MAGNESIA-CARBON REFRACTORY

Abstract: The unburnt refractory corn prises fine magnesia as a main constituent and significantiy differs from prior art refractories in that the maximum grain dia meter of the fine magnesia is 1.5 mm and in that magnesia having a grain diameter of 0.3 to 1.5 mm comprises at most 30% by weight of the refractory raw materials. By so limiting the particle size, a refractory having high compactness is obtained, as indicated by a high bulk density and low air permeability. The weight ratio of graphite to magnesium fine powder (particle size at most 0.3 mm) is from 2.5:1 to 0.4:1. The refractory does not crack when subjected to pressure at the time of moulding and has excellent resistance to corrosion and oxidation. It prererably comprises 100 parts by weight of the refractory raw materials and 1 to 6 parts by weight of an additive, selected from Al, Si, B₄C, and SiC.

Description: MAGNESIA-CARBON REFRACTORY The present invention relates to unburned magnesiacaroon refractories comprising fine powder as a major component and having excellent resistance to corrosion and oxidation. More specifically, it relates to an improved magnesia-carbon (hereinafter referred to as MgO-C) refractory particularly appropriate for use in refining operations under severe working conditions. Refining outside the converter has become commonplace in steel manufacture. For example, in ASEA-SKF, VAD, LF, and similar types of ladles, arc heating, stirring, and vacuum degasification are carried out. Accordingly, refractories used as lining materials in such ladles are exposed to extremely severe working conditions. In particular, damage to the refractory lining in the slag line portion of the ladle is very great. In the past, normal direct bonded and rebounded magnesia-chrome bricks and dolomite bricks were used in the slag line portion, but stripping damage of these types of bricks due to attack by slag as well as heat and mechanical spalling is very great. Therefore, in recent years, they have come to be replaced by unburned MgO-C bricks in ASEA-SKF and other types of ladles. However, even when using unburned MgO-C bricks, the slag line portion experiences considerable damage owing to the severity of the working conditions, and a satisfactory unburned MgO-C brick for use in ladles has yet to be found. In the course of experiments aimed at producing an MgO-C brick having improved properties, the present inventors made the following observations. 1) If the space between fine aggregate particles of the brick is sufficiently filled with graphite, a closed cell structure is formed which results in the bricK having increased resistance to corrosion. 2) If the amount of MgO fine powder in the brick is too large, laminations develop at the time of moulding. 3) In conventional MgO-C bricks, coarse grains of magnesia are used to give the brick compactness and resistance to corrosion. However, if the amount of coarse grains is too large, the refractory willsplit when pressure is applied to it during moulding, owing to the veins in the coarse grains. In particular, veins are numerous in high grade electrofused MgO grains. While electrofused MgO is very effective in providing corrosion resistance, its grains split very easily when pressure is applied. 4) Graphite in refractories acts as a lubricant and increases compactness From the above observations, it was deduced that, by limiting the magnesia grain size to a level lower than that used in the prior art, a magnesia-caroon brick having greater compactness and greater resistance to corrosion than the unburned MgO-C bricks according to the prior art should be achievable. Further, by using MgO grains of small grain diameter, it should be possible to mould the brick without producing laminations. The unburned MgO-C refractory according to tne present invention has a completely different grain size distribution from unburned MgO-C refractories according to the prior art. It comprises 100 parts by weight of refractory raw materials, the refractory raw materials comprising at most 30 parts by weight of fine grains of magnesia having a grain diameter of approximately 1.5 to approximately 0.3 mm and at least 70 