 15.0 3.05 50 >1700Runcast BMAL/MM 5.0 93 0.1 1.4 - - 15.5 3.05 50 >1700Runcast BMAL/M55 5.0 93 0.1 1.3 - - 13.5 3.10 80 >1700Runcast BKW 0.8 97 0.1 1.5 0.1 - 14.0 3.10 90 >1700Runcast BMAL/L3M 4.4 93 0.06 1.4 - - 14.0 3.00 65 >1700Mixes and mortarsStartmix UZS2 - - - - 25.0 34.6 - - - -Izomix UZKI/M 37.0 14.0 6.8 2.9 36.0 - - - - -Izomix UZKI/MK 40.0 13.4 - - 37.5 - - - - -Izomix UZI/L 0.7 - 0.2 0.6 84.0 - - - - -Startmix MS1 7.0 10.0 20.5 - - 31.9 - - - -Konmix SMKB - 70.0 0.9 - - - - - - -Konmix SMKC - 73.0 0.2 - - - - - - -Izomix UZI/W 42.1 13.7 - - 32.2 - - - - -Slagmix UZRA 2.0 25.0 1.5 55.0 8.0 - - - - -Slagmix UZRA/SWO 5.4 9.10 1.2 78.2 5.2 - - - - -Slagmix UZRA/S 4.9 25.2 1.2 53.8 12.0 - - - - -Slagmix UZRA/O 1.0 35.9 1.06 52.5 4.5 - - - - -Slagmix UZRA/KP 4.6 41.7 1.3 42.3 4.7 - - - - -Slagmix UZRA/SU 1.0 4.5 0.7 90.5 3.9 - - - - -Slagmix UZRA/SSO 3.9 16.0 1.0 72.0 5.0 - - - - -Startmix UZS/W - 11.6 23.0 - 20.5 36.5 - - - -Startmix UZS 7.1 11.4 21.7 - 25.0 34.5 - - - -Protmix ZOK 58.0 1.0 6.0 1.0 31.0 - - - - -Konmix MKX2 56.0 6.3 12.8 1.2 1.9 19.0 22.0 2.90 >25 >1700Konmix MKX3 92.0 0.7 1.9 0.7 2.6 - 29.0 2.46 12 -Gunmix MTMW 80.0 1.2 3.4 5.5 4.5 - - - - -Sealmix MKX/W 96.5 - 0.7 1.4 1.0 - - - - -

Quality Chemical Analysis Open

Porosity Bulk


% % g/cm3 MPa T0.6oC


Straight

Semi Universal

17©2010

SHAPE Dimensions [mm]a b h

1 230 114 641-32 230 114 322 250 124 642-32 250 124 3225/0 250 150 1002-65 250 124 65KD-2 300 160 80KP-400 400 400 1003P0-K 250 155 1004P0-K 250 187 1005P0-K 250 220 1005P0-D 250 200 100

SHAPE Dimensions [mm]a b l h φ

SU630 178,1 209,5 100 152,4 1701SU645 188,7 209,5 100 152,4 2703SU745 185,2 209,5 100 177,8 2652SU760-4 191,4 209,5 100 177,8 3760SU845 181,6 209,5 100 203,2 2602SU860 188,7 209,5 100 203,2 3504


Side Arch

18

©2010

SHAPE Dimensions [mm]a b l h r

5/6 147 153 125 100 30625/20 140 160 125 100 8756/8 146 154 152,4 100 27816/20 140 160 152,4 100 10662B-150 128 123 65 250 159911/18-76 212 230 76 115 139325/16 142 158 100 250 134525/30 135 165 100 250 112530/20 140 160 100 300 20933P10-K 95 105 250 155 14753P20-K 90 110 250 155 69540LK 80 100 300 150 6004P12-K 94 106 250 187 14674P22-K 89 111 250 187 7584P8-K 96 104 250 187 22585P16-K 92 108 250 220 12675P8-K 96 104 250 220 2657B7A 192 240 100 180 720B8 200 225 100 150 1208KD11 200 225 80 115 914KD12 210 225 80 115 1605KD13 192 225 80 155 901KD14 204 225 80 155 1521KD15 204 225 90 185 1847KD17 210 225 80 90 1284

Steel Degassing

The degasser operation imposes severe stress into the refractory lining system owing to rapid changes i temperature.

