11:00 am
Tailor-made Polycarboxylate Ethers to Improve Properties of Castable Mix Designs
Dr. Joachim Riedmiller | BASF Construction Additives | Germany
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Authors:
Dr. Joachim Riedmiller | BASF Construction Additives | Germany
Dr. Alexander Ganss | BASF Construction Additives | Germany
Since about 30 years polycarboxylate ether (PCE) are widely known as a family of tailor-made dispersants for castables containing calcium aluminate cement, reactive alumina, microsilica and aggregates improving their water reduction, wetting, and setting. By using these types of dispersants, the castables benefit of improved properties such as reduced porosity, prolonged lifetime, increased density, and strength combined with a significantly improved workability.
Compared to the electrostatic dispersants such as sodium tripolyphosphate or polyacrylic acid polycarboxylate ether (PCE) show a superior dispersing power due to the electrosteric dispersing mechanism. The PCE molecules adsorb onto the cement grains by their anionic backbones. In addition to the short-range electrostatic interaction between the now negatively charged cement grains the steric repulsion between the PCE sidechains is essential for the long-range interaction. Furthermore, the PCE-based chemistry enables a huge structural variety providing dispersants for each specific application in the field of refractory castables by a systematic variation of suitable monomers, molecular weight, sidechain length and charge density.
Therefore, not all PCEs structures are suitable for refectory applications. We will show how specific PCEs in combination with adequate raw materials interact and can be used to formulate custom tailored castables according to specific requirements.
PCEs are highly valuable, essential ingredients to develop and manufacture new, enhanced refractory materials.
11:20 am
Innovative approaches for energy-intensive production processes of shaped refractory products for the steel industry
Daniel Cölle | EKW GmbH | Germany
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Authors:
Daniel Cölle | EKW GmbH | Germany
Michael Dombrow | EKW GmbH | Germany
Lutz Reißberg | EKW GmbH | Germany
Bastian Vesenberg | EKW GmbH | Germany
Peter Schwalb | Hagenburger Feuerfeste Produkte GmbH | Germany
An overview is provided of consistent use of resource-efficient raw
materials for the production of functional components for the
secondary steel metallurgy, e.g. ingot casting, pouring nozzles.
In recent years, the incorporation of regionally available raw
materials in particular into existing production processes has
proven to be promising, both from a technological and an economic
point of view. In this context, the product-specific carbon footprint
is of particular importance, which is also discussed in association
with its complexity in calculative considerations.
11:40 am
Digitalization to realize an automatic and continuous refractory maintenance system SCANTROL™ 4.0 for the EAF
Rolf Lamm | Minteq International GmbH - Ferrotron Division | Germany
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Author:
Rolf Lamm | Minteq International GmbH - Ferrotron Division | Germany
Continuous changes in the economic environment and the increasing number of EAF plants accompanied by competitive pressure require steel producers to introduce innovative measures to reduce costs, CO2 emissions and improve safety. The paper introduces the latest development in digitization to realize an automatic and continuous refractory maintenance system for the electric arc furnace (EAF), tailored of the requirements of modern steel production at an American steelplant. The automatic system has eliminated the disadvantages and inherent in intermittent refractory maintenance and follows the “No Person on the floor”- Safety-Philosophy. The functionality of the SCANTROL™ 4.0 system (laserscanner driven measurement of refractory thickness, visual representation of scanned results and intelligent material application) has significant enhanced productivity, working conditions and decision-making capabilities of steel operators. The 5th generation Laserscanner technology with more than 10 million measuring points per Scan in a furnace enables wear to be determined with a very high degree of accuracy. With the help of the measurement data, a program calculates exactly the critical areas that need to be repaired. Furthermore, quality and required quantity of the repair gunning material is proposed. The information thus obtained is used to automatically control a gunning robot for repair of the refractory lining. This machine applies the repair compounds exactly where they are needed in the furnace. The overall effect at the steelplant has included: Reduction in total refractory consumption, increased furnace availability by reducing “Power Off” delays, improved operational safety, integration of the determined data into “Industry 4.0” environment.