Materials selection of furnace linings with multi-component refractory ceramics based on an evolutionary screening procedure

Santos, dos; Pelissari, P.I.B.G.B.; Oliveira, B.S.; Leiva, Daniel Rodrigo; Mello, Rodrigo Fernandes de; Pandolfelli, V. C.

doi:10.1016/j.ceramint.2019.10.127

Cited by 8 publications

(5 citation statements)

References 25 publications

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“…For its production on an industrial scale, melting furnaces are used, which are mainly made up of refractory ceramics based on aluminosilicates (CRAS) due to their low cost, high availability, good mechanical properties, and resistance to corrosion and thermal shock [7][8][9][10][11][12]. However, this type of substrate presents a high corrosion rate in contact with liquid aluminum alloys (up to 6 mmh −1 ) due to the strong reducing effect of aluminum on silicon, leading to the critical task of selecting refractories for melting furnaces [13][14][15][16][17].…”

Section: Introductionmentioning

confidence: 99%

Chemical Interaction between the Sr4Al6O12SO4 Ceramic Substrate and Al–Si Alloys

Rodríguez-García,

Calles-Arriaga,

López-García

et al. 2024

Eng

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Samples of Sr4Al6O12SO4 are obtained through a solid-state reaction of Al2O3, SrSO4, and SrCO3. The samples are then made into 1 and 4 cm pellets by compacting them at 100MPa and sintering them at 1400 °C for 4 h. The compound is analyzed using X-ray diffraction. Static immersion and wettability tests are carried out to evaluate corrosion resistance in contact with Al–Si. Corrosion tests are conducted by immersing the samples at 800, 900, and 1000 °C for 24, 50, and 100 h, while wettability is studied at 900, 1000, and 1100 °C for 2 h. Afterwards, the samples are subject to metallographic preparation. The samples are then analyzed using optical microscopy, scanning electron microscopy, and image analysis. In general, reaction products consisting of alumina, spinel, oxides, and sulfates are found. The contact angles obtained are between 124° and 135°. It is concluded that the Sr4Al6O12SO4 ceramic substrate is resistant to corrosion by the Al–Si alloy because of the slight thickness of the reaction products found in the samples (73 μm), considering the severe conditions of the experiment: 1000 °C and 100 h of isothermal temperature. Furthermore, Sr4Al6O12SO4 is not wettable by Al–Si alloys. These results suggest that the ceramic substrate could be used in the refractory industry, possibly as an additive to commercial refractory ceramics. For future work, it is recommended to carry out the same study with the aluminum–magnesium alloy and as an additive in commercial refractory ceramics.

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Section: Introductionmentioning

confidence: 99%

Chemical Interaction between the Sr4Al6O12SO4 Ceramic Substrate and Al–Si Alloys

Rodríguez-García,

Calles-Arriaga,

López-García

et al. 2024

Eng

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“…Multicomponent clay and cenosphere linings are routinely used in industry to protect parts of continuous steel casting (CSC) lines from thermo-mechanical shock developing during their first contact with molten metal [1,2]. Even if they are of the self-sacrificial type, these linings are capable of significantly extending the lifetime of glazed corundum lances through which gases are pumped into molten metal.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Phase Composition Changes in Polymer Fiber-Modified Thermacoat™ Lining Exposed to Contact with Liquid Steel

Prochwicz,

Pomorska,

Maj

et al. 2024

Coatings

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Multicomponent clay and cenosphere linings protecting ceramic parts exposed to contact with liquid metal during continuous steel casting (CSC) are intended to diminish thermo-mechanical stresses at the beginning of this process. They are effective in their role, but due to their brittle nature, parts of them come off during transport or mounting. The admixture of polypropylene fibers into linings helps to alleviate problems with handling such parts, though the interaction of such a modified material with liquid steel should be re-assessed. The present experiment involved the preparation of a crucible with a Thermacoat™ (Vesuvius, Skawina, Poland) lining with the addition of Belmix™ (Belgian Fibers Group NV, Mouscron, Belgium) fibers and filling it with a drop of liquid steel. Next, the crucible was sectioned and the changes in its microstructure and phase composition were investigated with optical, scanning and transmission electron microscopy (OM/SEM/TEM) methods. This showed that the modified lining retained its non-wetting property against the steel of the non-modified material. The part with the lining, being in direct contact with the liquid steel, developed a highly porous layer filled with AlSiOx amorphous flakes with some larger blocky Al2O3 and SiO2 particles. Right below this, a heat-affected zone (HAZ) consisting of fine γ-Al2O3 platelets immersed in amorphous silica was formed. Some of the voids with a size corresponding to polymer fiber diameter carried significant carbon deposits on their walls. The performed investigation indicated that the polymer fiber-modified linings were capable of withstanding at least short-term contact with liquid steel without instantaneous defragmentation, i.e., they retained the good high-temperature properties of the non-modified material.

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“…The selection of refractory materials for these layers depends on their designed purpose, such as thermomechanical behavior, thermal insulation, and chemical stability. [11][12][13] The working lining is the most critical layer in the steel ladle. It is the innermost layer in direct contact with liquid steel therefore subjected to high operating temperatures and temperature variation.…”

Section: Introductionmentioning

confidence: 99%

“…Each layer comprises refractory material with different thermal, mechanical, and chemical properties. The selection of refractory materials for these layers depends on their designed purpose, such as thermomechanical behavior, thermal insulation, and chemical stability 11–13 . The working lining is the most critical layer in the steel ladle.…”

Section: Introductionmentioning

confidence: 99%

Development and experimental characterization of the thermomechanical behavior of a scaled steel ladle

Gajjar,

Put,

Pereira

et al. 2024

Int J Applied Ceramic Tech

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A steel ladle usually employs mortarless refractory masonry in the innermost layer in direct contact with molten steel. The behavior of such masonry under high thermal loading is complex and essential for designing such installation. A large‐scale experimental campaign was carried out focusing on a simplified, laboratory‐scaled, pilot steel ladle built with multiple refractory linings as in an industrial ladle. Tests were performed under transient thermal loading up to 1400°C with new and used working linings. The results showed that the distribution of temperatures between the refractory linings was similar for all specimens and confirmed the importance of the selection of the refractory materials in the distinct linings of the ladle to limit heat losses. The heterogeneity in the distribution of dry joints and the effect of the dry joint thickness were also measured using strain gauges. The measurements indicate the effect of viscoplasticity in the working lining on the steel shell, which shows a progressive reduction in the strain starting at 1200°C. The tests performed on the working linings show lower strain built‐up due to large viscoplastic deformation and increased joint thickness.

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Materials selection of furnace linings with multi-component refractory ceramics based on an evolutionary screening procedure

Cited by 8 publications

References 25 publications

Chemical Interaction between the Sr4Al6O12SO4 Ceramic Substrate and Al–Si Alloys

Chemical Interaction between the Sr4Al6O12SO4 Ceramic Substrate and Al–Si Alloys

Microstructure and Phase Composition Changes in Polymer Fiber-Modified Thermacoat™ Lining Exposed to Contact with Liquid Steel

Development and experimental characterization of the thermomechanical behavior of a scaled steel ladle

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