Well brick of vessel for molten metal

Abstract: The present invention relates to a well brick or a tuyere brick for receiving a nozzle brick or a porous brick for injecting gas which is disposed on the bottom of a vessel for molten metal such as a ladle, various types of ladles for refining, a tundish, or the like, whereby the brick is formed into a shape of a cylinder or a frustum of cone by using an isostatic press.

Description: Field of the Invention The present invention relates to a well brick or a tuyere brick for receiving a nozzle brick or a porous brick for injecting gas which is disposed on the bottom of a vessel for molten metal such as a ladle, various types of ladles for refining, a tundish, or the like. Description of the Prior Art As shown in FIG. 3 and FIG. 4, for example, a conventional well brick for receiving a nozzle brick of a vessel for molten metal or a porous brick for injecting gas has a hole 14 or 16 of the shape of a frustum of cone, in the center of a rectangular brick 12, for inserting a nozzle brick for discharging molten metal or a porous brick for injecting an inert gas for stirring the molten metal in a ladle. The well brick like this has been integrally formed by a hydraulic press or a friction press because it is big in size. And the brick has, for example, a rectangular contour of 200 - 500 mm and a height of 150 - 500 mm. A burnt brick of zirconium or alumina or a precast product of Al 2 O 3 -C or the like is used as the material of above described well brick for molten metal. But since this well brick is large in size, if it is a burnt product made by a press forming technique, from a viewpoint of physical property, it has high porosity, low bulk specific gravity and low strength and thus it is greatly fused by the molten metal to have a short life. Moreover, since a precast product of Al 2 O 3 -C is a molded product using alumina cement, it has problems that it has high porosity and thus is impregnated with slag and is apt to be spalled. Accordingly, since any of them has a short life as a well brick and thus a shorter life than a side wall brick or a bottom brick of a vessel for molten metal, thereby shortening a life of lining refractory material such as a side wall brick or a bottom brick of a vessel for molten metal and increasing a unit consumption of the lining refractory material and manufacturing cost of steel. Therefore it is strongly requested to make a life of the well brick longer. To be more specific, when the nozzle brick or the porous brick for injecting gas is fixed into the above described well brick, they are inserted into the above described hole of the shape of a frustum of cone and fixed with refractory mortar or the like. The nozzle brick or the porous brick for injecting gas has usually a life of one charge and thus is frequently exchanged. Therefore it is necessary to remove sticking material such as skull on the surface fixing the nozzle brick or the porous brick for injecting gas (hereinafter referred to as "a nozzle brick or the like") into the well brick; the well brick is therefore exposed to severe environmental conditions such as fusion damage caused by oxygen cleaning, mechanical shock by an inserting or removing operation or wear caused by molten metal flow or the like. Moreover, the nozzle brick or the like needs to have erosion resistance to slag in the vessel for molten metal. Further, since the conventional well brick is large in size, it has also problems that it has a long manufacturing term and is frequently deformed, strained or cracked when it is burned. Furthermore, since the well brick is large in size and has a complex shape, it has a low packing degree of material and its quality varies widely. In particular, since a precast of Al 2 O 3 - C is a molded product of alumina cement and contains carbon material, it has many problems such as variance in the packing degree and low strength and thus it has been desired to solve these problems. Thus in Examined Utility Model Publication No. 61-45964 a well brick is divided into an upper well brick and a lower well brick to disperse thermal stress during its use it and thus to prevent breaking. But it is inconvenient for laying brick to make the well brick in two parts. The US-PS 5,198,126 discloses a new casting nozzle for continuos casting comprising, for example, alumina-graphite material formed by isostatic press an then sintered. A conventional well block is formed in rectangular parallelopiped block because surrounding refractory blocks are formed in rectangular parallelopiped block. The well block should be used for many casting, meanwhile a upper part of a nozzle or a long nozzle is changed for a new one when a nozzle is used for one or a few casting. Summary of the Invention It is an object of the present invention to provide a tuyere brick which is little impregnated with slag and has little