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É. M. Manasheva - One of the best experts on this subject based on the ideXlab platform.
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SHS Ferrosilicon Nitride NITRO-FESIL®TL as a New Tap-Hole Clay Refractory Component for Blast Furnaces1
Refractories and Industrial Ceramics, 2014Co-Authors: I. M. Shatokhin, M. Kh. Ziatdinov, É. M. ManashevaAbstract:The scientific and technical manufacturing firm Etalon developed and perfected industrial technology for manufacturing SHS ferrosilicon nitride NITRO-FESIL® TL, which is a composite consisting of silicon nitride, iron silicide, and free iron. On an industrial scale together with OAO MMK and ZAO Metallurgremont test Tap-Hole clays are provided containing ferrosilicon nitride NITRO-FESIL® TL. TapHole clays with the new component demonstrate higher corrosion and erosion resistance, and oxidation resistance, and also better sintering capacity. As a result of this reliable sealing of iron Tap-Holes, a smooth, more prolonged iron and slag flow regime with stable discharge parameters is provided. The clay is recommended for introduction.
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shs ferrosilicon nitride nitro fesil tl as a new Tap Hole clay refractory component for blast furnaces1
Refractories and Industrial Ceramics, 2014Co-Authors: I. M. Shatokhin, Kh M Ziatdinov, É. M. ManashevaAbstract:The scientific and technical manufacturing firm Etalon developed and perfected industrial technology for manufacturing SHS ferrosilicon nitride NITRO-FESIL® TL, which is a composite consisting of silicon nitride, iron silicide, and free iron. On an industrial scale together with OAO MMK and ZAO Metallurgremont test Tap-Hole clays are provided containing ferrosilicon nitride NITRO-FESIL® TL. TapHole clays with the new component demonstrate higher corrosion and erosion resistance, and oxidation resistance, and also better sintering capacity. As a result of this reliable sealing of iron Tap-Holes, a smooth, more prolonged iron and slag flow regime with stable discharge parameters is provided. The clay is recommended for introduction.
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SHS Ferrosilicon Nitride NITRO-FESIL®TL as a New Tap-Hole Clay Refractory Component for Blast Furnaces^1
Refractories and Industrial Ceramics, 2014Co-Authors: I. M. Shatokhin, M. Kh. Ziatdinov, É. M. ManashevaAbstract:The scientific and technical manufacturing firm Étalon developed and perfected industrial technology for manufacturing SHS ferrosilicon nitride NITRO-FESIL® TL, which is a composite consisting of silicon nitride, iron silicide, and free iron. On an industrial scale together with OAO MMK and ZAO Metallurgremont test Tap-Hole clays are provided containing ferrosilicon nitride NITRO-FESIL® TL. TapHole clays with the new component demonstrate higher corrosion and erosion resistance, and oxidation resistance, and also better sintering capacity. As a result of this reliable sealing of iron Tap-Holes, a smooth, more prolonged iron and slag flow regime with stable discharge parameters is provided. The clay is recommended for introduction.
Tetsui Hakone - One of the best experts on this subject based on the ideXlab platform.
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numerical study on metal slag drainage rate deviation during blast furnace Tapping
Tetsu To Hagane-journal of The Iron and Steel Institute of Japan, 2010Co-Authors: Masakazu Iida, Kazuhiro Ogura, Tetsui HakoneAbstract:Remarkable deviation of metal fraction in the liquid drained out of blast furnace Tap Hole has been occasionally observed between the operated Tap Holes and/or Tapping time stages. Introducing the concept of low permeability zone whose wall, due to the difference in two liquid phases' viscosity and/or wettabilitiy to coke particle, allows for metal to permeate freely but for slag not to permeate, the liquid drainage behaviors are examined by furnace hearth mathematical model simulations.The deviation of metal fraction between two operated Tap Holes is materialized under the hypothesis that furnace heath is divided into two sections by planar vertical low permeability wall (VLPW). While, the variation of time series change in liquid metal fraction during Tapping operation is reproduced by hypothesizing the formation of cylindrical low permeability wall (CLPW) which concentrically parts the furnace hearth into center and peripheral area.Since the results of calculation for VLPW or CLPW formation indicate the notable raise of liquid level in furnace which could influence on abrupt increase of blowing pressure, the effectiveness of several operational optimization is assessed, resulting in suggestive conclusion that increasing the initial Tap Hole diameter is the most effective.
