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Technical Report No.58 (2015)

Shinagawa Technical Report
No.58 (2015)

CONTENTS

Preface

The 60th Anniversary of Shinagawa Technical Report

Director, Managing Executive Officer  Eishi IIDA

Special Thme

Change in Refractory Technology Seen in “Shinagawa Technical Report” Over 60 Years

Masanori OGATA

Abstract

 Shinagawa Technical Report was first published in 1954, 60 years ago. Japan's postwar high economic growth also started at about this point. During the first decade, many articles concerning the import of technology from Europe and the U. S. were published in the Report. After that, Japan's refractory technology drastically evolved, in parallel with the evolution of customer's operating process including steelmaking. As a result, the first International Refractory Conference was held in Japan in 1983, roughly three decades after the start of economic growth. Most of the current refractory products originated during those three decades. During the subsequent three decades, however, various new refractory technologies with high performance, advanced function or eco-friendly use have been continuously developed. The development can be seen not only in evolving fields such as continuous casting but the fields that were considered to be technically matured at that time. Reviewing the full 60 years of the reports suggests that the first three decades was an era of new material or installation development to cope with the customer's operating process change, and that the next three decades was the era of value creation for the material or installation.

Reports

SENs for Quality Improvement of Steel in Bloom or Billet Caster

Hiroyasu NIITSUMA, Yukio OHKAWA, Shinsuke INOUE and Takayuki MATSUNAGA

Abstract

 The structure of SEN controls the molten steel flow pattern in the mold and influence on steel quality.  Using a water model test and CFD calculation, we developed a SEN structure that can optimize the molten steel flow pattern in the mold for bloom or billet continuous casters. It became clear that a stable swirling flow in the mold was created using “Bend port” SEN which had unique ports on the side of the nozzle. In addition, improvement of steel quality was confirmed by the results of an actual test in a round billet caster. A Mogul SEN with a reverse-taper port which had mogul projections in the bore and an increased nozzle diameter, solved the biased outlet flow problem and decreased the depth of the outlet flow.

Characteristics of Slag Penetration Layer in Tundish Castables

Yumi KIMURA, Kiyoyuki KOMATSUBARA and Koji ASAKAWA

Abstract

 One of the major damage factors affecting tundish castables is slag penetration. The slag penetration layer, which is formed when the castable reacts with the slag which was penetrated it, is considered to be a caused of cracking, peeling and reaction bonding with magnesia gunning materials.  The effects of the slag penetration layer in tundish castables were examined by analysis of collected samples from an actual furnace. The analysis includes a reproduction of the slag penetration layer and evaluation of its properties. As a result, it is assumed that the main effect of the slag penetration layer in tundish castables is "peeling" caused by the difference in the physical properties, it generates between the hot face and back side.

Improved Permanent Lining for BF Trough with Unshaped Materials

Kazuya NAKABO, Takashi IIDA and Masatsugu KITAMURA

Abstract

 Recently, cases of constructing the permanent lining of the blast furnace trough with unshaped refractories have been increasing. When introducing unshaped refractories to the permanent lining, ensuring sufficient corrosion resistance, spalling resistance and mechanical strength is important.  In terms of applied materials, we developed a chemical bonded castable material suitable for the permanent lining which has high corrosion resistance, high spalling resistance and high strength. Moreover, in terms of improvement in structure, we have been able to provide a new structure utilizing a dry vibration material which has an excellent effect on reducing cracks and protecting the steel shell.

Development of Chrome-free Brick for Highest Temperature Zone of Cement Rotary Kiln

Koichi IGABO, Yoshihiro TODA and Masakazu IIDA

Abstract

 Highly corrosion-resistant chrome-free brick "ELK-11CW" was newly developed particularly for the highest temperature area (hot spot) of the cement rotary kiln. High corrosion resistance under higher temperature conditions results from a suitable matrix texture formed by optimizing the raw material composition, grain size distribution and firing conditions.  The superior corrosion resistant property of ELK-11CW was confirmed by corrosion test as well as commercial application. This desirable property ensures thicker residual lining thickness at the hot spot of the kiln where the brick surface is exposed to excessively high temperature temporarily or locally due to unstable combustion of high-calorie industrial waste.

