CA1321405C - Making a taphole - Google Patents
Making a tapholeInfo
- Publication number
- CA1321405C CA1321405C CA000582518A CA582518A CA1321405C CA 1321405 C CA1321405 C CA 1321405C CA 000582518 A CA000582518 A CA 000582518A CA 582518 A CA582518 A CA 582518A CA 1321405 C CA1321405 C CA 1321405C
- Authority
- CA
- Canada
- Prior art keywords
- refractory
- taphole
- fibers
- graphite
- aluminum sulfate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Abstract
ABSTRACT A preformed taphole for a steelmaking vessel such as a BOF furnace or a ladle is made by forming refractory material about a steel pipe, the refractory comprising refractory aggregate, a water soluble binder, metal fibers such as stainless steel fibers, and graphite, preferably flake graphite.
Description
~32~
File TITLE~ Making a ~aphole BACKGROUND OF THE INVENTION
This invention concerns a method of making a preformed taphole and a refractory composition for use therein.
Tapholes are openings, usually round, in the wall of a melting furnace such as a BOF furnace or other metal melting furnace through which molten metal and/or slag can be poured when the furnace i~ tilted or when a plug or other closing device in the ~aphole is removed. Tapholes are generally made o~ refractory material which is compatlble with the refractory material used in lining the furnace or other molten metal container.
As the steel or other molten metal pours through the taphole, it causes wear on the re~ractory making up the taphole. ~enerally, the refractory making up the taphole wears much faster than the refractory making up the furnace lining and therefore the taphole has to be replaced on a 20 regular basis during the life of the lining.
While it is possible ko repair the taphole in place, for example by gunning refractory around a form placed in the old taphole (which has become enlarged by wear), such repair is les~ than totally satisfactory. Since such repairs have to be made on a hot furnace (it not being economical to cool the furnace down to make the repair), the refractory forming the repaired taphole is of lesser strength and density, due to the increased amount oP water required to gun refractory material, and hence will last for an even shorter time, than a taphole 30 formed by meth~ds such as casting or pressing, methods which result in greater density and strength but which cannot be used to repair a hot furnace.
.~
~ 3 ~ U3 Accordingly, it has become the practice to preform refractory tapholes and then place them in tha furnace to be repaired, the preformed taphole being held in place by, for example, refractory material gunned around it.
Generally, such preformed tapholes are made by forming suitable refractory material, for example by casting, about a hollow metal pipe used as a form. In the first few seconds that molten metal flows through the taphole so formed, it washes away the metal and thereafter the refractory channels the metal flow.
This invention is concerned with a method of making an improved preformed taphole and particularly with a refractory composition useful in making such an improved taphole.
SUMMARY OF THE INVENTION
According to this invention, an improved preformed taphole can be made by the method comprising (1) selecting a metal pipe of the desired length and diameter, (2) admixing (a~ from 1% to 8% of a water soluble binder, (b) from O.l~ to 2% of metal fibers, (c) and 0 5~ to 5% of graphite with (d) 20 refractory grain making up the balance of the admixture, all percentages being by weight and based on the total weight of the admixture, ~3) adding sufficient tempering liquid to the admixture to make a formable refractory mass, (4) forming the tempered admixture about khe outer sur~ace of the metal pipe, and (5) drying the so-formed refractory mass to mak~ a preformed taphole.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a perspective view of a preformecl taphole which can be made by the method o~ this invention.
DETAILED DESCRIPTION OF THE INVENTION
The pipe used as a ~orm about which to mold the refractory can be of any metal, for exampl~ aluminum, but u ~
generally will be of iron or steel. Commonly steel pipe is used. The diameter o the pipe will be chosPn to conform to the size of taphole desired by the customer ~e.g., a steelmaker) and the length also will be chosen to fit the particular furnace in which the taphole is to be used.