parts by weight of graphite fine powder and magnesia fine powder, the weight ratio of graphite to magnesia being approximately 2.5 to approximately 0.4, and preferaDly further comprises 1 to 6 parts by weight of an additive, the additive comprising at least one substance selected from the group consisting of aluminium, silicon, B4C, and Sic. The invention will be described further, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a graph showing the bulk density of seven MgO-C bricks comprising fine graphite powder and fine MgO powder, each having a different weight ratio of graphite to MgO; and Figure 2 is a graph showing the apparent porosity of each of 7 different MgO-C bricks comprising fine graphite powder and fine MgO powder after drying at 1500C for 10 hours and after burning in a reducing atmosphere at 10000C for 3 hours. In conventional unburned MgO-C bricks, an aggregate having a maximum particle diameter of 5 mm (with a large percentage of the aggregate having a diameter of 2.38 mm) is normally used. Wnen refractory raw materials comprising such a coarse aggregate are subjected to moulding pressure, the aggregate grains come directly into contact with one another and the fine powder portion which fills the spaces between coarse grains of the aggregate is prevented from being compressed, resulting in insufficient compactness. However, in the present invention, a refractory of great compactness is achieved by limiting tne size of the aggregate (if any) to 1.5 mm - 0.3 mm, the diameter of the fine powder portion consequently being limited to at most 0.3 mm. When refractory raw materials comprising this aggregate are compressed at the time of moulding, the fine powder portion between the aggregate grains can be fully compressed, and laminations do not occur. Generally, unburned bricks having a fine powder structure have considerable burning snrinkage and are lacking in serviceability. In the present invention, however, the addition of grapnite holds down this shrinkage. Because the graphite is able to be fully compressed during moulding, the resulting unburned brick has low air permeability, and oxidation loss of the graphite is prevented. The resistance of the graphite to oxidation may be further increased by the addition of a conventionallyused anti-oxidizing agent comprising at least one substance selected from aluminium, silicon, B4C, and SiC. This additive comprises 1 to 6 parts by weight of the unburned refractory per 100 parts by weight of refractory raw materials. Figure 1 shows the results of an experiment measuring the bulk density (used as an index of compactness) of a number of bricks comprising a fine powder. Mixtures containing graphite (having a particle diameter of at most 1 mm) and MgO (having a particle diameter of at most 0.3 mm) in various ratios were prepared and moulded at 1000 kg/cm2 into standardbricks (230 x 114 x 65 mm). AS seen from Figure 1, graphite and MgO fine powder used in ratios in accordance with the present invention produced bricks having high compactness. comprising at most 30 parts by weight of fine grains of magnesia having a grain diameter of approximately 1.5 to approximately 0.3 mm and at least 70 parts by weight of graphite fine powder and magnesia fine powder, the weight ratio of graphite to magnesia being approximately 2.5 to approximately 0.4, and preferaDly further comprises 1 to 6 parts by weight of an additive, the additive comprising at least one substance selected from the group consisting of aluminium, silicon, B4C, and Sic. The invention will be described further, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a graph showing the bulk density of seven MgO-C bricks comprising fine graphite powder and fine MgO powder, each having a different weight ratio of graphite to MgO; and Figure 2 is a graph showing the apparent porosity of each of 7 different MgO-C bricks comprising fine graphite powder and fine MgO powder after drying at 1500C for 10 hours and after burning in a reducing atmosphere at 10000C for 3 hours. In conventional unburned MgO-C bricks, an aggregate having a maximum particle diameter of 5 mm (with a large percentage of the aggregate having a diameter of 2.38 