Final Scientific Report Steel Foundry Refractory Lining Optimization
The overall objective of the program was to optimize refractory materials and foundry processing used in casting steel. This objective was to be met by completing the following: (1) Surveying the steel foundries both through paper/electronic surveys sent to North American steel foundries as well as plant visits to participants. Information concerning refractory selection and performance as well as refractory and steelmaking practices provides a baseline for future comparison and to identify opportunities for substantial improvement in energy efficiency. (2) Conducting post-mortem analysis of materials from existing refractory/steelmaking practices to determine wear/failure mechanisms. (3) Identify areas for research on developing refractories for use in steel foundry furnaces, adjusting steelmaking practices to improve efficiency and modifying slag practices to improve refractory performance. The overall objective of the steel foundry refractory lining optimization program was to review established refractory and steelmaking practices to identify opportunities for improvements that would yield substantial energy savings for steel foundries. Energy savings were expected to arise from improved efficiency of the electric arc furnaces and from reductions in the post-casting welding and grinding that are normally required. Ancillary energy savings related to a reduction in the amount of refractories currently produced to meet the needs of the steel foundry industry, and a shift from pre-fired materials (shaped refractories) to monolithic refractories that are heat treated ''in situ'' were anticipated. A review of the complete program results indicates that techniques for achieving the overall goal were demonstrated. The main difference between the predicted and the actual achievements relates to the areas from which actual energy savings could be realized. Although reductions in furnace tap temperature would result in a reduction in the power required for melting, such reductions are realized through changes within the ladle transfer portion of the process, through modified ladle pre-heat and refractory insulation. Reductions in clean room energy usage proved very difficult to track, and some questions as to just how much impact refractory related inclusions have on the degree of welding and grinding required for completion of a casting, remain. Post-mortem analysis of casting defects did identify refractory derived inclusions but the greatest concentration of inclusions related to steel reoxidation issue. In almost every instance, the suggested refractory/process modifications were proven to be both technically and economically feasible. The difficulty in implementation of the proposed changes relates to the ''up front'' expense and the learning curve associated with any process modification. These two issues were compounded by production slow downs that are too common in the current market. Such slow downs normally result in less energy efficient processing coupled with reductions in capital or ''up front'' expenditures. A return to historical norms should allow foundries to implement the suggested modifications and then evaluate the overall benefit.
- Research Organization:
- University of Missouri-Rolla, Rolla, MO (US)
- Sponsoring Organization:
- USDOE Office of Industrial Technologies (OIT) (EE-20) (US)
- DOE Contract Number:
- FC07-99ID13717
- OSTI ID:
- 805266
- Report Number(s):
- DOE/ID13717-1; TRN: US200305%%996
- Resource Relation:
- Other Information: PBD: 2 Dec 2002
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
36 MATERIALS SCIENCE
37 INORGANIC
ORGANIC
PHYSICAL AND ANALYTICAL CHEMISTRY
42 ENGINEERING
CASTING
CLEAN ROOMS
EFFICIENCY
ELECTRIC ARCS
ENERGY EFFICIENCY
FOUNDRIES
FURNACES
IMPLEMENTATION
LINERS
MODIFICATIONS
OPTIMIZATION
REFRACTORIES
STEELS
STEEL
REFRACTORY
FURNACE