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Leistungen
The project has allowed to develop an improved cost-effective, environmentally friendly spinel-Ca6 bonded high-alumina refractory which increases life span and reliability of ladle lining at secondary steel treatment area. The new refractory products obtained are ready-to-commercialise to be applied under monolithic and gunnable form to wall and bottom ladle lining to steel manufacturing market. New developed products overcome the most current brick lining applications.
An innovative way was used to obtain a refractory by studying and completing the ternary diagram Al2O3-MgO-CaO in a basic research focused on specific unexplored chemical range compositions. New explored zone of this ternary diagram allowed 2 publications in Journal of American Ceramic Society.
The qualification of the raw materials, the procedures and the manufacturing technology for castable and gunnable refractory products were stated. The final characteristics and specific refractoriness properties were measured. Resistance to corrosion and penetration against molten steel and slag attack received special attention to select final refractory product composition.
To complete the project, in order to reinforce the availability of the new products, several trials were carried out at industrial scale in 2 steel factories by lining 130 and 250 tons ladles at different stages of the secondary steel process. Assessments were made to establish lining procedures, repair compounds application, pre-heating and firing conditions. Special attention was paid to resistance against penetration, corrosion, wear rate, thermo-mechanical properties and spalling effects under operating conditions.
Innovative techniques of monolithic ladle lining like infilcasting and shotcreting were tested and assessed. These techniques showed to be compatible to the new products and reliable to extend its functionality. During ladles trials wall lining have surpassed 298 heats and bottom-lining 860 heats.
Finally, a technical-economic balance sheet was established comparing trials' data to current refractory ladle lining performance. It has been demonstrated the availability, reliability and marketing potential in European and worldwide markets of the refractory products developed in the project.
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