Title

CAPEX FREE INCREASE OF STEEL LADLE CAPACITY BY AN INNOVATIVE REFRACTORY LINING CONCEPT

CAPEX FREE INCREASE OF STEEL LADLE CAPACITY BY AN INNOVATIVE REFRACTORY LINING CONCEPT

Authorship

BASTIAN, MARCEL; DIETER, GABRIEL STEGEMANN; LINDEN, CHARLOTTE; DANNERT, CHRISTIAN

BASTIAN, MARCEL

I am this author

DIETER, GABRIEL STEGEMANN

I am this author

LINDEN, CHARLOTTE

I am this author

DANNERT, CHRISTIAN

I am this author

DOI

10.5151/2594-5300-41985

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Abstract

Today’s steelmaking aims for maximum productivity while complying with process and occupational safety requirements. Limiting factors are often the ladle sizes (capacity). One possibility is to purchase new ladles. An inexpensive alternative is to redesign your refractory ladle lining concept. The permanent lining and the insulation layer should be focused, since the wear lining is in direct contact with steel. Alumina- or bauxite-based linings are often used as permanent lining to achieve good corrosion resistance in case of a breakthrough of the wear lining but have the disadvantage of a high thermal conductivity. If lining thickness is decreased, the temperature of the insulating layer and the steel shell will rise, which is leading to unsafe operation situations. The aim of this study was to increase the steel ladle volume using a new lining concept. Therefore, thermal conductivity measurements and FEM simulations were carried out, to calculate the temperature distribution in the lining. It was shown that the ladle volume could be increased by 7 % with the new lining concept and materials, without any negative effects on the temperature distribution, durability and corrosion resistance of the permanent lining. The increase in capacity enables a significantly higher throughput per heat, which contributes to improved operating efficiency and overall productivity of the plant and to a reduction in fixed costs without CAPEX while ensuring safety requirements.

TODAY’S STEELMAKING AIMS FOR MAXIMUM PRODUCTIVITY WHILE COMPLYING WITH PROCESS AND OCCUPATIONAL SAFETY REQUIREMENTS. LIMITING FACTORS ARE OFTEN THE LADLE SIZES (CAPACITY). ONE POSSIBILITY IS TO PURCHASE NEW LADLES. AN INEXPENSIVE ALTERNATIVE IS TO REDESIGN YOUR REFRACTORY LADLE LINING CONCEPT. THE PERMANENT LINING AND THE INSULATION LAYER SHOULD BE FOCUSED, SINCE THE WEAR LINING IS IN DIRECT CONTACT WITH STEEL. ALUMINA- OR BAUXITE-BASED LININGS ARE OFTEN USED AS PERMANENT LINING TO ACHIEVE GOOD CORROSION RESISTANCE IN CASE OF A BREAKTHROUGH OF THE WEAR LINING BUT HAVE THE DISADVANTAGE OF A HIGH THERMAL CONDUCTIVITY. IF LINING THICKNESS IS DECREASED, THE TEMPERATURE OF THE INSULATING LAYER AND THE STEEL SHELL WILL RISE, WHICH IS LEADING TO UNSAFE OPERATION SITUATIONS. THE AIM OF THIS STUDY WAS TO INCREASE THE STEEL LADLE VOLUME USING A NEW LINING CONCEPT. THEREFORE, THERMAL CONDUCTIVITY MEASUREMENTS AND FEM SIMULATIONS WERE CARRIED OUT, TO CALCULATE THE TEMPERATURE DISTRIBUTION IN THE LINING. IT WAS SHOWN THAT THE LADLE VOLUME COULD BE INCREASED BY 7 % WITH THE NEW LINING CONCEPT AND MATERIALS, WITHOUT ANY NEGATIVE EFFECTS ON THE TEMPERATURE DISTRIBUTION, DURABILITY AND CORROSION RESISTANCE OF THE PERMANENT LINING. THE INCREASE IN CAPACITY ENABLES A SIGNIFICANTLY HIGHER THROUGHPUT PER HEAT, WHICH CONTRIBUTES TO IMPROVED OPERATING EFFICIENCY AND OVERALL PRODUCTIVITY OF THE PLANT AND TO A REDUCTION IN FIXED COSTS WITHOUT CAPEX WHILE ENSURING SAFETY REQUIREMENTS.

Keywords

steel making productivity, ladle capacity, refractory lining, permanent lining

steel making productivity, ladle capacity, refractory lining, permanent lining