In the recirculatory degassing operation, liquid steel is forced from the ladle into an evacuated refractory chamber by atmospheric pressure. The low pressure in the chamber then allows the entrapped gases to expand and rise to the surface, resulting in the denser degassed steel returning to the ladle. The action of the degassing process also results in high turbulence within the steel volume giving rise to homogenisation. Gases from the chamber are removed through off takes and coolers.

RH AND DH DEGASSING VESSELS

Vacuum degassing is carried out in two distinct recirculatory units, the DH -Dortmund-Hoerde utilising a single snorkel leg whereby steel is drawn into the chamber and after degassing leaves through the same leg. RH - Ruhrstaal - Heraeus using an upleg snorkel leg through which steel is drawn into the chamber and the denser degassed steel leaves through the down leg.

The DH degassing system is typically used in the production of high alloy and speciality steels from low tonnage electric arc furnace shops, whereas the RH degassing system is associated with high tonnage BOS shops producing low-carbon aluminium-killed steel.

RH degassing is generally preferred owing to the metallurgical advantage of downstream refining processes to produce large tonnage’s of high quality lower cost continuously cast steel.

Development of the RH degassing system has led to:

RH-OB - oxygen blown to produce low carbon (<0.015%) steel.

RH-PB - powder injection of synthetic slag desulphurisers to remove or modify sulphur inclusions.

RH-OB - aluminium heating by the addition of aluminium metal.

REFRACTORY WEAR PROCESSES

Refractory selection for the lining of vacuum degassers is invariably determined by consideration of the various features of the process.

TEMPERATURE

Temperatures in the degassing vessel vary from 1480 to 1760oC, with the temperature often being sustained at 1480oC between heats, and increased up to 1760oC during treatment.

EROSION

The action of molten steel and slag entering the vacuum chamber places a highly erosive action upon the refractory lining.

ABRASION

Abrasive forces exists in the gas off takes owing to the action of fine steel particles entrapped in the exiting gases.

19©2010

Steel Degassing

THERMAL CYCLING

Owing to the intermittent nature of the process there is inevitably temperature cycling in the vessel, this coupled with invasion into brick matrices leads to disruptive spalling of the refractory lining.

REQUIREMENTS OF THE REFRACTORY LINING

The performance of the working lining is totally governed by the presence of basic slags and iron oxide, demanding a basic refractory lining. The greatest wear occurs in the snorkel legs and bottom of the chamber. Refractory requirements are high strength, good slag resistance, and high thermal shock resistance.

SNORKEL LEG

Materials based upon direct bonded sintered and fused co-clinker have been shown to give optimum performance. Snorkel leg materials are supplied with all mating faces diamond ground to tight tolerance to allow construction without the use of mortar joints.

SNORKEL LEG OUTER LINING

Many plants provide the snorkel leg with an outer cast using a high quality refractory concrete. ISI/ZMR Refractories prefer to enhance the refractory concrete with metal fibres to increases the resistance to material loss by Thermo-mechanical damage.

WORKING BOTTOM AND LOWER SIDEWALL

The working bottom of the degasser is normally constructed using a soldier course design, with materials based upon fused magnesia chrome clinker. In this area of the vessel, high demand is placed upon the materials ability to resist both erosion and slag attack.

ALLOY CHUTE

The alloy chute demands refractory materials with high resistance to thermal shock and abrasion, and here again fused grain magnesia chrome clinker are preferred.

UPPER VESSEL WORKING LINING

The upper vessel working is less prone to attack by either erosion or slag, but places special demands upon the refractory material. The upper working lining is primarily affected by temperature variation, and to a lesser extent by metal and or slag contact. As such a refractory lining offering high resistance to thermal shock is required.

SAFETY LININGS

All areas of the vessel require a high quality economical safety lining capable of resisting metal at high temperature. Materials based upon Andalusia have proven to be the most sensible choice.