skull formation or the like stuck thereon and has a high degree of packing of raw material as the tuyere brick and has low porosity and, in addition, has a long life with strength, thereby improving the manufacturing yield. Inventors discovered, through intense study for solving above described problems, the fact that it is possible to increase the degree of packing of the brick, to increase the density thereof and thus to eliminate drawbacks such as laminating or cracking by applying an isostatic pressing method, instead of a conventional forming method, to form the tuyere brick containing carbon material, thereby accomplishing the following invention. The embodiment of the invention is a tuyere brick which is disposed on a bottom of a vessel for molten metal and comprises a product formed into a shape of a cylinder or a frustum of cone by using an isostatic press (CIP). It is possible to increase the degree of packing of the tuyere brick uniformly in three-dimensional direction and thus to increase a density thereof by forming the tuyere brick into a shape of a cylinder or a frustum of cone by using an isostatic press (CIP) which can press the tuyere brick in three-dimensional direction and moreover by forming the tuyere brick into a shape of a cylinder or a frustum of cone it is possible to make thermal stress produced during using it occur uniformly in the tuyere brick and thus it is possible to improve a life of the tuyere brick. The embodiment of the invention is a tuyere brick of a vessel for molten metal which is made by mixing a raw material comprising aggregate of Al 2 O 3 as a main element, 0.3 to 10.0 weight % carbon material, 0.2 to 0.5 weight % metal or metallic powder of at least one element selected from the group consisting of Al, Mg, Ca and Si, and 0.1 to 30 weight % Mg, and thermosetting resin as a binding material and by forming into the tuyere brick. Since the aggregate of Al 2 O 3 has high thermal shock resistance, it is most suitable for a main element of the tuyere brick. The raw material comprising 0.3 to 10.0 weight % carbon material, 0.2 to 0.5 weight % metal or metallic powder of at least one element selected from the group consisting of Al, Mg, Ca, and Si, and 0.1 to 30 weight % Mg, and the thermosetting resin as a binding material are added to the aggregate and mixed together, and then they are formed into the tuyere by using an isostatic press (CIP). The tuyere brick formed in this way has a particularly long life. The embodiment of the invention is a tuyere brick of a vessel for molten metal, wherein the above described thermosetting resin is made by blending at least one resin selected from the group consisting of phenolic resin, urea resin, epoxy resin, and urethane resin. It is considerably easy and inexpensive to get the above described phenolic resin, urea resin, epoxy resin, and urethane resin and they are convenient to manufacturing the tuyere brick. Moreover, after the tuyere brick is used, these resins will harden refractory material as a raw material to improve the strength thereof. The embodiment of the invention is a tuyere brick of a vessel for molten metal, wherein the above described vessel for molten metal is any one of a ladle for molten metal, a ladle for refining, or a tundish. Any one of a ladle for molten metal, a ladle for refining, or a tundish uses a nozzle brick or a porous brick for injecting gas and since the nozzle brick or the like according to the present invention has a long life, it is effectively used for these bricks. Brief Description of the Drawings Fig. 1 shows an embodiment of a well brick according to the present invention. Fig. 2 shows another embodiment of a well brick according to the present invention. Fig. 3 shows a shape of a conventional well brick. Fig. 4 shows a shape of a conventional well brick. Detailed Description of the Invention Since a hydraulic pressing or a friction pressing, which is a kind of conventional pressing method, is one axial pressing method, it has a low degree of packing the raw material. Therefore, in the present invention a well brick disposed on a bottom of a vessel for molten metal is formed into a shape of a cylinder or a frustum of cone by using an isostatic press (CIP) which can compress it in the three-dimensional direction. Since the well brick is integrally formed by use of the isostatic press (CIP), it becomes uniform and dense in the degree of packing in the three-dimensional direction, thereby having remarkably improved strength. Moreover, it is possible to increase a degree of packing the well brick uniformly in three-dimensional direction and thus to increase of density thereof by forming the well brick into a shape of a cylinder or a frustum of cone. Further, by forming the well brick into a shape of a cylinder or a frustum of cone it is possible to make thermal stress produced during using it occur uniformly