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Numerical Study on Metal/Slag Drainage Rate Deviation during Blast Furnace Tapping
Isij International, 2009Co-Authors: Masakazu Iida, Kazuhiro Ogura, Tetsui HakoneAbstract:Remarkable deviation of metal fraction in the liquid drained out of blast furnace Tap Hole has been occasionally observed between the operated Tap Holes and/or Tapping time stages. Introducing the concept of low permeability zone whose wall, due to the difference in two liquid phases' viscosity and/or wettabilitiy to coke particle, allows for metal to permeate freely but for slag not to permeate, the liquid drainage behaviors are examined by furnace hearth mathematical model simulations.The deviation of metal fraction between two operated Tap Holes is materialized under the hypothesis that furnace heath is divided into two sections by planar vertical low permeability wall (VLPW). While, the variation of time series change in liquid metal fraction during Tapping operation is reproduced by hypothesizing the formation of cylindrical low permeability wall (CLPW) which concentrically parts the furnace hearth into center and peripheral area.Since the results of calculation for VLPW or CLPW formation indicate the notable raise of liquid level in furnace which could influence on abrupt increase of blowing pressure, the effectiveness of several operational optimization is assessed, resulting in suggestive conclusion that increasing the initial Tap Hole diameter is the most effective.
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analysis of drainage rate variation of molten iron and slag from blast furnace during Tapping
Tetsu To Hagane-journal of The Iron and Steel Institute of Japan, 2009Co-Authors: Masakazu Iida, Kazuhiro Ogura, Tetsui HakoneAbstract:Despite its importance in practical blast furnace (BF) operation, the dominant factors to control drainage rate or Tapping time have not been well studied. In most cases, short Tapping time has been attributed to rapid Tap Hole diameter enlargement. On the other hand, the experiential tendency about positive correlation between furnace hearth bottom temperature and drainage rate has been widely recognized.In order to examine the dominant factors to control the liquid drainage rate or Tapping time at BF, a simulative calculation model is introduced, where the liquid drainage path consists of coke particles packed layer (coke filter) and Tapping Hole and the overall drainage rate is determined as one of smaller fluid rate in coke filter or Tapping Hole. For calculating the fluid rate in coke filter, a hypothesis that liquid iron and slag in coke filter is driven toward the Tap Hole entry point consuming the coke particles, whose extent depends on molten iron C saturation degree and FeO fraction in molten slag, was introduced.The calculation results present good matches with the observed Tapping operation. This result can be explained by the two influences of low permeability zone formation or elimination at furnace hearth. Considering the two influences of low permeability zone formation, (1) to lower hearth bottom temperature and (2) to induce low C saturation of pig iron due to short traveling time in liquid pool to Tap Hole entry point, the simulation result conforms to the above mentioned experiential tendency.
I. M. Shatokhin - One of the best experts on this subject based on the ideXlab platform.
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SHS Ferrosilicon Nitride NITRO-FESIL®TL as a New Tap-Hole Clay Refractory Component for Blast Furnaces1
Refractories and Industrial Ceramics, 2014Co-Authors: I. M. Shatokhin, M. Kh. Ziatdinov, É. M. ManashevaAbstract:The scientific and technical manufacturing firm Etalon developed and perfected industrial technology for manufacturing SHS ferrosilicon nitride NITRO-FESIL® TL, which is a composite consisting of silicon nitride, iron silicide, and free iron. On an industrial scale together with OAO MMK and ZAO Metallurgremont test Tap-Hole clays are provided containing ferrosilicon nitride NITRO-FESIL® TL. TapHole clays with the new component demonstrate higher corrosion and erosion resistance, and oxidation resistance, and also better sintering capacity. As a result of this reliable sealing of iron Tap-Holes, a smooth, more prolonged iron and slag flow regime with stable discharge parameters is provided. The clay is recommended for introduction.
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shs ferrosilicon nitride nitro fesil tl as a new Tap Hole clay refractory component for blast furnaces1
Refractories and Industrial Ceramics, 2014Co-Authors: I. M. Shatokhin, Kh M Ziatdinov, É. M. ManashevaAbstract:The scientific and technical manufacturing firm Etalon developed and perfected industrial technology for manufacturing SHS ferrosilicon nitride NITRO-FESIL® TL, which is a composite consisting of silicon nitride, iron silicide, and free iron. On an industrial scale together with OAO MMK and ZAO Metallurgremont test Tap-Hole clays are provided containing ferrosilicon nitride NITRO-FESIL® TL. TapHole clays with the new component demonstrate higher corrosion and erosion resistance, and oxidation resistance, and also better sintering capacity. As a result of this reliable sealing of iron Tap-Holes, a smooth, more prolonged iron and slag flow regime with stable discharge parameters is provided. The clay is recommended for introduction.
