Fundamental Design of Steelmaking Refractories

12 Premature Refractory Life by Other Parameters

12.1 Introduction

A conversation between a steel melting shop manager (Mr. X) and an application engineer (Mr. Y) of the refractory manufacturer is the starting point of this chapter.

• MR. X: Why does your refractory not have consistent performance?
• MR. Y: Sir, what happens? Please inform.
• MR. X: Ladle-1 had 125 lives, more than expected, but Ladle-8 is only 60 with the same brick. Please supply quality products; otherwise, your company will be blacklisted.

Mr. Y was afraid and immediately enquired to his host organization and found that both ladle bricks were from the same consignment. Both the personalities were right from their viewpoint, productivity, and business perspective. The question is why such difference and what are the reasons for such premature refractory life? We have to look at several reasons from both parties to find the solutions, sometimes not encountered and invisible. Herein, the prime motivation is to pick up the probable factors that eventually affect the performance either by uncontrolled processing defects, packaging and transport from the refractory manufacturer side or delay in procurement and unusual installation practice, and operational mismanagement from the steel sector side.

From the understanding of the heat transfer, refractory processing and properties, and their mode of application for vessels and continuous casting, it is clear that all steel vessels and continuous casting refractories ...