Operators often see cracks and damage in ladle shrouds, long nozzles, and refractory parts. This happens because of a few main reasons:
The quality of materials is important. Good raw materials and careful making of parts help stop cracks. Having the right amount of porosity makes parts stronger and better at handling shock.
Good design and alignment lower stress and stop leaks. Smooth shapes and tight fits help keep ladle shrouds and nozzles strong. Checking them often also helps.
Common scenarios for thermal shock cracking:
Ladle preheating with fast temperature rise.
Steel pouring with sudden molten metal exposure.
Quenching or cooling steps in steelmaking.
High-temperature furnace linings in steel, cement, glass, and ceramics.
Thermal shock can cause early failure with small and large cracks. Operators often see pieces breaking off, falling apart, and cracks along the ladle shroud and nozzle. Checking often and tracking temperature changes helps teams stop damage before it gets worse. Using materials that handle thermal shock better and heating slowly can help lower the chance of cracks. Slide gate plate
These types of mechanical stress often cause cracks or bending:
Pulling forces from blocked thermal expansion.
Pushing forces that make the part bend for good.
The steel shell grows wider and faces thermal shock.
The table below shows how these forces can hurt the structure:
Slag temperature and thickness decide how fast slag moves in.
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Key Takeaways
The quality of materials is important. Good raw materials and careful making of parts help stop cracks. Having the right amount of porosity makes parts stronger and better at handling shock.
Good design and alignment lower stress and stop leaks. Smooth shapes and tight fits help keep ladle shrouds and nozzles strong. Checking them often also helps.
1. Thermal Shock
Temperature Changes
When the temperature changes quickly, it puts stress inside refractory materials. During ladle preheating, the working layer gets hot on one side and stays cool on the other. This big difference in temperature causes strong pulling stress at the top of the working layer. Sometimes, this stress can get as high as 39.06 MPa. Damage often starts at the top and near the sidewall burner nozzles. If the ladle heats up too fast, alumina-magnesia castables get stiffer but weaker. The material turns more brittle and can break more easily. When steel isCrack Formation
Thermal shock cracks show up a lot in high-temperature furnace linings and steel ladles. These parts go through fast heating and cooling many times. When the temperature changes too quickly, the refractory grows or shrinks more than it can handle. If the material is brittle, especially under 1100°C, cracks form easily. Big parts, uneven heating, and outside forces make cracking worse. Changes in the material’s structure can also raise the risk.isostatical pressed refractoryCommon scenarios for thermal shock cracking:
Ladle preheating with fast temperature rise.
Steel pouring with sudden molten metal exposure.
Quenching or cooling steps in steelmaking.
High-temperature furnace linings in steel, cement, glass, and ceramics.
Thermal shock can cause early failure with small and large cracks. Operators often see pieces breaking off, falling apart, and cracks along the ladle shroud and nozzle. Checking often and tracking temperature changes helps teams stop damage before it gets worse. Using materials that handle thermal shock better and heating slowly can help lower the chance of cracks. Slide gate plate
Operational Impact
Mechanical stress keeps happening when the equipment is used. Taking off coatings or moving the ladle shroud can hurt the refractory. Forces between the upper nozzle and ladle bottom can cause stress. These forces come from heat changes, steel shell growth, and heavy loads.These types of mechanical stress often cause cracks or bending:
Pulling forces from blocked thermal expansion.
Pushing forces that make the part bend for good.
The steel shell grows wider and faces thermal shock.
The table below shows how these forces can hurt the structure:
3. Slag Erosion
Slag Penetration
Hot slag attacks the outside of ladle shrouds and nozzles. The molten slag moves over the refractory and brings heat and chemicals. These things break down the material. Slag penetration happens when liquid slag gets into small pores and cracks. This changes the inside of the refractory and makes a weak layer. That weak layer can break apart easily.Slag temperature and thickness decide how fast slag moves in.
4. Material Quality
Manufacturing Defects
Material quality is very important for how long ladle shrouds and nozzles last. Cracks often begin because of mistakes made during manufacturing. These mistakes can happen from using bad raw materials or errors in making the parts. Operators notice more cracks when impurities like K₂O and Na₂O are in the material. These impurities make stress inside the part and make sintering worse. If the part shrinks unevenly while drying or firing, cracks can form. This happens when the mix or particle size is not controlled well.Tundish Refractory Material
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