Abstract:
A shield comprising a refractory material resistant to pentration by a continuous stream of molten steel and a retaining means to hold the refractory material contiguous to a heat absorption surface.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a protective shield for use on a basic oxygen steelmaking furnace. Such furnaces, known in the art as a BOF, comprise large open ended steelmaking vessels which have thick refractory linings for protecting their outer steel shells from the molten metal and high temperatures contained within the vessels during the refining process. Such BOF vessels are usually mounted within a water-cooled trunnion ring which permits rotation of the vessel about a horizontal axis for charging and tapping operations and also functions as a heat sink transferring heat away from the hot steelmaking vessel walls. 
     Even though the BOF vessel is protected from the high refining temperatures by both its thick refractory lining and the heat sink effect of the water-cooled trunnion ring, there have been instances when the molten steel, being refined within the vessel, has burned through both the refractory lining and outer steel shell of the vessel. When such unexpected failures happen, the molten steel can erupt from the burn through area within the vessel wall and penetrate the water-cooled trunnion ring causing a massive steam explosion and considerable damage to the furnace and surrounding facilities. These occasional, violent explosions, have led to attempts to develop protective shields located at strategic positions along the inside wall of the water-cooled trunnion ring. However, past protective shield designs have failed because when such structures are installed within the narrow confines between the BOF trunnion ring and the steelmaking vessel they interrupt normal transfer of heat from the hot steelmaking vessel to the cooling water within the trunnion ring, radiate heat back toward the BOF vessel, and cause hot spots within the vessel wall resulting in structural damage. 
     SUMMARY OF THE INVENTION 
     It has been found that protective shields, installed between the water-cooled trunnion ring and a steelmaking vessel must posses high heat conductivity properties to insure an adequate transfer of heat from the hot steelmaking vessel to the cooling water within the trunnion ring. It has also been found that in order to facilitate maximum heat transfer, a protective shield must make considerable surface contact with the inside wall of the trunnion ring. In addition, it has been found that a protective shield must be both resistant to penetration by molten steel and relatively light in weight to prevent a large change in the vessel&#39;s center of gravity which would adversely effect shop safety when the vessel is tilted during charging and pouring operations. And finally, a protective shield must be thin enough to fit within the limited space between the water-cooled BOF trunnion ring and the steelmaking vessel and yet be able to withstand damage from falling debris. 
     It is therefore an object of this invention to provide a protective shield which is both heat conductive and resistant to penetration by molten steel. 
     It is a further object of this invention to provide a protective shield having considerable contact with an adjacent trunnion ring surface. 
     It is still a further object of this invention to provide a thin, light weight protective shield which will not adversely effect the center of gravity of the vessel. 
     I have discovered that the foregoing objects can be attained with a protective shield comprising a conductive refractory material resistant to molten steel penetration cast within a container formed by attaching a conductive shell to a heat absorption means. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross-sectional view of a portion of a steelmaking furnace showing a protective shield installed adjacent the inside wall of a water-cooled trunnion ring. 
     FIG. 2 is a cross-sectional view taken along the lines 2--2 of FIG. 1. 
     FIG. 3 is an enlarged portion of the protective shield shown in FIG. 2. 
     FIG. 4 is a cross-sectional view similar to FIG. 1 showing an alternate embodiment of the invention. 
     FIG. 5 is a cross-sectional view taken along the lines 5--5 of FIG. 4. 
     FIG. 6 is a cross-sectional view showing a second alternate embodiment of the invention. 
     FIG. 7 is a cross-sectional view taken along the lines 7--7 of FIG. 6. 
     FIG. 8 is an schematic view of test apparatus used to evaluate various protective shield materials. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1-3 of the drawings, the preferred embodiment of the invention shows one of a plurality of shields which are strategically located along the surface of an inside wall 9 of a water cooled trunnion ring 10. The protective shield 8, shown in the drawings, is located adjacent an area of the steelmaking vessel 11 which is predisposed to molten steel burn through. Each protective shield 8 is contiguous with the inside wall 9 of a water-cooled trunnion ring 10 which supports the steelmaking vessel 11 and the steelmaking vessel includes an outer steel shell 12 and in inner refractory lining 13. The protective shield 8 comprises a pair of spaced apart curved plates 17 and 19 connected by a base plate 20. The first curved plate 17 is substantially parallel to the inside wall 9 of the water-cooled trunnion ring 10 and includes a pair of extending angle shaped side plates 18 attached to the inside wall 9 forming a box like container 14 having a hollow chamber 22, an open end 15 and a closed opposite end 16 at base plate 20. The second, shorter, curved plate 19, of box like container 14, is attached to the lower portion of the water-cooled trunnion ring 10 and reinforcing wire or mesh 23 extends from an upper fastener plate 24 downward between the first curved plate 17 and inside wall 9 to a lower fastener plate 25 forming an anchoring means for a castable refractory material 26 which is poured into the hollow chamber 22. 
     The material used for the construction of the box like container 14 must be a highly conductive material such as steel in order to properly transfer heat to the trunnion ring cooling water, and, as shown in the following test data, the castable refractory material 26, within the box like container 14, must be silicon carbide or another material having similar heat conductive and penetration resistant properties. 
     Referring to FIGS. 4 and 5 of the drawings, an alternate embodiment 27, of the protective shield invention, is shown comprising a box like container 28, for receiving a castable refractory material 38, having a pair of spaced apart curved plates 29 and 30 connected by a base plate 31 and side plates 32 and 33 to form a box like container 34 having an open end 35 and an closed opposite end 36. 
     A plurality of spaced apart stiffener plates 37 extend between the first curved plate 29 and second curved plate 30 and stiffner plates 37 provide an anchoring means for the castable refractory material 38 which is poured into the box like container 34. As shown in FIG. 5, plates 37 are arranged symmetrically in parallel, staggered rows which provide open gaps between the plates to permit free flow of the castable material 38 when it is poured into the container 34. However, it should be understood, that plates 37 can be arranged randomly within container 34 as long as open gaps are provided between plates 37 to permit the castable refractory material 38 to flow freely when poured into container 38. 
     Referring to FIGS. 6 and 7 of the drawings, a second alternate embodiment of the invention is shown to comprising a precast protective shield 39 conforming to the contour of the surface of the inside trunnion ring wall 9. The precast protective shield is made from silicon carbide and is bonded and/or mechanically fastened to the inside wall surface by any suitable means well known in the art. 
     Having discovered that a protective shield installed adjacent the inside wall of a water-cooled trunnion ring on a tiltable steelmaking furnace must be both resistant to penetration by molten steel and highly conductive to enable heat to be transferred from the hot steelmaking vessel into the cooling water flowing through the trunnion ring, tests were conducted on various heat shield materials using the molten steel penetration test apparatus as shown in FIG. 8 of the drawings. Referring to FIG. 8, the test apparatus 1 comprises a support stand 2, a 1,200 pound capacity induction furnace 3, a tundish 4 for containing a reservoir of molten steel for discharge onto the shield test specimen 5, and a nozzle 6 for controlling the stream 7 of molten steel being discharged onto the test specimen. The test specimen 5 is inclined at about a 45° angle to reduce and control splashing of hot metal at the test area, decrease slag build up on the test specimen and allow the test specimen to be exposed to a continuing fresh stream of molten steel throughout the penetration test. Each of the various materials tested was subjected to a continuous stream of molten steel until the specimen was either completely burned through or the entire 1,200 pound heat of molten test metal was depleted. 
     Prior to testing, it was discovered that in order for a protective shield material to be successful, it must, (a) be able to withstand penetration from molten steel for a period of 2 to 3 minutes and, (b) the presence of the protective shield material between the steelmaking vessel and the water cooled trunnion ring cannot cause the outside shell temperature of the steelmaking vessel to increase by more than about 100° F. where the steelmaking vessel has an 8&#34; thick refractory brick lining. As shown in the following [Table-A], the silicon-carbide test specimen was found to be the material most resistant to molten steel penetration among the various materials tested. 
     