Generally, the steel pipe will be longer than the refractory wall thickness of the furnace. The wall thickness of the steel pipe is not critical, for example it can be from 1/8 inch to 1/4 inch; generally the steel pipe will be the thinnest which can be used in the forming process and which can be shipped and handled without deforming.
The aggregate used ln the refractory surrounding the pipe should be compatible with the refractory making up the lining into which the taphole is to be place. Generally, this will be a basic lining such as periclase or periclase/chrome. A
particularly preferred aggregate is high purity periclase, i.e., one containing 95% or more MgO. The aggregate will be sized, as is well known in the industry~ to provide maximum packed density.
The water soluble bond can be any such material or combination of materials compatible with the aggregate and able to provide a strong bond in the composition. Such bonds are well known in the refractory art; a particularly preferred one is shown in the example below.
The metal fibers may be any such; preferably they will have a length of from 1 to 3 cm and a diameter of 0.2 to 0.6 mm. Usually the fibers will be steel and most preferably stainless steel. A variety o~ such metal fibers are commercially available.
The graphite used may be any of various commercially available graphites but a preferred graphite is the type known, from its morphology, as flake graphite~ It will ~ 3 ;~
pre~erably be of a size so that at least 90% of it is larger than 0.05 mm.
In ~orming the taphole, the requisite amounts of re~ractory aggregate, bond, fibers, and graphite will be admixed in a suitable mixer, for example a Hobart epicyclic mixer, as is well known in this art. A tempering liquid, usually water but other liquids such as alcohol might be used in particular cases, is then added to the admixture. The amount of tempering liquid will depend on the ~orming method to be used. A pxeferred forming method is casting and this will generally require from about 3 ~ to about 8 ~ water, based on the weight of dr~ ingredients. For pres~ing, on the other hand, a much smaller amounk, perhaps about 2% water, will be used.
The tempered refractory admixture is then placed about the metal pipe. As mentioned, placement by casting the re~ractory about the metal pipe as the inner form, and using a removable sleeve, for example a split steel pipe, as the outer form, is a preferred forming m~thod~ The thickness of the 20 refractory may be, ~or example, from 3/4 inch (2 cm) to 2 inches (5.1 cm)O
The refractory will be placed completely about the circum~erence of the metal pipe, but will generally not extend to both ends of the pipe. In some cases, it may be terminated short of each end of the pipe, as shown in the drawing, wherein the preformed taphole is indicated generally by the numeral 11, the metal pipe by 12, and the re~ractory by 13.
The reason for the pipe to extend beyond the refractory is to provide means to handle the pre~ormed taphole without damaging 30 the re~ractory and also to prevent damage due to inadvertent hitting o~ the taphole against the furnace or other structure.
~ t3 h .~
The formed taphole will then be dried or otherwise cured (depending on the type of bond used) before being shipped to the customer, who will install it i~ his ~urnace or other device.
EXAMPLE
A taphole was made according to this invention by admixing 97.9 parts by weight sized periclase grain with 0.8 part aluminum sulfate, 0.7 part boric acidl 0.6 part citric aoid, 0.5 part F-310 stainless steel fibers 3/4 inch (19 mm) 10 long, and 1.0 part natural flake graphite.
The periclase had the following typical chemical analysis: 0.8 % CaO, 0.3 % sio2, 0.2 % Fe2O3, 0.05 % A12O3, less than 0.02 % B2O3, and ~by difference) 98.6 % MgO, and was sized so that all passed a 3 mesh screen (i.e., was finer than 6.7 mm) and 22 % passed a 100 mesh screen (i.e., was finer than 0.15 mm).
The aluminum sulfate~ boric acid, and citric acid were the commercially available materials described in detail in US
Patent 3,~79,208.
The dry ingredients were mixed in an epicyclic Hobart mixer for 1 minute and then 5 % water (based on the weight of dry ingredients) added and the mixing continued ~or a further 4 minutes.