mm) is normally used. Wnen refractory raw materials comprising such a coarse aggregate are subjected to moulding pressure, tne aggregate grains come directly into contact with one another and the fine powder portion which fills the spaces between coarse grains of the aggregate is prevented from being compressed, resulting in insufficient compactness. However, in the present invention, a refractory of great compactness is achieved by limiting tne size of the aggregate (if any) to 1.5 mm - 0.3 mm, the diameter of the fine powder portion consequently being limited to at most 0.3 mm. When refractory raw materials comprising this aggregate are compressed at the time of moulding, the fine powder portion between the aggregate grains can be fully compressed, and laminations do not occur. Generally, unburned bricks having a fine powder structure have considerable burning snrinkage and are lacking in serviceability. In the present invention, however, the addition of grapnite holds down this shrinkage. Because the graphite is able to be fully compressed during moulding, the resulting unburned brick has low air permeability, and oxidation loss of the graphite is prevented. The resistance of the graphite to oxidation may be further increased by the addition of a conventionallyused anti-oxidizing agent comprising at least one substance selected from aluminium, silicon, B4C, and Sic. This additive comprises 1 to 6 parts by weight of the unburned refractory per 100 parts by weight of refractory raw materials. Figure 1 shows the results of an experiment measuring the bulk density (used as an index of compactness) of a number of bricks comprising a fine powder. Mixtures containing graphite (having a particle diameter of at most 1 mm) and MgO (having a particle diameter of at most 0.3 mm) in various ratios were prepared and moulded at 1000 kg/cm2 into standardbricks (230 x 114 x 65 mm). As seen from Figure 1, graphite and MgO fine powder used in ratios in accordance with the present invention produced bricks having high compactness. To determine the best proportion of electrofused magnesia clinker to graphite in the fine powder portion of the unburned refractory, specimens were prepared comprising seven different mixtures of graphite and MgO, as shown in Table 1. The blends snown in the table were moulded at 1000 kg/cm2 into standard bricks, using liquid resol resin as a binder, dried at 1500C for 10 hours, and then burned in a reducing atmosphere at 10000C for 3 hours. Figure 2 shows the apparent porosity of these bricks after drying (the .-. line) and after reduction burning (the X-X line). Table 1 (units: parts by weight) EMI7.1 <tb> <SEP> Sample <SEP> No. <tb> <SEP> Raw <SEP> Materials <tb> <SEP> 1 <SEP> 2 <SEP> 3 <SEP> 4 <SEP> 5 <SEP> 6 <SEP> 7 <tb> <SEP> Electro-fused <tb> magnesia <SEP> clinker <SEP> 20 <SEP> 30 <SEP> 40 <SEP> 50 <SEP> 60 <SEP> 70 <SEP> 80 <tb> <SEP> # <SEP> 0.3 <SEP> mm <SEP> dia. <tb> <SEP> Crystalline <SEP> graphite <tb> <SEP> 80 <SEP> 70 <SEP> 60 <SEP> 50 <SEP> 40 <SEP> 30 <SEP> 20 <tb> <SEP> # <SEP> <SEP> 1.0 <SEP> mm <SEP> dia. <tb> <SEP> Liquid <SEP> resol <SEP> resin <SEP> 6 <SEP> 6 <SEP> 6 <SEP> 6 <SEP> 6 <SEP> 6 <SEP> 6 <tb> Specimens No. 1 and 7 had an extremely high apparent porosity, and are therefore unsuitable. It is clear that a fine powder structure of which the weight ratio of graphite to MgO is in the range of approximately 0.4:1 to approximately 2.5:1 (represented by Specimens 2-6) is most appropriate. For the purpose of comparison, tne inventors measured the bulk density of a first, conventional unburned MgO refractory comprising 55% by weight of MgO coarse particles (5.3 - 1.5 mm particle diameter), 20% by weight of MgO fine powder (at most 0.3 mm particle diameter), and 25% by weight of graphite. The refractory as whole nad a bulk density of approximately 2.85 - 2.90. The fine powder portion, however, had a bulk density of approximately 2.20 (a figure obtained by subtracting the bulk density of the MgO coarse particles) indicating a low degree of compactness. In contrast, the bulk density of a second refractory comprising 25% by weignt of MgO (1.5 - 0.3 mm particle diameter), 50% by weight of MgO fine powder (at