Al2O3-MgO-C Bricks with High Resistance Against Peeling Wear for Steel Ladle

Naoko DOI, Hisashi TOMIYA, Atsuhisa IIDA and Keita KAMIYAMA

Abstract

 We developed Al2O3-MgO-C bricks with high peeling resistance for the impact zone of steel ladles. Reduction of the amount and size of pores in Al2O3-MgO-C bricks is effective for inhibiting the penetration of molten steel into the bricks. These bricks showed good performance at many EAF (Electric Arc Furnace) steelmakers.

Technical Information on Products

Properties of the Block for Coke Oven Door Over 12 Years Commercial Application

Hidekuni NISHIGUCHI, Kazuki SAKAWA, Kyohei YAMASHITA and Masakazu IIDA

Abstract

 This report describes the properties of a glaze coated block for the coke oven door which had been used for over 12 years. The smooth surface of the block, which is maintained over a long time application, demonstrates the satisfactory performance of our glaze coating technology. Though some cracks were found on the inside of the block, a rigid structure was maintained. That reveals the stableness of our product. A highly stable structure is also expected for our unburned block without glaze coating.

Variety of Castable for Coke Oven Block

Kazuki SAKAWA, Natsumi HIGASHIKAWA and Kyohei YAMASHITA

Abstract

 Many kinds of precast blocks have been applied as coke oven refractories, according to the individually varying requirements. Corresponding to the requirements, we produce various kinds of castable materials optimizing in chemical composition, grain size, and binding system to achieve the desirable properties for each application. In this report, the characteristics of those castables and their applications are introduced.

Dry Coating Material for Tundish

Kiyoyuki KOMATSUBARA and Natsumi HIGASHIKAWA

Abstract

 We developed a dry coating for the tundish in order to improve steel quality and extend the life of work lining materials. In this report, we showed installation technique of the dry coating material and the characteristics of our developed material.

Improvement of Steel Quality by Application of Carbon Free Mold Powder

Shogo YAMASHITA and Takayuki SUZUKI

Abstract

  Carbon free mold powder was developed in order to improve the quality of steel in where it is required to have no carbon pick up. Improvements to steel quality by the application of the carbon free mold powder on ultra-low carbon steel, high oxygen steel, and stainless steel are introduced.

Characteristics and Performance of Basic Bricks for Cement Kilns

Yoshihiro TODA, Tamiatsu KOYAKE, Koichi IGABO and Koichiro MORI

Abstract

 In cement kilns in Japan, service condition of refractory lining is becoming more severe, which causes increased wear of the lining. The magnesia-spinel bricks for cement kilns which we produce have shown superior performance in severe conditions, and contribute to achieving economical and stable operation. This report introduces the characteristics and performance of bricks for each application zone.

Information on Products of Associated Companies

CERA TECHNO Co., Ltd.
 “Fumeless Hot Casting Repair Mixes for The Bottom of DC Arc Furnace”

Yuichi TAKAKURA, Masanori HAZAKI and Shinya HARA

Abstract

 Dolomite and dolomite-based hot casting mixes are used to repair EAF bottoms. We have developed fumeless hot casting repair mixes which have good adhesion and electrical conductivity. This material has been applied to repair the bottom electrode of a DC arc furnace and has contributed to life extension of the bottom electrode and stable operation of the furnace.

Isolite Insulating Products Co., Ltd.
“Advanced Ceramic Fiber Board with High Heat Resistance and High Heat Insulation”

Ken ONO, Tatsuki SOMIYA and Tetsuji KAMIO

Abstract

 Ceramic fiber usually contains some amount of “shot”, non-fibrous by-product grains formed during the fiber-making process. Because shot reduces the heat insulation property, ISOLITE developed advanced ceramic fiber board 1260 SI BOARD (1260-degrees-C grade) by reducing the shot content of the fiber. Recently, ISOLITE has newly developed 1400 SI BOARD with higher heat resistance (1400-degrees-C grade). Due to high heat resistance and a high pressure resistance quality, 1400 SI BOARD can be used as the backup heat insulation of molten metal containers. Also 1400 SI BOARD is suitable for heat insulation of panel heaters. This advanced fiber board can be expected to contribute to energy saving in various industrial furnaces.

Shinagawa Refractories Australasia Pty. Ltd.
“Product Selection for Alumina Calciner Applications”

Nathan LEICHT

Abstract

 Calcination is the final step in the production of smelter grade alumina from bauxite and modern design alumina calciners use the fluid bed calcination process. While there are many different refractory materials used throughout a calciner, this paper will focus on the monolithic materials used in the main calciner, cyclones and ductwork of a fluid bed calciner.