Research on Composite Slag Dam Cast with Magnesia Castables and Alumina Magnesia Castables

To enhance the serdice life of magnesia based slag dam, composite slag dam was designed to be cast with alumina magnesia castables in slag line and magnesia castables in molten steel zone. Workability of the magnesia castables for the slag dam was improved and a suitable vibration shaping method was adopted to combine it with alumina magnesia castables. The result shows： （1） workability and setting performance of magtwsia castables can be improved to match with alumina magnesia castables by adjusting setting retarder and water reducing agent, and adding proper silica fume ; （2） composite slag dam cart be prepared with alumina m,agnesia castables and the improved magnesia castables, whether by up - down composite method or right - left composite method; in order to get full vibration arrd make interface .fluctuation have proper amplitude, the vibration time oJ the two methods after two different castables contact with each other is 3 and 2.5 minutes, respectively; （3）the result of the on-site test proves that the design aims for reducing pollution to hot metal and improving corrosion resistance have been achieved.

Corrosion Behavior of Slags with Different Basicities to Alumina Magnesia Castables

Alumina magnesia castable crucible specimens were prepared using tabular corundum （ ≤ 5 mm ）, fused magnesia powder （ ≤0. 088 mm ） , fused spinel powder （ ≤0. 044 mm ） , and α-Al2O3. micropowder （d50 ≤0. 7 μm ） as main starting materials, batching, mixing, shaping, and drying. Slag resistance was determined by static crucible method at 1 600℃ for 3 h adopting two ladle slags with different basicities （3. 40 and 1.03 ）. The corrosion and penetration indexes and microstructure characteristics of the specimens after slag resistance test were analyzed to study the corrosion behaviors of the two slags to alumina magnesia castables. The results show that the corrosion of the low basicity slag to alumina magnesia custables is much more serious than that of the high basicity slag for that their reactions with castables form different products;for the low basicity slab,, the multi-phase coexistence of CA6 and compounds of CaO - Al2O3 -SiO2 in the materials together with volume expansion caused by the formation of CA6 intensify the slag corrosion and penetration ; for the high basicity slag, the reaction between slag and castables generates a CA2 dense layer and a large amount of in-situ MA in the interface, reducing the slag corrosion to the materials effectively.

Enhanced slag resistance and mechanical properties of magnesia castables with strontium carbonate addition

Magnesia castables have been widely used in metallurgical industries with the advantages of high refractoriness,non-polluting steel,and resistance to alkaline slag.Magnesia castables were prepared using strontium carbonate(SrCO_(3))as additive to enhance slag resistance and mechanical properties,and the influence of SrCO_(3) on the evolution of phases,microstructure and properties of magnesia castables sintered at different temperatures was clarified.The results show that,with the introduction of SrCO_(3)(lower than 3 wt.%),elastic modulus,mechanical strength,thermal shock resistance and densification of magnesia castables were significantly enhanced owing to the formation of needle-like Ca_(0.9)Sr_(0.1)MgSi_(2)O_(6) phase and liquid phase when sintering at high temperatures,and the introduced SrCO_(3) presented minor effects on the mechanical properties of castables for its highly structural stability below 1100℃.During the slag corrosion process,SrCO_(3) and SiO_(2) in castables reacted with Al^(3+)in molten slag to form SrAl_(2)SiO_(8) phase,resulting in the increased slag viscosity and suppressed continuing penetration.

Rheological Behavior of Zero Cement Al_2O_3-MgO Castables

Al2O3 -MgO castables have been widely used for working linings of steel ladle due to their superior hot strength and corrosion resistance. In this- work, effects of＂ microsilica, ultrafine alumina and MgO fines additions on the rh, eological behavior of the castables were investi- gated by means of IBB rheometer V1. 0 to measure torque （shear stress） under varying shear rates. The re- sults show that rheological properties of castables at varying shear rates are significantly improved with increase of microsilica additions （from 1 mass% to 5 mass% ） and corresponding decrease in water addition; there is only little change in rheological behavior with variation of ultrafine alumina and MgO fines additions. Optimum ultrafine alumina and microsilica additions are recommended for castables with good rheological behavior.

Effect of Microsilica Addition on Properties of CMA72 Bonded Al2O3-MgO Castables

CMA72 bonded Al2 O3 - MgO castable is promising for application of steel ladle wall, because of unique combination of thermo-mechanical properties, slag corro- sion resistance and cost benefit. In these castables, mi- crosilica can be introduced to counterbalance the expan- sion generated by spinel formation. In this paper, the of microsilica dosage on properties of eastables was evaluated. Expansion, expressed by the permanent linear change （PLC）, is highly dependent on the dosage of microsilica. Unexpected expansion occurs when the dos- age of microsilica is too low due to dominant effect of spinel and CA6 formation. Too high dosage results in sintering shrinkage, which is related to amount of liquid phase generated by microsilica addition. In addition, HMOR declines dramatically with increasing microsilica dosage. Considering the balance between expansion con- trol and hot property retention, 1.0 mass% of microsili- ca is recommended for the castable containing 4 mass% of magnesia.