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SHS Ferrosilicon Nitride NITRO-FESIL®TL as a New Tap-Hole Clay Refractory Component for Blast Furnaces^1
Refractories and Industrial Ceramics, 2014Co-Authors: I. M. Shatokhin, M. Kh. Ziatdinov, É. M. ManashevaAbstract:The scientific and technical manufacturing firm Étalon developed and perfected industrial technology for manufacturing SHS ferrosilicon nitride NITRO-FESIL® TL, which is a composite consisting of silicon nitride, iron silicide, and free iron. On an industrial scale together with OAO MMK and ZAO Metallurgremont test Tap-Hole clays are provided containing ferrosilicon nitride NITRO-FESIL® TL. TapHole clays with the new component demonstrate higher corrosion and erosion resistance, and oxidation resistance, and also better sintering capacity. As a result of this reliable sealing of iron Tap-Holes, a smooth, more prolonged iron and slag flow regime with stable discharge parameters is provided. The clay is recommended for introduction.
Liu Haifeng - One of the best experts on this subject based on the ideXlab platform.
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Model of slag flow and heat transfer at slag Tap Hole region of Shell gasifier
2012Co-Authors: Liu HaifengAbstract:In China,there are often big slag blockages at the slag Tap Hole region of Shell gasifier during long time operation,which is an important threat to the safe,economic and stable operation of industrialization device.A model of flow and heat transfer of molten coal slag at the slag Tape Hole region of Shell gasifier was proposed to discuss the reason of slag blockage.The thicknesses of solid slag layer and liquid slag layer,and the surface temperature of liquid slag layer were predicted with the proposed model.The results show that there is solid slag layer with certain thickness on the slag screen wall because of slag deposition during gasifier operation.The slag is totally solidified to solid slag at early start-up.When the surface temperature is above the critical temperature,the liquid slag layer appears.The thicknesses of solid slag layer and liquid slag layer both increase with the increase of time until to its stable state.The farther the distance from the slag Tap Hole is,the thicker the solid and liquid slag layer are and the higher the surface temperature of liquid slag layer is.The lower the slag Tap Hole temperature and the deposition rate are,the thicker the solid slag layer is and the longer the characteristic time is.
J. D. Steenkamp - One of the best experts on this subject based on the ideXlab platform.
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Tap-Hole Life Cycle Design Criteria: A Case Study Based on Silicomanganese Production
JOM, 2016Co-Authors: J. D. Steenkamp, J. J. Sutherland, D. A. Hayman, J. MullerAbstract:Managing the Tapping of furnaces is a challenge to most furnace operators. As a Hole is made in the refractory lining and re-filled with clay, several times a day, the Tap-Hole is one of the weak spots in the refractory lining. Tap-Hole failures are high-risk events, and steps should be taken to minimize the risks. Designing for the life–cycle of the Tap-Hole is proposed and discussed as a way of minimizing the risks associated with Tap-Hole failure. Design criteria are proposed not only for a total reline and normal operation but also for emergency conditions, as well as maintenance, and repair of the Tap-Hole. The criteria are discussed in the context of silicomanganese production in South Africa.
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Insights into the potential for reduced refractory wear in silicomanganese smelters
Journal of The South African Institute of Mining and Metallurgy, 2016Co-Authors: J. D. Steenkamp, Petrus Christiaan Pistorius, J. MullerAbstract:arc furnace (SAF) used for silicomanganese (SiMn) production, it was found that the TapHole and hearth were high refractory wear areas (Steenkamp, 2014). In both these highwear areas, carbon-based cold ramming paste formed the hot face refractory lining (crucible). The wear profile of this SAF is presented in Figure 1. The hot face refractory lining was formed by cold ramming of high-grade carbon ramming material. This material consisted of 50–70% anthracite, 15–25% graphite, 6–12% resin, 2–7% tar, 1–5% clay, and 1–5% alumina. The Tap-Hole was built using SiC bricks, consisting of 75% SiC, 23.4% Si3N4, 0.3% Fe2O3, 0.3% Al2O3, and 0.2% CaO. In the Tap-Hole area, the wear of the SiC refractory material was estimated at 0.4 t, and that of the high-grade carbon ramming material, at 1.9 t (Steenkamp, Pistorius, and Tangstad, 2015). The amounts of slag and metal Tapped during six years of operation of the Tap-Hole (September 2007 to April 2013) were estimated at 33 088 t (Steenkamp et al., 2015) and 41 360 t, respectively. The original thickness of the high-grade carbon ramming paste installed in the hearth was 850 mm, of which a minimum of 600 mm was seen to remain after ten years of operation (April 2003 to April 2013). Over the lifetime of the hearth refractory, 384 000 t of SiMn metal was Tapped from the furnace (Gous, 2015). The difference in metal exposure of hearth and Tap-Hole is due to the fact that