Vesuvius USA Corporation

Roger L Maddalena

Dominique Janssen

Jose Antonio Simoes

Beda Mohanty

Daniel T Schaner

Sunilkumar C Pillai

Babu Patel

A refractory composition for forming a working lining in a metallurgical vessel contains a coarse-grain refractory particle fraction and a fine-grain refractory particle fraction, or at least 0.25% additive calcium oxide, or at least 0.25% titanium dioxide. The coarse-grain refractory particles can include alumina particles, magnesia particles, magnesium aluminate spinel particles, zirconia particles, or doloma particles, or a combination of any of these particles. The fine-grain refractory particles can be comprised of any low-magnesia refractory oxide. The refractory composition can be applied to a metallurgical vessel by spraying, gunning, shotcreting, vibrating, casting, troweling, or positioning preformed refractory shapes, or a combination of any of these techniques. When contacted by molten metal, the molten metal penetrates into the refractory material, wetting the coarse-grain refractory particles, and forming a refractory-metal composite barrier layer that decreases or blocks oxygen transport through the refractory lining.

Refractory compositions and in situ anti-oxidation barrier layers

A lining structure for a refractory vessel contains a first layer containing refractory material; a second layer, in communication with and parallel to the first layer, containing a metal layer or component; and a third layer, in communication with and parallel to the second layer, containing refractory material. The metal component in the second layer contains filled transverse passages, between the surface of the second layer in contact with the first layer and the surface of the second layer in contact with the third layer, producing support structures to maintain the structural integrity of the refractory vessel in use.

Metallurgical vessel lining with enclosed metal layer

A lining for a metallurgical vessel is configured to have an engineered porosity. The lining contains a plurality of regions, each extending in a primary plane of the lining, each region having a differing value of total pore or perforation area as measured in a primary plane of the lining. The lining may be used to form part or all of the working surface of the floors or walls of the vessel. In casting use the lining produces an oxidation buffering layer at an interphase of metal melt extending from the interface between metal melt and the walls and floor of the metallurgical vessel, such that when in casting use, the metal flow rate in said oxidation buffering layer is substantially nil, and the concentration of endogenous inclusions, in particular oxides, in said oxidation buffering layer is substantially higher than in the bulk of the metal melt.

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Pittsburgh, PA, United States of America

Roger L Maddalena