Synthesis of Lightweight Spherical Forsterite Aggregates and Research on Their Application in Mgo Based Castables

Magnesite fine powder, natural silica powder,light-burned magnesia fine powder, silica fume and middle grade magnesia fine powder were used as the starting materials,and silica sol as binder to get high purity lightweight spherical forsterite aggregates. The mixture was granulated on a disc pelletizer and then calcined at 1 400 ℃ for 3h. The synthesized spherical forsterite aggregates were added in Mg O based castables with MgO-SiO2-H2O binding system to replace equaldensity high purity common forsterite aggregates. Effect of spherical forsterite aggregates addition on properties of MgO based castables was investigated. The results show that: compared with common aggregates,lightweight spherical forsterite aggregates can improve castables ’flow ability and decrease water addition; addition of spherical aggregates has little effect on cold strength of castables; with the increase of spherical aggregate addition,shrinkage of specimens after drying and heating at intermediate temperatures decreases,but the expansion of specimens after heating at high temperatures increases,bulk density decreases and apparent porosity increases,and thermal conductivity declines.

Fracture behavior and microstructure analysis of Al2O3–MgO–CaO castables for steel-ladle purging plugs

Three different castables based on the Al_2O_3–MgO –CaO system were prepared as steel-ladle purging plug refractories： corundum-based low-cement castable（C-LCC）, corundum-spinel-based low-cement castable（C-S-LCC）, and corundum-spinel no-cement castable（C-S-NCC）（hydratable alumina（ρ-Al_2O_3） bonded）. The fracture behavior at room temperature was tested by the method of ＂wedge-splitting＂ on samples pre-fired at different temperatures; the specific fracture energy G′f and notched tensile strength σNT were obtained from these tests. In addition, the Young＇s modulus E was measured by the method of resonance frequency of damping analysis（RFDA）. The thermal stress resistance parameter R′′′′ calculated using the values of G′f, σNT, and E was used to evaluate the thermal shock resistance of the materials. According to the microstructure analysis results, the sintering effect and the bonding type of the matrix material were different among these three castables, which explains their different fracture behaviors.

Compositions and Properties of Hydration-Resistant Coating of Magnesia-Calcia Materials

The complex coating on the MgO CaO clinker was prepared by dipping method and adding the second mineral to restrain the formation and expansion of the cracks. Meanwhile, the microstructure and the morphology of the coating and hydration resistance of the MgO CaO clinker were also investigated. The result shows that the coating consists mainly of Ca 2P 2O 7, MgO and CaCO 3, its thickness ranges from 5μm to 20μm, and the coating is dense and even, no micro cracks are observed. Also, the coating adheres closely to the matrix. The hydration resistance of the MgO CaO clinker after treatment is improved greatly, and the castables prepared with the treated MgO CaO clinker have better physical properties than MgO castable.

Self-flowing Cement-free MgO Castables Using a New Additive Package

Although high-performance basic refractory materials play an essential role in state-of-the-art steel-making,magnesia castables have not been widely used until now. A major challenge is that brucite formation（ Mg（ OH）2） during Mg O hydration causes volume expansion and subsequent cracking—a phenomenon commonly called ＂slaking＂. To overcome problems related to slaking,a new specialty product,Siox X- Mag,has recently been developed for cement-free Mg O castables based on Mg O- SiO 2- H2 O bond. Specimens from industrial-scale-sized blocks after dry-out were characterised by SEM and XRD techniques. Using Siox X- Mag in combination with microsilica,cracking caused by brucite formation is suppressed. The results demonstrate that the dosage of microsilica plays essential roles in the crack formation in large samples. Furthermore,the compatibility of Siox X- Mag with different types of basic aggregates, medium to high-grade dead-burned magnesia and olivine, has also been evaluated. High-performance,self-flowing cement-free Mg O castables have been developed.

Effect of Si_3N_4 on Resistance of Magnesia Based Castable

The magnesia based curable specimens with different Si3N4 contents were casted using sintered magnesite （w（MgO）=95%） as starting material, SiO2 micro-powder as binder, 0.3%, 4% and 5% β-Si3N4 powder replacing the equal addition of magnesia powder respectively. The slag resistance test was carried out at 1550℃ for 3h using Baosteel tundish slag and static crucible method. The result indicates that： introducing Si3N4 could obviously improve the slag resistance of MgO based castable, which increased with increasing Si3N4. Dense SiO2 sintered layer formed on the surface of magnesia based castable because of the oxidation of Si3N4 addition, which can prevent the further slag penetration. In the deep inner of castable, the partial-pressure of oxygen was very low, so Si3N4 can exist stably. Meanwhile in reducing atmosphere, Si3N4 was hard to be sintered, which resulted in the loose interior structure of MgO based castable.

Research Development on Refractory Lining for Continuous Casting Tundish

The research development on new dry vibrating refractories, magnesia based slag dam and bubble curtain barricade for contimwus casting tundish was introduced.

Interaction between microporous magnesia castable and 38CrMoAl steel

The microporous magnesia refractory shows a promising application prospect as tundish lining due to excellent thermal insulation and slag resistance.The effect of interaction between microporous magnesia castable and 38CrMoAl steel containing 0.876 wt.%Al on the cleanliness of 38CrMoAl steel was studied and compared with that of fused magnesia castable.The results show that the micropores in the microporous magnesia castable can promote the formation of dense and continuous MgO-Al_(2)O_(3)layer,which can inhibit the further pollution of molten steel by refractories,whereas the MgO-Al_(2)O_(3)layer formed in test of fused magnesia castable is not continuous.After 30 min holding,the total oxygen content in the steel samples for the test of microporous magnesia castable is only 42.2%of that for the test of fused magnesia castable.The inclusions in the steel samples for the test of microporous magnesia castable are also less than those for the test of fused magnesia castable.It shows that microporous magnesia castable is a promising tundish refractory for the preparation of clean high-Al steel.