in the well brick and thus it is possible to reduced occurrence of cracking during its use. Since the aggregate of Al 2 O 3 has high thermal shock resistance, it is most suitable for a main element. To be more specific, sintered alumina of about 98 weight % Al 2 O 3 , fused alumina of about 99 weight % Al2O3, bauxite of about 90.8 weight % Al 2 O 3 or the like can be used. And it is desirable that a grain size of it is about 1 to 5 mm. Carbon material is blended to improve the resistance of the well brick to being impregnated with slag. Natural graphite, artificial graphite, pulverized pitch, amorphous carbon, carbon coke or the like is used as carbon material. If carbon material is less than 0.5 weight %, an effect of the carbon material, or the resistance of the well brick to being impregnated with slag, is not sufficient and thus spalling resistance becomes also worse. On the other hand, if carbon material is more than 10 weight %, a degree of packing the raw material is decreased and the strength is also decreased and thus for example, wear resistance to molten metal or slag is also decreased and therefore it is desirable that carbon material is from 0.5 to 10 weight %. When graphite is used as carbon material, it is desirable that the grain size of it is about 0.043 to 0.2 mm. When metallic powder is added, it reacts with Al 2 O 3 , MgO or the like in the matrix and has great effect on preventing carbon material from oxidizing and improving the strength. It is desirable that the metallic powder is the powder of a metal or an alloy of at least one element selected from the group consisting of Al, Mg, Ca, and Si. It is because these metallic powder reacts with Al 2 O 3 , MgO or the like in the matrix to become oxides and thus accelerates binding the raw material to improve the strength thereof. If the metallic powder is blended in less than 0.3 weight %, its effect can not be generated and if the metallic powder is blended in more than 0.5 weight %, wear is accelerated by molten metal flow because the metal is softened and fused. Accordingly, the metallic powder is added in form 0.3 to 5.0 weight %. It is desirable that the grain size of the metallic powder is about 0.043 to 0.2 mm. Since MgO improves erosion resistance of the raw material to slag and gives proper remaining expansion, it is suitable to add MgO in from 0.1 to 30 weight %. It is desirable that the grain size of MgO is about 0.150 to 3 mm. Since the well brick according to the present invention is used as a non- burnt brick, thermosetting resin is blended as a binding material. The thermosetting resin is made by blending at least one resin selected from the group consisting of phenolic resin, urea resin, epoxy resin, and urethane resin. It is considerably easy and inexpensive to get the above described phenolic resin, urea resin, epoxy resin, and urethane resin on the market and they are convenient to manufacturing the well brick. Moreover, if the well brick is used for a ladle, these resins will harden refractory material of the raw material to improve the strength thereof. Examples Referring now to the examples, the present invention is described. Metallic Al of 1.0 weight % and phenolic resin of 3.0 weight % were added to a raw material having composition of elements shown in Table 1 and they were mixed and then were formed into a well brick shown in FIG.1, which is a receiving brick for a porous brick. This well brick has an outside diameter (D1) of 320 mm, a height (H 1) of 210 mm, a upper diameter of an inner hole (D1 (u)) of 143 mm, a lower diameter of an inner hole (D1 (d)) of 187 mm. This well brick was formed by using an isostatic press at a pressure of 1 ton/ cm 2 . A well brick for a ladle of molten steel as shown in FIG. 2 was made as anther example. This well brick has an outside diameter (D2) of 365 mm, a height (H2) of 300 mm, a upper diameter of an inner hole (D2 (u))of 159 mm, a lower diameter of an inner hole (D2 (d)) of 220 mm. This well brick has the same conditions in other points as the above described example. As a comparative example, a well brick of a conventional rectangular shape of an outside diameter (L3) of 420 mm and a height of 387 mm was formed by using a friction press of 500 ton and then a hardening processing (250 °C x 10 hours) was applied to it to make a well brick. Table 1 shows chemical elements and physical properties of the products according to the present invention No.1 to No. 3 and those of comparative products No. 4 to No. 6. A wear test was performed with a rotating drum method. This test was performed as follows: a plurality of samples with trapezoidal section (the upper side is 50 mm, the base is 90 mm, the height is 60 mm, the leg is 115 mm) were made of the well brick according to the present invention and the well brick of the comparative product and then these samples were stuck to the inner wall of a plurality