The admixture was then cast about a 6 inch (15 cm) diameter steel pipe 5 ~eet (1.5 m~ long and having a wall thickness of 3/16 inch (5 mm). A steel form of 7.5 inches tl9 cm) inner diameter was placed concentrically about the metal pipe and the refractory admixture cast between the two using vibratisn to obtain maximum density.
The taphole thus formed was stripped of the outer form after setting at ambient tempsrature over night and then was heated on a preset schedule to a temperature of 600 F (315 1 ~2 ~ `3 C) over a period of 30 hours be~ore being shipped to the customer.
Pre~vrmed tapholes made according to this invention were installed in BOF furnaces in a steelmaking plant. In the newest furnace, the tapholes made according to this invenkion had an average life o~ 48.6 heats, and in the oldest furnace an average life o~ 32.3 heats. This compares ko an average life for prior art preformed tapholes not containing the combination of graphite and metal fibers of 33 heats in the newest ~urnace and 22.5 heats in the oldest ~urnace.
While the reasons ~or the superior per~ormance o~
tapholes made with the combination of metal ~ibers and graphite is not fully understood, and it is not desired to be bound to any particular theory, it is believed that the graphite prevents slag penetration into the refractory, allowing the metal fibers to perform their strengthening and reinforcing function for a longer time.
In the specification and claims, percentages and parts are by weight unless otherwise indicated. Mesh sizes referred 20 to herein are Tyler standard screen sized which are defined in Chemical Engineers' Handbook, John S. Perry, Editor-in-Chief, Third Editlon, 1950, published by McGraw Hill Book Company, at page 963. Analyses of mineral components are reported in the usual manner, expressed as simple oxides, e.g. MgO and SiO
although the components may actually be present in various combinations, e.g. as a maynesium silicate.
File TITLE~ Making a ~aphole BACKGROUND OF THE INVENTION
This invention concerns a method of making a preformed taphole and a refractory composition for use therein.
Tapholes are openings, usually round, in the wall of a melting furnace such as a BOF furnace or other metal melting furnace through which molten metal and/or slag can be poured when the furnace i~ tilted or when a plug or other closing device in the ~aphole is removed. Tapholes are generally made o~ refractory material which is compatlble with the refractory material used in lining the furnace or other molten metal container.
As the steel or other molten metal pours through the taphole, it causes wear on the re~ractory making up the taphole. ~enerally, the refractory making up the taphole wears much faster than the refractory making up the furnace lining and therefore the taphole has to be replaced on a 20 regular basis during the life of the lining.
While it is possible ko repair the taphole in place, for example by gunning refractory around a form placed in the old taphole (which has become enlarged by wear), such repair is les~ than totally satisfactory. Since such repairs have to be made on a hot furnace (it not being economical to cool the furnace down to make the repair), the refractory forming the repaired taphole is of lesser strength and density, due to the increased amount oP water required to gun refractory material, and hence will last for an even shorter time, than a taphole 30 formed by meth~ds such as casting or pressing, methods which result in greater density and strength but which cannot be used to repair a hot furnace.
.~
~ 3 ~ U3 Accordingly, it has become the practice to preform refractory tapholes and then place them in tha furnace to be repaired, the preformed taphole being held in place by, for example, refractory material gunned around it.
Generally, such preformed tapholes are made by forming suitable refractory material, for example by casting, about a hollow metal pipe used as a form. In the first few seconds that molten metal flows through the taphole so formed, it washes away the metal and thereafter the refractory channels the metal flow.
This invention is concerned with a method of making an improved preformed taphole and particularly with a refractory composition useful in making such an improved taphole.
SUMMARY OF THE INVENTION
According to this invention, an improved preformed taphole can be made by the method comprising (1) selecting a metal pipe of the desired length and diameter, (2) admixing (a~ from 1% to 8% of a water soluble binder, (b) from O.l~ to 2% of metal fibers, (c) and 0 5~ to 5% of graphite with (d) 20 refractory grain making up the balance of the admixture, all percentages being by weight and based on the total weight of the admixture, ~3) adding sufficient tempering liquid to the admixture to make a formable refractory mass, (4) forming the tempered admixture about khe outer sur~ace of the metal pipe, and (5) drying the so-formed refractory mass to mak~ a preformed taphole.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a perspective view of a preformecl taphole which can be made by the method o~ this invention.