most 0.3 mm particle diameter), and 25% by weight of graphite (at most 1.0 mm particle diameter) had a high bulk density of 2.61, indicating extremely high packing of the fine powder portion. in addition, after heating in a reducing atmosphere at 10000C for 3 hours, the above-described first (conventional) refractory had an air permeability index of 0.096 x l02cm3.cm/cm2.cm H2O.sec, while tne unburned second refractory had a far lower value of 0.019 x 10 2cm3.cm/cm2.cm H2O.sec. This indicates that the inner structure of the second refractory is extremely minute and homogeneous. It is also clear thatthe-fine powder structure is effective in providing resistance to corrosion. Next, 50 mm x 50 mm x 50 mm cubes were cut from the above-described unburned MgO-C refractories. The cubes were machined, heated in an oxidizing atmosphere in an electric furnace at 15000C for 2 hours, and then cooled, after which they were cut open in order to measure decarburization depth. While the first (conventional) unburned MgO-C refractory had a decarburization depth of 9 mm, the second unburned MgO-C refractory had a decarburization depth of only 3 mm. In addition, when 1 part by weight of B4C and 2 parts by weight. of Al per 100 parts by weight of refractory materials were added to the second refractory as an anti-oxidizing agent to prevent oxidation of the graphite, the decarburization depth was further decreased to 2 mm. Example The raw materials shown in Table 2 were formed into unburned bricks by moulding at 1000 kg/cm2. Moulding was followed by drying at 1500C for 10 hours and reduction burning at 10000C for 3 hours. After drying and burning, the various properties shown in Table 2 were measured. The completed bricks were then used to line the slagline portion of an ASEA-SKF 90-ton ladle, disposed at the 10th and 11th rows of bricks on both the slag line and trunion side. In tne bricKs according to the present invention, the weight ratio of graphite fine powder to magnesia fine powder was 1:1. Table 2 EMI10.1 Raw <SEP> Materials <SEP> Grain <SEP> Size <SEP> (mm) <SEP> Prior <SEP> Art <SEP> Present <SEP> Invention <tb> Electro-fused <SEP> 5 <SEP> - <SEP> 3 <SEP> 15 <SEP> magnesia <SEP> clinker <tb> " <SEP> 3 <SEP> - <SEP> 1 <SEP> 30 <SEP> " <SEP> 1.5 <SEP> - <SEP> 0.3 <SEP> 25 <SEP> 20 <tb> Composition <tb> of <SEP> Refractory <SEP> " <SEP> # <SEP> 0.3 <SEP> 10 <SEP> 40 <tb> (parts <SEP> by <SEP> Crystalline <SEP> graphite <SEP> # <SEP> 1.0 <SEP> 20 <SEP> 40 <tb> weight) <tb> Al <SEP> (commercial <SEP> product) <SEP> Micropulverized <SEP> 3 <SEP> 3 <tb> Powder <tb> B4C <SEP> ( <SEP> " <SEP> ) <SEP> " <SEP> 1 <SEP> 1 <tb> Liquid <SEP> resol <SEP> resin <SEP> - <SEP> 3.5 <SEP> 4 <tb> Water <SEP> absorption <SEP> (%) <SEP> 1.7 <SEP> 2.2 <tb> After <tb> Apparent <SEP> porosity <SEP> (%) <SEP> 5.0 <SEP> 5.6 <tb> drying <tb> at <SEP> Bulk <SEP> density <SEP> (g/cm3) <SEP> 2.84 <SEP> 2.58 <tb> 150 C <tb> Apparent <SEP> specific <SEP> gravity <SEP> (g/cm3) <SEP> 2.99 <SEP> 2.73 <tb> for <SEP> 10 <tb> hours <SEP> Cold <SEP> Crushing <SEP> Strength <SEP> (kg/cm2) <SEP> 291 <SEP> 264 <tb> Characteristics <SEP> Water <SEP> absorption <SEP> (%) <SEP> 2.8 <SEP> 3.5 <tb> After <tb> reduc- <SEP> Apparent <SEP> porosity <SEP> (%) <SEP> 7.9 <SEP> 9.0 <tb> tion <tb> Bulk <SEP> density <SEP> (g/cm3) <SEP> 2.87 <SEP> 2.57 <tb> burning <tb> at <SEP> Apparent <SEP> specific <SEP> gravity <SEP> (g/cm3) <SEP> 3.11 <SEP> 2.82 <tb> 1000 C <tb> Cold <SEP> orushing <SEP> strength <SEP> (kg/cm2) <SEP> 279 <SEP> 267 <tb> for <SEP> 3 <tb> hours <SEP> Air <SEP> permeability <tb> 0.102 <SEP> 0.026 <tb> (x <SEP> 10-2cm3.cm/cm2.cmH2O.second) <tb> After the ladle had been used 22 times using bricks according to the present invention, the dimension of the bricks were measured. The thickness of the bricks according to the present invention decreased by 33 mm from 150 mm to 117 mm. In contrast, conventional MgO-C bricKs which were used in tne same ladle under the same conditions (the content of the conventional bricks is shown in Table 2) had a decrease in thickness of 59 mm from 150 mm to 91 mm, giving clear proof of the increased durability of the MgO-C bricks according to the present invention.