of drums and then fused slag (whose component comprised 45 weight % CaO, 30 weight % SiO 2 , 10 weight % Al 2 O 3 and 15 weight % FeO) was poured into the drums and then the drums were rotated with their axes horizontal and thereafter wear was measured. In this test, the degree of wear was measured with the wear of the product No. 1 according to the present invention as a wear index of 100. Moreover, a slag fusion damage index was measured as follows: a plurality of samples were made of the above described product according to the present invention and the comparative product and then these samples were stuck to the inner wall of a small induction furnace and then fused slag (whose elements were the same as the above described fused slag) was poured into the drum and thereafter fusion damage was measured. In this case, the degree of fusion damage was also measured with the fusion damage of the invented product No. 1 according to the present invention as a slag fusion damage index of 100. Moreover, as for the number of occurrence of cracking, the samples after the above decribed rotating drum testing were cut and the length of the crack in the cut surface was measured and then the number of occurrence of cracking is displayed with the length of 10 mm as one unit. As clearly shown in Table 1, in physical properties, the cylidrical well brick according to the present invention made by an isostatic press has lower porosity and higher bulk specific gravity than the conventional well brick and it has greatly improved wear index and slag fusion damage index. As clearly shown in Table 1, the cylidrical well brick according to the present invention is better in the number of occurrence of cracking, wear index and slag fusion damage index than the conventional well brick. And the above described well brick was actually used in the ladles of 50 ton and 300 ton and number of use (number of heat) was counted. The result is shown in Table 2. The well brick according to the present invention was less impregnated with slag and had less skull or the like, no breakage and no crack and thus had good spalling resistance, thereby having a long life two times the life of the conventional well brick. As above described, since the well brick according to the present invention is formed into a shape of a cylinder or a frustum of cone by an isostatic press and includes aggregate of Al 2 O 3 as a main element, the life of the well brick is more than two times that of the conventional well brick even if it is put into contact with molten metal and is heated and cooled many times, and therefore can improve the life of many kinds of ladles, thereby producing a remarkable improvement. And it is needless to say that the above described brick is used as not only a well brick but also other kind of brick which is heated and cooled many times. While the present invention has been described in conjunction with a preferred embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. Quality Index Invented Product Comparative Product No.1 No.2 No.3 No.4 No.5 No.6 Al 2 O 3 (wt%) 85.0 80.0 72.0 85.0 80.0 72.0 MgO (wt%) 2.0 5.0 15.0 2.0 5.0 15.0 C (wt%) 1.5 3.5 7.5 1.5 3.5 7.5 Porosity (vol%) 5.0 5.3 5.6 11.5 12.3 14.6 Spec.density gr/cm 3 3.10 3.07 3.06 2.85 2.81 2.80 Compres. strength (Mpa) 105 98 96 45 42 40 Number of occurrence of Cracking 0 0 0 0 0 0 Wear Index 100 103 104 135 147 168 Slag Fusion Damage lindex 100 91 86 151 163 179 Result of Practical Test Unit: Number of Heat Number of Practical Life Invented Product No.1 Conventional Product No.2 50 ton Ladle 22 10 300 ton Lade 50 30

Claims: A well brick to be disposed on a bottom of a vessel for a molten metal, wherein said brick is manufactured by mixing a raw material comprising 0.3 to 10.0 weight % carbon material, 0.1 to 30 weight % MgO an aggregate of Al 2 O 3 as a main element, and a thermosetting resin as a binding material, and by forming said raw material into a shape of a cylinder or a frustum of cone by using an isostatic press. A well brick of a vessel for molten metal as claimed in Claim 1, wherein said raw material further comprises 0.2 to 0.5 weight % metal or metallic powder of at least one element selected from the group consisting of Al, Mg, Ca and Si. A well brick of a vessel or molten metal as claimed in Claim 1 or 2, wherein said thermosetting resin is a resin or a mix of resins selected from the group consisting of phenolic resin, urea resin, epoxy resin, and urethane resin. A well brick of a vessel for molten metal as claimed in Claim 1 to 3, wherein said vessel is a ladle for refining a molten metal or a tundish vessel for continuous casting of a molten metal.

Inventors: EGASHIRA HIROAKI, MIZUNO HIDEAKI, EGASHIRA, HIROAKI, MIZUNO, HIDEAKI
Applicants: TOKYO YOGYO KK, TOKYO YOGYO KABUSHIKI KAISHA
Application year: 1996
Main classification: C04B35
IPC codes: C04B35, C21C7, B22D41, B22D11