the furnace had two single-level Tap-Holes, and that the Tap-Holes were rebuilt during the lifetime of the hearth refractory. Further details of the refractory design, and history of operations have been discussed elsewhere (Steenkamp et al, 2014, 2015; Steenkamp, 2014). Analysis of the potential for chemical wear in the Tap-Hole area of the SAF excavated in 2013 (Figure 1) was included in a larger study on Tap-Hole wear in SAFs producing SiMn (Steenkamp, 2014). In that study the potential for chemical reaction between slag (and metal) and refractory materials being responsible for wear in a single-level Tap-Hole where slag and metal are Tapped typically at 1600°C was tested. It was previously established that reaction between silicomanganese slag and carbonbased Tap-Hole refractory is possible (Steenkamp, 2014). Predictions by thermodynamic calculations were supported by laboratory-scale experiments with nominally pure materials as well as industrial materials (Steenkamp, 2014), as reaction products SiC and SiMn droplets formed. For the reaction of C-based refractory with slag, if the SiC Insights into the potential for reduced refractory wear in silicomanganese smelters by J.D. Steenkamp*, P.C. Pistorius, and J. Muller
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Wear Mechanisms of Carbon-Based Refractory Materials in Silicomanganese Tap Holes—Part I: Equilibrium Calculations and Slag and Refractory Characterization
Metallurgical and Materials Transactions B-process Metallurgy and Materials Processing Science, 2015Co-Authors: J. D. Steenkamp, Petrus Christiaan Pistorius, Merete TangstadAbstract:Silicomanganese (SiMn) as an alloy supplies silicon and manganese to the steelmaking industry. It is produced through carbothermic reduction in a submerged arc furnace. The slag and metal are typically Tapped through a single-level Tap Hole at 50 K (50 °C) below the process temperature of 1873 K to 1923 K (1600 °C to 1650 °C). In one Tapblock refractory design configuration, the Tap Hole is installed as a carbon Tapblock and rebuilt during the life of the lining using carbon-based cold ramming paste. The carbon Tapblock lasts for a number of years and ramming paste only for months. The purpose of the study presented here was to determine to what extent chemical reactions between carbon-based refractory and slag or metal in the Tap Hole of a SiMn furnace can contribute to wear of Tap-Hole refractory. The results of the study are reported in two parts. In Part I, the results of thermodynamic calculations of the potential for chemical reaction between carbon-based refractory material and slag or metal are reported. The results were tested experimentally using pure graphite and synthetic SiMn slag (produced from pure oxides). The paper also reports the composition, microstructure, and phases of industrial SiMn slag, and commercially available carbon block and cold ramming paste refractory materials. These compositions were used in predicted equilibria of refractory–slag reactions. Thermodynamic calculations suggest that reaction between SiMn slag and carbon-based Tap-Hole refractory is possible, and experiments with nominally pure materials support this. However, practical refractory materials are by no means pure materials, and contain secondary phases and porosity which can be expected to affect reaction with slag. Such reactions are examined in Part II.
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Wear Mechanisms of Carbon-Based Refractory Materials in SiMn Tap-Holes—Part II: In Situ Observation of Chemical Reactions
Metallurgical and Materials Transactions B-process Metallurgy and Materials Processing Science, 2014Co-Authors: J. D. Steenkamp, P. Chris Pistorius, Merete TangstadAbstract:The purpose of the study presented here is to determine to what extent chemical reactions between carbon-based refractory and slag or metal in the Tap-Hole of a SiMn furnace can contribute to wear of Tap-Hole refractory. The results of the study are reported in two parts. In Part I, thermodynamic calculations suggested that reaction between silicomanganese slag and carbon-based Tap-Hole refractory is possible, and experiments with nominally pure materials support this. However, practical refractory materials are by no means pure materials and contain secondary phases and porosity which can be expected to affect reaction with slag. In Part II, such reactions are examined experimentally, in cup and wettability tests, using commercially available carbon block and cold-ramming paste refractory materials and mainly industrial SiMn slag. Clear evidence was found of chemical reaction at approximately 1870 K (approximately 1600 °C), forming SiC and, it appears, metal droplets. Both carbon block and ramming paste refractory reacted with slag, with preferential attack on and penetration into the binder phase rather than aggregate particles. The two types of carbon-based refractory materials showed similar extents of chemical reaction observed as wetting and penetration in the laboratory tests. The differences in refractory life observed practically in industrial furnaces should therefore be attributed to wear mechanisms other than pure chemical wear as studied in this work.