                                           TABLE-A__________________________________________________________________________                         BURNTEST               TAP  TUNDISH                         THROUGHNO. SHIELD MATERIAL              TEMP.                   TEMP. SECONDS__________________________________________________________________________1   Base Test      3026° F.                   2950° F.                         25    16&#34; × 16&#34; × 1&#34; Steel Plate2   Plasma Fusion Weld Overlay              3155° F.                   3100° F.                         14.84    On 1&#34; Steel Plate    0.010&#34; Tungsten Carbide    Base, 0.015&#34; Zirconium    Silicate Top3   Steel Hexmesh w/Alusa              3150° F.                   3100° F.                         21.62    Castable, 70.8% Al, 23.3% Si4   TZM Plate, 99.25 Mo              3140° F.                   3100° F.                         675   Cast Iron      3137° F.                   3100° F.                         9.256   Ceramic Fiber Sandwich              3153° F.                   3100° F.                         8.137   Graphite Block 3169° F.                   3100° F.                         31.18   Silicon Carbide Block              3163° F.                   3100° F.                          49 No Burn                         Through9   Cast Iron Grating w/              3120° F.                   3100° F.                         29    Ramming Mix Refractory,    85% Alumina10  Silicon Carbide Containing              3120° F.                   NOT   82    Ramming Mix         GIVEN11  100% Silicon Carbide              3127° F.                   NOT   140 No Burn    Castable            GIVEN Through12  PP-22 Molybdenum Plate              3130° F.                   NOT   89                   GIVEN__________________________________________________________________________ 
    
     As shown in the following [Table-B], conductivity calculations were made on some of the materials exposed to the above molten steel penetration test. Knowing that effective heat transfer would be reduced by less than perfect surface contact along the inside wall of the trunnion ring, the conductivity calculations were preformed using a criteria which simulated gaps between the shield and trunnion ring wall. The first calculations were based on a shield design having a 0.012&#34; air gap between the shield and the trunnion ring wall, and the second calculations were based on a 0.25&#34; air gap between the two surfaces. 
     
                       TABLE B______________________________________(BASED ON A BOF VESSEL HAVING AN 8&#34; THICKREFRACTORY LINING)SHIELD                  VESSELMATERIAL       GAP      TEMP.  TEMP.NO.  (1&#34; Thick Specimens)               INCHES   °F.                               INCREASE______________________________________1    NONE           NA       1022.00                               NA2    Plasma Fusion Weld               0.012    1058.64                                36.64Overlay On 1&#34;Steel Plate    0.25     1175.71                               153.710.010&#34; Tungsten Car-bide Base, 0.015&#34;Zirconium SilicateTop5    Cast Iron      0.012    1052.55                                30.55               0.25     1165.89                               143.896    Ceramic Fiber  0.012    1049.96                                27.96Sandwich       0.25     1161.45                               139.457    Graphite Block 0.012    1050.26                                28.26               0.25     1162.37                               140.3711   Silicon Carbide               0.012    1052.91                                30.91Castable       0.25     1166.50                               144.5 ##STR1##12   PP-22 Molybdenum               0.012    1050.97                                28.97Plate          0.25     1161.63                               139.33______________________________________ 
    
     Based on the calculation results shown in [Table-B], in addition to being highly resistant to molten steel penetration, silicon carbide also possesses good heat conductive properties making it a suitable material for use as a protective shield adjacent a water cooled trunnion ring in a BOF steelmaking vessel.