DETAILED DESCRIPTION OF THE INVENTION
The pipe used as a ~orm about which to mold the refractory can be of any metal, for exampl~ aluminum, but u ~
generally will be of iron or steel. Commonly steel pipe is used. The diameter o the pipe will be chosPn to conform to the size of taphole desired by the customer ~e.g., a steelmaker) and the length also will be chosen to fit the particular furnace in which the taphole is to be used.
Generally, the steel pipe will be longer than the refractory wall thickness of the furnace. The wall thickness of the steel pipe is not critical, for example it can be from 1/8 inch to 1/4 inch; generally the steel pipe will be the thinnest which can be used in the forming process and which can be shipped and handled without deforming.
The aggregate used ln the refractory surrounding the pipe should be compatible with the refractory making up the lining into which the taphole is to be place. Generally, this will be a basic lining such as periclase or periclase/chrome. A
particularly preferred aggregate is high purity periclase, i.e., one containing 95% or more MgO. The aggregate will be sized, as is well known in the industry~ to provide maximum packed density.
The water soluble bond can be any such material or combination of materials compatible with the aggregate and able to provide a strong bond in the composition. Such bonds are well known in the refractory art; a particularly preferred one is shown in the example below.
The metal fibers may be any such; preferably they will have a length of from 1 to 3 cm and a diameter of 0.2 to 0.6 mm. Usually the fibers will be steel and most preferably stainless steel. A variety o~ such metal fibers are commercially available.
The graphite used may be any of various commercially available graphites but a preferred graphite is the type known, from its morphology, as flake graphite~ It will ~ 3 ;~
pre~erably be of a size so that at least 90% of it is larger than 0.05 mm.
In ~orming the taphole, the requisite amounts of re~ractory aggregate, bond, fibers, and graphite will be admixed in a suitable mixer, for example a Hobart epicyclic mixer, as is well known in this art. A tempering liquid, usually water but other liquids such as alcohol might be used in particular cases, is then added to the admixture. The amount of tempering liquid will depend on the ~orming method to be used. A pxeferred forming method is casting and this will generally require from about 3 ~ to about 8 ~ water, based on the weight of dr~ ingredients. For pres~ing, on the other hand, a much smaller amounk, perhaps about 2% water, will be used.
The tempered refractory admixture is then placed about the metal pipe. As mentioned, placement by casting the re~ractory about the metal pipe as the inner form, and using a removable sleeve, for example a split steel pipe, as the outer form, is a preferred forming m~thod~ The thickness of the 20 refractory may be, ~or example, from 3/4 inch (2 cm) to 2 inches (5.1 cm)O
The refractory will be placed completely about the circum~erence of the metal pipe, but will generally not extend to both ends of the pipe. In some cases, it may be terminated short of each end of the pipe, as shown in the drawing, wherein the preformed taphole is indicated generally by the numeral 11, the metal pipe by 12, and the re~ractory by 13.
The reason for the pipe to extend beyond the refractory is to provide means to handle the pre~ormed taphole without damaging 30 the re~ractory and also to prevent damage due to inadvertent hitting o~ the taphole against the furnace or other structure.
~ t3 h .~
The formed taphole will then be dried or otherwise cured (depending on the type of bond used) before being shipped to the customer, who will install it i~ his ~urnace or other device.
EXAMPLE
A taphole was made according to this invention by admixing 97.9 parts by weight sized periclase grain with 0.8 part aluminum sulfate, 0.7 part boric acidl 0.6 part citric aoid, 0.5 part F-310 stainless steel fibers 3/4 inch (19 mm) 10 long, and 1.0 part natural flake graphite.
