ISBN-13: 9781119790730 / Angielski / Twarda / 2023 / 400 str.
ISBN-13: 9781119790730 / Angielski / Twarda / 2023 / 400 str.
Preface xvAcknowledgment xviiAbout Author xix1 Heat and Mass Transfer 11.1 Introduction 11.2 Energy Conservation 21.3 Conduction 61.3.1 Basic Concept and Properties 61.3.2 One-Dimensional Steady-state Conduction 91.3.3 Two-Dimensional Steady-state Conduction 141.4 Convection 161.4.1 Boundary Layers 181.4.2 Laminar and Turbulent Flow 211.4.3 Free and Forced Convection 231.4.4 Flow in Confined Region 241.5 Radiation 291.5.1 Basic Concepts 291.5.2 Emission from Real Surfaces 291.5.3 Absorption, Reflection, and Transmission by Real Surfaces 311.5.4 Exchange Radiation 321.6 Mass Transfer 341.6.1 Convection Mass Transfer 351.6.2 Multiphase Mass Transfer 351.6.3 Analogy--Heat, Mass, and Momentum Transfer 371.7 Heat Transfer in Refractory Lining 391.7.1 Tunnel Kiln 391.7.2 Ladle Lining 40References 432 Equilibrium and Nonequilibrium Phases 452.1 Introduction 452.2 Basics of Phase Diagram 452.2.1 Gibb's Phase Rule 452.2.2 Binary Phase Diagram and Crystallization 472.2.3 Ternary Phase Diagram and Crystallization 552.2.4 Alkemade Lines 602.3 One-Component Phase Diagrams 622.3.1 Water 622.3.2 Quartz 632.4 Two-Component Phase Diagrams 642.4.1 Fe-C 642.4.2 Two Oxides Phase Diagrams 662.5 Three-Component Phase Diagrams 722.5.1 Three Oxides Phase Diagrams 722.5.2 FeO-SiO2 -C 782.6 Nucleation and Crystal Growth 792.6.1 Homogenous and Heterogeneous Nucleation 792.6.2 Crystal Growth Process 822.7 Nonequilibrium Phases 83References 853 Packing, Stress, and Defects in Compaction 873.1 Introduction 873.2 Refractory Grading and Packing 883.2.1 Binary and Ternary System 893.2.2 Particle Morphology and Mechanical Response 913.2.3 Nanoscale Particles and Mechanical Response 933.2.4 Binder and Mixing on Packing 953.3 Stress-Strain during Compaction 983.4 Agglomeration and Compaction 993.5 Uniaxial Pressing 1023.6 Cold Isostatic Pressing 1043.7 Defects in Shaped Refractories 107References 1114 Degree of Ceramic Bonding 1134.1 Introduction 1134.2 Importance of Heating Compartment 1144.2.1 Loading and Heating 1144.2.2 Heat Distribution 1164.2.3 Temperature Conformity 1164.3 Initial Stage Sintering 1184.3.1 Sintering Mechanisms of Two-particle Model 1184.3.2 Atomic Diffusion 1204.3.3 Sintering Kinetics 1214.3.4 Sintering Variables 1254.3.5 Limitations of Initial Stage of Sintering 1264.4 Intermediate and Final Stage Sintering 1264.4.1 Intermediate Stage Model 1264.4.2 Final Stage Model 1284.4.3 Influence of Entrapped Gases 1294.5 Microstructure Alteration 1304.5.1 Recrystallization and Grain Growth 1304.5.2 Grain Growth: Normal and Abnormal 1314.5.3 Pores and Secondary Crystallization 1354.6 Sintering with Low Melting Constituents 1374.7 Bonding Below 1000°C 1384.7.1 Organic Binder 1394.7.2 Inorganic Binder 1404.7.3 Carbonaceous Binder 141References 1425 Thermal and Mechanical Behavior 1435.1 Introduction 1435.2 Mechanical Properties 1445.2.1 Elastic Modulus 1445.2.2 Hardness 1465.2.3 Fracture Toughness 1475.2.4 Strength 1495.2.5 Fatigue 1545.3 Cracking 1545.3.1 Theory of Brittle Fracture 1565.3.2 Physics of Fracture 1585.3.3 Spontaneous Microcracking 1595.4 Thermal Properties 1605.4.1 Stress Anisotropy and Magnitude 1605.4.2 Thermal Conductivity 1625.4.3 Thermal Expansion 1645.4.4 Thermal Shock 1665.4.5 Thermal Stress Distribution 1665.5 Thermomechanical Response 1685.5.1 Refractoriness under Load 1695.5.2 Creep in Compression (CIC) 1715.5.3 Hot Modulus of Rupture 1745.6 Wear 1765.6.1 System-dependent Phenomena 1765.6.2 Adhesive 1785.6.3 Abrasive 1795.6.4 Erosive 1805.6.5 Oxidative 181References 1826 High Temperature Refractory Corrosion 1836.1 Introduction 1836.2 Thermodynamic Perceptions 1846.3 Effect of Temperature and Water Vapor 1876.4 Slag-Refractory Interactions 1916.4.1 Diffusion in Solids 1936.4.2 Oxidation 1956.4.3 Infiltration 1986.4.4 Dissolution 2016.4.5 Crystallite Alteration 2046.4.6 Endell, Fehling, and Kley Model 2056.5 Phenomenological Approach and Slag Design 2066.5.1 Refractory Solubility 2096.5.2 Slag Composition and Volume Optimization 210References 2157 Operation and Refractories for Primary Steel 2177.1 Introduction 2177.2 Operational Features in BOF 2217.2.1 Charging and Blowing 2227.2.2 Mode of Blowing 2237.2.3 Physicochemical Change in BOF 2277.2.4 Tapping 2307.2.5 Slag Formation 2317.3 Operational Features in EAF 2327.4 Refractory Designing and Lining 2367.4.1 Steel Chemistry and Slag Composition 2367.4.2 Thermal and Mechanical Stress 2397.4.3 Refractory Lining and