20

©2010

21©2010

Runcast BMAL/M G

Topkrom MCB F

Topkrom MCV ETopkrom MCT E

Konmix MKX2 JKonmix MKX3 J

Konmix MKX2 JKonmix MKX2/L J

Runcast BMAL/L JKonmix MKX2/L JKonmix MKX2 J

Maskor MSK H

Topkrom MCB F

Topkrom MCW22K I

Dymax GU D&CDymax GUNSC D&CTopkrom MCZ21 D&C

Topkrom MCR5 A

Runcast BMAL/MS BRuncast BKW/S B

A Snorkel Inner Working Lining B Snorkel Outer Working LiningC Bottom Working Lining D Lower Vessel Working LiningE Upper Vessel Working Lining F Alloy Chute and Burner OpeningG Burner Opening Working Lining H Alloy Chute Working LiningI Lower Vessel Safety J Mix and Castable Gap Filler

RH Degasser

In order to minimse the down time in replacement of the Snorkel leg, we offer a preassembled version.

Preassembly of the Snorkel leg involves diamond grinding of the mating faces of eac brick to ensure a tight joint, and bonding of the bricks to provide a unit ready for direct placement in the degasser.

The steel can and the outer castable material provide the completed assembly.

The finished preassembled Snorkel leg is delivered to the customer.

22

©2010

Preassembled Snorkel Legs

Product Data

Basic Refractories for RH DegassersQuality Chemical Analysis Open

Porosity Bulk


% % g/cm3 MPa T0.6oCMagnesia chrome–bricksTopkrom MCR5 66.0 4.2 8.0 1.2 0.6 17.5 14.0 3.25 80 >1700Topkrom MCZ21 66.0 3.7 6.5 0.8 0.6 21.0 16.0 3.20 55 >1700Topkrom MCB 61.4 5.7 13.4 1.2 0.6 17.0 18.0 3.20 45 >1700Topkrom MCW22/K 57.5 6.4 11.1 0.7 0.9 23.1 18.0 3.20 55 >1700Topkrom MCT5 55.0 6.5 12.5 0.8 0.8 22.5 16.0 3.25 60 >1700Topkrom MCV 55.0 6.7 14.5 0.9 0.8 22.0 17.0 3.22 70 >1700Dymax GU 59.0 5.2 9.5 1.0 1.4 23.3 15.0 3.25 60 >1700Dymax GUNSC 59.0 5.2 9.5 1.0 1.4 23.3 9.5 3.42 90 >1700Mixes and low–cement prefabricated castablesKonmix MKX2 57.7 6.3 13.0 12.0 1.9 18.1 22.0 2.90 >25 >1700Konmix MKX2/L2 65.2 4.1 5.7 0.7 2.8 19.0 20.5 3.00 30 -Konmix MKX3 92.2 0.6 1.9 0.8 2.6 - 29.0 2.46 15 -Runcast BMAL/L2 4.5 93.5 0.1 1.5 - - 14.0 3.05 50 1700Runcast BMAL/MS1 5.0 92.5 0.2 1.6 - - 14.0 3.05 50 1690Runcast BKW/S1 - 97.0 0.2 1.7 - - 14.0 3.10 60 1680Maskor MSK - 78.5 - 0.6 15.0 SiC - 12.0 3.06 52 Gunmix BALM/BTM3 - 84.2 1.3 4.5 6.9 - - - - -

1 Steel fibres added2 Self flowing material3 Gunning mix for Snorkels

23©2010

Oxygen Converter Refractory Lining

A Cone Zone G Purging Plug M Replacable Tophole Shapes

B Cylindric Zone H Sealing Mix Throat N Tapping ZoneC Scrap Impact I Throat Zone O Trunnion ZoneD Near-Bottom and

Slag SpoutJ Housing for

Taphole ShapesP Filling Mix

E Bottom K Taphole Installation Mix R Safety Spandral Mix

F Safety Lining L Tophole Blocks

24

©2010

Carmag MWHL714S C

Carmag MWH631U ACarmag MWH632U ACarmag MWHLB34U (5) ACarmag MWH743U A

Carmag MWH743U BCarmag MWH753U BCarmag MWHL754U B

Carmag MWHGLN744Y DCarmag MWHL834U /S/ D

Carmag MWH713U ECarmag MWHGLN774Y ECarmag MWHL834 U (S) E

Normag M92 (SU) FThermag M96 (SU) F

Carmag MP753AS GCarmag MPL853AU G

Konmix MKNZ H

Normag M92SU IThermag M96SU ICarmag MW632AST4 I

Konmix MKNZ K

Carmag MP753AS LThermag M96F2SU L

Carmag MWL714S MCarmag MWHGL714Y M

Carmag MWL743U NCarmag MWHL834 U (S) N

Carmag MWHL834 (U, S) OCarmag MWHL754 (U, S) OCarmag MWHGL854U OCarmag MWHGLN744Y O