Claims: CLAIMS 1. An unburnt magnesia-carbon refractory material which comprises refractory raw materials comprising at most 30 percent by weight of fine grains of magnesia having a grain diameter of 1.5 to 0.3 mm and at least 7 0 percent by weight of graphite fine powder and magnesia fine powder, the weight ratio of graphite to magnesia fine powder being in the range from 2.5:1 to 0.4:1. 2. An unburned magnesia-carbon refractory material comprising: 100 parts by weignt of refractory raw materials comprising at most 30 parts by weight of fine grains of magnesia having a grain diameter of 1.5 to 0.3 mm and at least 70 parts by weight of graphite fine powder and magnesia fine powder, the weight ratio of graphite to magnesia fine powder being in the range from 2.5:1 to 0.4:1; and 1 to 6 parts by weight of an additive, the additive comprising at least one substance selected from aluminium, silicon, B4C, and SiC. 3. A material as claimed in claim 1 or 2, in whicn the graphite powder has a particle diameter of at most 1 mm. 4. A magnesia-carbon refractory material obtained by moulding and burning a material as claimed in any of claims 1 to 3. After the ladle had been used 22 times using bricks according to the present invention, the dimension of the bricks were measured. The thickness of the bricks according to the present invention decreased by 33 mm from 150 mm to 117 mm. In contrast, conventional MgO-C bricKs which were used in tne same ladle under the same conditions (the content of the conventional bricks is shown in Table 2) had a decrease in thickness of 59 mm from 150 mm to 91 mm, giving clear proof of the increased durability of the MgO-C bricks according to the present invention. CLAIMS 1. An unburnt magnesia-carbon refractory material which comprises refractory raw materials comprising at most 30 percent by weight of fine grains of magnesia having a grain diameter of 1.5 to 0.3 mm and at least 7 0 percent by weight of graphite fine powder and magnesia fine powder, the weight ratio of graphite to magnesia fine powder being in the range from 2.5:1 to 0.4:1. 2. An unburned magnesia-carbon refractory material comprising: 100 parts by weignt of refractory raw materials comprising at most 30 parts by weight of fine grains of magnesia having a grain diameter of 1.5 to 0.3 mm and at least 70 parts by weight of graphite fine powder and magnesia fine powder, the weight ratio of graphite to magnesia fine powder being in the range from 2.5:1 to 0.4:1; and 1 to 6 parts by weight of an additive, the additive comprising at least one substance selected from aluminium, silicon, B4C, and SiC. 3. A material as claimed in claim 1 or 2, in whicn the graphite powder has a particle diameter of at most 1 mm. 4. A magnesia-carbon refractory material obtained by moulding and burning a material as claimed in any of claims 1 to 3.

Inventors: KUROE, MASAMI, MOTOYA, SUNAO, NISHIO, HIDEAKI, OHARA, KENGO, WATANABE, JIRO
Applicants: SHINAGAWA REFRACTORIES CO., LTD., SHINAGAWA ROZAI KABUSHIKI KAISHA
Application year: 1983
Main classification: C04B35
IPC codes: C04B35