Corrosive Wear 2437.4.4 Refractory Composition and Properties 2497.5 Refractory Maintenance Practice 2527.6 Philosophy to Consider Raw Materials 2547.7 Microstructure-dependent Properties of Refractories 2577.7.1 Microstructure Deterioration Inhibition to Improve Slag Corrosion Resistance 2577.7.2 Slag Coating to Protect the Working Surface 2587.7.3 Microstructure Reinforcement by Evaporation-Condensation of Pitch 2597.7.4 Whisker Insertion to Reinforce Microstructure 2597.7.5 Fracture Toughness Enhancement and Crack Propagation Inhibition 259References 2608 Operation and Refractories for Secondary Steelmaking 2638.1 Introduction 2638.2 Steel Diversity, Nomenclature, and Use 2678.3 Vessels for Different Grades of Steel 2708.4 Operational Features of Vessels 2728.4.1 Ladle Furnace (LF) 2738.4.2 Argon Oxygen Decarburization (AOD) 2788.4.3 Vacuum Ladle Degassing Process 2798.4.4 Stirring and Refining Process in Degassing 2858.4.5 Composition Adjustment by Sealed Ar Bubbling with Oxygen Blowing (CAS-OB) 2888.4.6 RH Snorkel 2898.5 Designing Aspects of Refractories 2918.6 Refractories for Working Lining 3038.6.1 Magnesia-Carbon Refractories 3038.6.2 Alumina-Magnesia-Carbon Refractories 3068.6.3 Dolo-Carbon Refractories 3108.6.4 Magnesia-chrome (MgO-Cr2O3) 3138.6.5 Spinel Bricks 314References 3159 Precast and Purging System 3199.1 Introduction 3199.2 Composition Design of Castables 3209.2.1 Choice of Raw Materials and Properties 3229.2.2 Choice of Binders 3299.2.3 Aggregates Grading 3339.2.4 On-site Castable Casting 3359.3 Precast-Shape Design and Manufacturing 3379.4 Precast Shapes and Casting 3379.5 Purging Plugs 3419.5.1 Plug Design and Refractory 3419.5.2 Gas Purging 3449.5.3 Installation and Maintenance 3469.5.4 Clogging and Corrosion 348References 35010 Refractories for Flow Control 35310.1 Introduction 35310.2 First-Second-Third Generation Slide Gate 35510.3 New Generation Ladle Slide Gate System 35910.4 Ladle Slide Gate Plate 36010.4.1 Critical Design Parameters 36210.4.2 Selection of Slide Plate and Fixing 36610.4.3 Materials and Fabrication of SGP 36910.4.4 Mode of Failures 37410.4.5 FEA for Stress and Cracking 37810.5 Tundish Slide Gate and Plate 38010.5.1 Modern Slide Gate and Refractory Assembly 38110.5.2 Materials and Fabrication 38110.5.3 Cracking and Corrosion Phenomena 38310.6 Short Nozzles for Ladle and Tundish 38910.7 Nozzle Diameter and Gate Opening in Flow 390References 39311 Refractories for Continuous Casting 39511.1 Introduction 39511.2 Importance of Long Nozzles in Steel Transfer 39711.2.1 Furnace to Ladle Transfer 39711.2.2 Ladle to Tundish Transfer 39811.2.3 Tundish to Mold Transfer 39911.3 Tundish Lining 40011.3.1 Lining and Failure 40011.3.2 Lining Improvement and Maintenance 40711.4 Ladle Shroud (LS) 40911.4.1 Design and Geometry 40911.4.2 Failures, Materials and Processing 41811.4.3 Operational Practice 42411.4.4 Flow Pattern 42511.5 Mono Block Stopper 42711.5.1 Preheating Schedule 42711.5.2 Installation 42811.5.3 Failures 42911.5.4 Glazing 43011.6 Submerged-Entry Nozzle 43011.6.1 Installation and Failures 43111.6.2 SEN Fixing for Thin Slab Caster 43211.6.3 SES Installation and Failures 43211.6.4 Corrosion and Clogging 435References 44412 Premature Refractory Life by Other Parameters 44512.1 Introduction 44512.2 Refractory Manufacturing Defects 44612.2.1 Consistence Raw Material 44712.2.2 Processing Parameters 44912.2.3 Pressing and Firing 45112.3 Packing and Transport 45312.3.1 Packaging and Packing Material 45312.3.2 Vibration-free Packaging 45412.3.3 Loading, Transporting, and Unloading 45512.4 Procurement and Lining Failures 45612.4.1 Total Cost of Ownership Concept 45712.4.2 Preliminary Features of Lining 45812.4.3 Workmanship 46212.5 Preventive Maintenance in Operation 46312.5.1 Professional Service 46412.5.2 Slag Composition, Temperature, and Viscosity 46512.5.3 Monitor and Maintenance of Lining 47212.6 Consistent Supply and Time Management 47512.6.1 Cycle Concept 47612.6.2 Pull/Push Concept 476References 477Index 479
Debasish Sarkar, PhD, is currently Professor of the Department of Ceramic Engineering, National Institute of Technology, Rourkela, India. Prof. Sarkar has been working in the subject area of nanostructured ceramics, ceramic processing, iron and steel making refractories. process optimization and finite element analysis of structural ceramics for 26 years. He has published numerous peer-review articles, national and international patents, prototype developments, and books on the projected topics.
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