Protmix ZOM PKonmix MKX3 P

Sealmix MKX/TW R

Thermag M96F2SU J

Bottom Blow Shape

Replacable Caphole Shape

Taphole Block

Slag Stopper (Multimag KORKAT)

25©2010

Oxygen Converter Elements

26

©2010

Basic Refractories for Oxygen Converters

Quality Carbon Content

Magnesia component chemical analysis Open

PorosityBulk

Denisty

Cold Crushing StrengthMgO Al2O3 Fe2O3 CaO SiO2

% % % g/cm3 MPaBricks with 6 - 9 % carbonCarmag MWH713U 6.0 96.8 0.2 0.7 1.6 0.7 4.0 3.15 50Carmag MWL714S 6.0 97.5 0.1 0.2 1.7 0.4 1.5 3.1 80Carmag MWHGL714Y 6.0 97.5 0.1 0.1 1.9 0.4 1.0 3.2 70Carmag MWHL714S 7.0 97.5 0.1 0.5 1.4 0.5 2.0 3.15 50 Bricks with 10 - 13 % carbonCarmag MWH631U 10.0 96.5 0.2 0.6 1.9 0.8 6.0 3.00 35Carmag MWH632U 10.0 97.0 0.2 0.6 1.6 0.6 4.0 3.03 35Carmag MW632AST4 10.0 96.0 0.7 0.7 1.8 0.8 5.0 2.97 40Carmag MWHGLN744Y 11.0 97.5 0.1 0.3 1.7 0.4 1.5 3.05 30Carmag MWHL834 U 11.0 97.5 0.1 0.5 1.4 0.5 5.0 3.00 28Carmag MWH743U 12.0 97.0 0.2 0.6 1.6 0.6 6.0 2.98 28Carmag MWHL834S 12.5 97.5 0.1 0.5 1.4 0.5 2.0 3.05 30Bricks with 14 - 15 % carbonCarmag MPL853AU 14.0 97.7 0.1 0.2 1.6 0.4 2.5 2.92 35Carmag MWHGLN854U 14.5 97.5 0.1 0.4 1.6 0.4 4.0 2.98 28Carmag MWH753U 15.0 97.0 0.2 0.6 1.6 0.6 5.0 2.92 25Carmag MWHL754U 15.0 97.5 0.1 0.5 1.4 0.5 4.0 2.95 25Carmag MP753AS 15.0 97.0 0.2 0.7 1.4 0.6 2.5 2.93 35Carmag MWHL754 S 15.0 97.5 0.1 0.5 1.4 0.5 2.0 2.98 35Magnesia bricksThermag M96F2SU 3.7 96.5 0.2 0.5 1.8 0.7 8.0 3.05 70Thermag M96 SU 4.0 97.5 0.3 0.5 1.0 0.4 5.0 2.97 65Normag M92 SU 4.5 92.4 2.0 2.1 0.7 2.8 8.0 2.96 60

Powders and mixes Grain Size (mm)

Protmix ZOM

(MgO+CaO=81)(MgO+CaO=92)

89.0 1.2 1.3 2.0 4.7 0-1Konmix MKX3 92.0 0.7 1.9 0.7 2.6 0-3Sealmix MKX/TW 95.5 0.5 0.6 2.0 1.1 0-6Gunmix MTK3 3.1 4.5 7.5 3.7 0-2.5Gunmix MTK5 75.0 0.3 - 17.0 0.9 0-2Konmix MTK4 84.6 2.2 1.9 0.4 4.0 0-2Gunmix MTK3/M 71.0 12.0 1.2 2.7 4.0 0-3Konmix MKD 72.0 0.5 1.7 0.4 11.2 0-5Konmix MKNZ 89.8 - 0.5 1.8 1.6 0-5

Industrial Solutions International133 Milliken Creek Drive

Napa, CA 94558office (707) 255-5003cell (707) 738-2772fax (707) 255-1129

email [email protected]

ISI (Europe) Limited40 Allenby Drive Sheffield, S87Rs

office +44 114 2377379email [email protected]

www.indsolllc.com

ISI Products Manufactured by



Version 3

steel brochure

Documents

lowcement

industrial

standard brick

water cooled

carbon bonded

electric arc

large crystal

rh degassing