Indispensability and Vulnerability of Magnesia-carbon Bricks for Steelmaking Process

doi:10.19691/j.cnki.1004-4493.2021.01.002

China's Refractories ›› 2021, Vol. 30 ›› Issue (1): 7-16.DOI: 10.19691/j.cnki.1004-4493.2021.01.002

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Indispensability and Vulnerability of Magnesia-carbon Bricks for Steelmaking Process

GUO Zongqi¹^,^*(), ZAMBONI Stefano¹, GAO Jianying², GAN Feifang³

1 Trasteel International SA, Lugano CH-6900, Switzerland
2 Imerys (China) Co., Ltd., Tianjin 300457, China
3 Baoshan Iron & Steel Co., Ltd., Shanghai 201900, China

Online:2021-03-15 Published:2021-05-01
Contact: GUO Zongqi
About author:Dr. Guo Zongqi started his refractory career in 1983 after finishing his study in Xi’an University of Architecture & Technology. He then joined Luoyang Institute of Refractories Research to work on refractory researches and applications for more than 10 years. In 2001, he received his PhD degree in Ecole Polytechnique, University of Montreal, Canada. He then continues with refractory R&D activities and management in several international refractory companies. His refractory experiences include the pioneer research and production of high chromia refractories for slagging coal gasifiers and the technology development of burnt and unburnt basic bricks for steelmaking processes, cement rotary kilns and glass-making regenerators.

Abstract

Abstract:

The manufacturing techniques of magnesia-carbon bricks in China have been documented from raw materials, production (process and facilities) to performance and wear issues in the ladle. Magnesia-carbon bricks made of ordinary fused magnesia is the prevailing material used in the slagline of the ladle, but its service life is substantially lower than the bricks based on large-periclase-crystal fused magnesia. In two types of fused magnesia, the average values of periclase crystal size are in double for their difference. It is suggested that large-periclase-crystal fused magnesia should be used for manufacturing magnesia-carbon bricks for the slagline of the ladle by abandoning ordinary fused magnesia, in order to have a prolonged service life, increase the availability of the ladle and reduce the number of downtimes of the ladle. Free phenol in resin produced in China should be as low as that of resin made in Europe, to improve production environment and reduce smoke emission during the ladle preheating. There are large spaces to promote the productivity of magnesia-carbon bricks in China, with high intensity mixers and hydraulic presses. Expansion controlled magnesia-carbon bricks in the ladle depend on the optimized combination of sintered magnesia, Carbores and antioxidants as the matrix, to minimize the premature wear of vertical cracks and joint opening formed in the ladle lining.

Key words: magnesia-carbon brick, ladle, fused magnesia, graphite, resin

GUO Zongqi, ZAMBONI Stefano, GAO Jianying, GAN Feifang. Indispensability and Vulnerability of Magnesia-carbon Bricks for Steelmaking Process[J]. China's Refractories, 2021, 30(1): 7-16.

Figures/Tables 18

References 22

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Parameter	DOM mode	INT mode
Fused magnesia	Ordinary FM	Large crystal FM
Making process	One step	Two steps
Fusion input	Magnesite ore lumps	CCM briquettes
MgO content /mass%	> 97.50	> 97.50
Periclase crystal size /µm	400-600	800-1 000
MgO-C bricks /ladle	Slagline	Slagline
Total C content /mass%	14	14
Binder	Resin	Resin
Antioxidant	Yes	Yes
Ladle refining /%	100	100
RH degassing /%	50-75	50-75
Service lifetime /heat	32-35	72-75
Slagline in a ladle campaign	Three replacement	One replacement

Parameter	DOM mode	INT mode
Fused magnesia	Ordinary FM	Large crystal FM
Making process	One step	Two steps
Fusion input	Magnesite ore lumps	CCM briquettes
MgO content /mass%	> 97.50	> 97.50
Periclase crystal size /µm	400-600	800-1 000
MgO-C bricks /ladle	Slagline	Slagline
Total C content /mass%	14	14
Binder	Resin	Resin
Antioxidant	Yes	Yes
Ladle refining /%	100	100
RH degassing /%	50-75	50-75
Service lifetime /heat	32-35	72-75
Slagline in a ladle campaign	Three replacement	One replacement

Heating temperature	Phase transformation	Description
At 660 °C	Al liquid	Melting starting
At 660 °C	Al₂O₃ coating ripped	A fine layer of Al₂O₃
Over 660 °C	4Al(l)+3C(s) → Al₄C₃(s)	Surrounding carbon
Over 660 °C	2Al(s)+N₂(g) → 2AlN(s)	In presence of air
At 1 100 °C	Al liquid disappears
Over 1 100 °C	Al₄C₃+3O₂(g) → Al₂O₃+3C	In presence of air
	2AlN(s)+CO(g) → Al₂O₃(s)+N₂(g)+3C(s)
	Al₂O₃+MgO(s) → MgO·Al₂O₃(s)	Spinel crystals forming
At 1 500 °C	Al₄C₃ and AlN disappear	Spinel crystals growing

Heating temperature	Phase transformation	Description
At 660 °C	Al liquid	Melting starting
At 660 °C	Al₂O₃ coating ripped	A fine layer of Al₂O₃
Over 660 °C	4Al(l)+3C(s) → Al₄C₃(s)	Surrounding carbon
Over 660 °C	2Al(s)+N₂(g) → 2AlN(s)	In presence of air
At 1 100 °C	Al liquid disappears
Over 1 100 °C	Al₄C₃+3O₂(g) → Al₂O₃+3C	In presence of air
	2AlN(s)+CO(g) → Al₂O₃(s)+N₂(g)+3C(s)
	Al₂O₃+MgO(s) → MgO·Al₂O₃(s)	Spinel crystals forming
At 1 500 °C	Al₄C₃ and AlN disappear	Spinel crystals growing

Antioxidant	Phase and VE coefficient
Al	Al₂O₃	MgO·Al₂O₃
Al	1.30	1.43
Si	SiO₂	2MgO·SiO₂
Si	2.20	1.95

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Indispensability and Vulnerability of Magnesia-carbon Bricks for Steelmaking Process

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References 22

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Specification	Domestic resin DH	Domestic resin RM	European resin H9905
Viscosity at 20-25 °C /(Pa·s)	10-16	1.1 (1.05-1.55)	1.85-2.15
Solid content at 135 °C /mass%	≥ 79	75 (70-80)	70-74
Moisture content /mass%	≤ 4	8.0 (7.0-10)	7.0-8.0
Carbon residue fired at 800 °C /mass%	≥ 40	45 (≥ 39)	~50
Free phenol content GC /mass%	9.0 ± 2.0	12 (10.5-13.5)	Max. 0.2

Stage		DOM mode	INT mode
Mixing	Facility	Conventional mixer	High speed intensity mixer
	Duration	40-50 min	< 10 min
	Capacity	< 1 t	2 t
Pressing	Facility	Screw press	Hydraulic press
	Manner	Deairing, impacting	Deairing, static pressing
	Pressing	8-15 strokes	1 static pressing
	Charging	Weighing feeder	Volumetric feeder
	Green brick	Manual removal	Robotic device
	Output	1 shape	3 shapes
Tempering	Tunnel kiln	Electrically heated	Fired by natural gas
	Operation	Intermittent	Continuous
	Capacity	10 000 t/a for a kiln	Min. 50 000 t/a for a kiln
	Duration	12 h	8 h

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