The periclase had the following typical chemical analysis: 0.8 % CaO, 0.3 % sio2, 0.2 % Fe2O3, 0.05 % A12O3, less than 0.02 % B2O3, and ~by difference) 98.6 % MgO, and was sized so that all passed a 3 mesh screen (i.e., was finer than 6.7 mm) and 22 % passed a 100 mesh screen (i.e., was finer than 0.15 mm).
The aluminum sulfate~ boric acid, and citric acid were the commercially available materials described in detail in US
Patent 3,~79,208.
The dry ingredients were mixed in an epicyclic Hobart mixer for 1 minute and then 5 % water (based on the weight of dry ingredients) added and the mixing continued ~or a further 4 minutes.
The admixture was then cast about a 6 inch (15 cm) diameter steel pipe 5 ~eet (1.5 m~ long and having a wall thickness of 3/16 inch (5 mm). A steel form of 7.5 inches tl9 cm) inner diameter was placed concentrically about the metal pipe and the refractory admixture cast between the two using vibratisn to obtain maximum density.
The taphole thus formed was stripped of the outer form after setting at ambient tempsrature over night and then was heated on a preset schedule to a temperature of 600 F (315 1 ~2 ~ `3 C) over a period of 30 hours be~ore being shipped to the customer.
Pre~vrmed tapholes made according to this invention were installed in BOF furnaces in a steelmaking plant. In the newest furnace, the tapholes made according to this invenkion had an average life o~ 48.6 heats, and in the oldest furnace an average life o~ 32.3 heats. This compares ko an average life for prior art preformed tapholes not containing the combination of graphite and metal fibers of 33 heats in the newest ~urnace and 22.5 heats in the oldest ~urnace.
While the reasons ~or the superior per~ormance o~
tapholes made with the combination of metal ~ibers and graphite is not fully understood, and it is not desired to be bound to any particular theory, it is believed that the graphite prevents slag penetration into the refractory, allowing the metal fibers to perform their strengthening and reinforcing function for a longer time.
In the specification and claims, percentages and parts are by weight unless otherwise indicated. Mesh sizes referred 20 to herein are Tyler standard screen sized which are defined in Chemical Engineers' Handbook, John S. Perry, Editor-in-Chief, Third Editlon, 1950, published by McGraw Hill Book Company, at page 963. Analyses of mineral components are reported in the usual manner, expressed as simple oxides, e.g. MgO and SiO
although the components may actually be present in various combinations, e.g. as a maynesium silicate.
Claims (30)
1. Method of making a preformed taphole comprising (1) selecting a metal pipe of the desired length and diameter, (2) admixing (a) from 1% to 8% of a water soluble binder, (b) from 0.1% to 2% metal fibers, (c) and 0.5% to 5% graphite with (d) basic refractory grain making up the balance of the admixture, all percentages being by weight and based on the total weight of the admixture, (3) adding sufficient tempering liquid to the admixture to make a formable refractory mass, (4) forming the tempered admixture about the outer surface of the metal pipe, and (5) drying the so-formed refractory mass to make a preformed taphole.
2. Method according to claim 1 wherein the basic refractory grain is periclase.
3. Method according to claim 1 wherein the metal fibers are steel fibers.
4. Method according to claim 3 wherein the fibers are stainless steel.
5. Method according to claim 1 wherein the graphite is flake graphite.
6. Method according to claim 1 wherein the water soluble binder comprises aluminum sulfate, boric acid, and citric acid.
7. Method according to claim 6 wherein the bond comprises about 0.8% aluminum sulfate, about 0.7% boric acid, and about 0.6% citric acid.
8. Method according to claim 1 wherein the basic refractory grain is periclase, the fibers are stainless steel, and the graphite is flake graphite.
9. Method according to claim 8 wherein the binder comprises aluminum sulfate, boric acid, and citric acid.
10. Method according to claim 9 wherein the binder comprises about 0.8% aluminum sulfate, about 0.7% boric acid, and about 0.6% citric acid.
