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Fundamental design of steelmaking refractories
- Author / Creator
- Available as
- Online
- Summary
-
"The first part of the book accentuates the valuable basics of 'Heat and Mass Transfer', 'Equilibrium and Non-equilibrium phases', 'Packing and Stress in Compaction', 'Degree of Ceramic Bonding', '...
"The first part of the book accentuates the valuable basics of 'Heat and Mass Transfer', 'Equilibrium and Non-equilibrium phases', 'Packing and Stress in Compaction', 'Degree of Ceramic Bonding', 'Thermal and Mechanical Behavior', and 'High Temperature Corrosion' including relevant finite element analysis in the perception of composition design, manufacturing, and failure mechanism of steelmaking refractories. While considering the steelmaking refractories, a detailed 'Refractories for Primary Steel Making', 'Refractories for Secondary Steel Making', 'Refractories for 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, and 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. In these concerns, Chapter 5 highlights the thermal and mechanical behavior, and Chapter 6 underscores the high temperature corrosion mechanism with a relevant model"--
Details
- Creator
- Debasish Sarkar
- Format
- Books
- Language
- English
- Publication
-
- Hoboken, NJ : John Wiley & Sons, Inc., 2023
- ©2023
- Physical Details
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- xix, 507 pages : illustration ; 24 cm
- ISBNs
- 9781119790860, 1119790867, 9781119790846, 9781119790853, 1119790840, 1119790735, 1119790859, 9781119790730
- OCLC
- on1357020461
- Includes bibliographical references and index.
- Intro -- Fundamental Design of Steelmaking Refractories -- Contents -- 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-SiO2-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-Cr2O3) -- 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 -- EULA