11. Refractory composition consisting essentially of (1) from 1% to 8% of a water soluble binder, (2) from 0.1% to 2%
metal fibers, and (3) from 0.5% to 5% graphite, the balance being (4) sized refractory grain, all percentages being by weight based on the total weight of the composition.
metal fibers, and (3) from 0.5% to 5% graphite, the balance being (4) sized refractory grain, all percentages being by weight based on the total weight of the composition.
12. Refractory according to claim 11 wherein the refractory grain is a basic refractory grain.
13. Refractory according to claim 12 wherein the grain is periclase.
14. Refractory according to claim 11 wherein the metal fibers are steel fibers.
15. Refractory according to claim 14 wherein the fibers are stainless steel fibers.
16. Refractory according to claim 11 wherein the graphite is flake graphite.
17. Refractory according to claim 11 wherein the water soluble bond comprises aluminum sulfate, boric acid, and citric acid.
18. Refractory according to claim 17 wherein the bond comprises about 0.8% aluminum sulfate, about 0.7% boric acid, and about 0.6% citric acid.
19. Refractory according to claim 11 wherein the refractory grain is basic refractory grain, the fibers are stainless steel fibers, and the graphite is flake graphite.
20. Refractory according to claim 19 wherein the bond comprises aluminum sulfate, boric acid, and citric acid.
21. A preformed taphole comprising (1) a hollow metal pipe and (2) a refractory mass formed about the exterior circumference of said pipe over at least a portion of its length, said refractory mass consisting essentially of (a) from 1% to 8% of a water soluble binder, (b) from 0.1% to 2%
metal fibers, (c) and 0.5% to 5% graphite with (d) basic refractory grain making up the balance of the admixture, all percentages being by weight and based on the total weight of the admixture.
metal fibers, (c) and 0.5% to 5% graphite with (d) basic refractory grain making up the balance of the admixture, all percentages being by weight and based on the total weight of the admixture.
22. Taphole according to claim 21 wherein the basic refractory grain is periclase.
23. Taphole according to claim 21 wherein the metal fibers are steel fibers.
24. Taphole according to claim 23 wherein the fibers are stainless steel.
25. Taphole according to claim 21 wherein the graphite is flake graphite.
26. Taphole according to claim 21 wherein the water soluble binder comprises aluminum sulfate, boric acid, and citric acid
27. Taphole according to claim 26 wherein the bond comprises about 0.8% aluminum sulfate, about 0.7% boric acid, and about 0.6% citric acid.
28. Taphole according to claim 21 wherein the basic refractory grain is periclase, the fibers are stainless steel, and the graphite is flake graphite.
29. Taphole according to claim 28 wherein the binder comprises aluminum sulfate, boric acid, and citric acid.
30. Taphole according to claim 29 wherein the binder comprises about 0.8% aluminum sulfate, about 0.7% boric acid, and about 0.6% citric acid.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US23200588A | 1988-08-15 | 1988-08-15 | |
| US07/232,005 | 1988-08-15 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1321405C true CA1321405C (en) | 1993-08-17 |
Family
ID=22871496
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000582518A Expired - Fee Related CA1321405C (en) | 1988-08-15 | 1988-11-08 | Making a taphole |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1321405C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112979320A (en) * | 2021-03-30 | 2021-06-18 | 河南远洋新材料技术有限公司 | Silicon carbide hot-melt-solid repair paste and preparation method thereof, and repair method for blast furnace and submerged arc furnace taphole |
-
1988
- 1988-11-08 CA CA000582518A patent/CA1321405C/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112979320A (en) * | 2021-03-30 | 2021-06-18 | 河南远洋新材料技术有限公司 | Silicon carbide hot-melt-solid repair paste and preparation method thereof, and repair method for blast furnace and submerged arc furnace taphole |
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Effective date: 19960219 |