STUDY MATERIAL

ON

MONOLITHICS









































S.M. No. : SNTI / MOC /REF/ SM- 14
Rev. No. : 01
Effective Date : 21/02/2007


(An ISO 9001 Organisation)
..: : :.+-- +- :.+








With the change in steel making scenario there was enormous development in
Refractories materials to meet the demand of the plant. The application of monothics
trends have increased day by day in the steel plant to avoid the hot metal leakage and
smooth operations

This study material has been prepared for the persons involved in Refractories units to
develop the knowledge & skill in Retractories.














Prepared by Approved by

U.K.Mishra K.N.Choubey
Refractories Group Head MOC
SNTI SNTI






MONOLITHICS

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CONTENTS:

Sl. No. Topic Page #
1. Monolithic 2
2. Castables 3
3. Conventional Castables 4
4. Wearing Profile 5
5. Application Of Castables 6
6.
Shape & size of the anchor

7
7. Application Technique, Ramming 8
8.
Cost Of Monolithic / Castable

9-10
9. Specification of monolithics 11-12

















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MONOLITHICS




Monolithics
Mono single
Lithics structure
Monolithics are joint free (single joint) materials which are applied for patch- work,
spraying, gunniting, ramming, castables, etc. in place of the shaped refractory structure.

Thus monolithics are joint less structure
Advantages of Monolithics
Saves the handling, storage, & delivery time in compare to the odd shaped refractories
Saves the manufacturing cost of odd shaped bricks
Saves the handling, storage, & delivery time in compare to the odd shaped refractories
Design and application technique is more flexible and
Joint free lining (greatest advantage).
Saves the downtime of furnace, vessel,
Saves the maintenance & manpower cost.
Better spalling resistance.
Volume stability.
Better customer approach with satisfied results.


Classification of monolithics












Spraying
mass
Plastic
mass
Gunniting
mass
Castables
mass
Ramming
mass
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Castables







Low Alumina
( 40-50 % ) Intermediate
Alumina( up to 70 % )


Constituents of Monolithics

It mainly consists of three categories of materials:

Aggregate

Binder

Additives

Aggregates are selected on the basis of operation parameters i.e. temperature,
batch/continuous operation practices, chemical attack, surrounding atmospheric
condition











Voids

Aggregates
Binders to
fill up the
voids
High Alumina
( >70 % )
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Castables

At the initial stage refractories castables consists of crushed fireclay, grog with refractories
cement. Normally calcined clay are used as aggregates for the places of low temperature
condition. Selection of aggregates and their binders depend upon the quality of castable.

Conventional castables

It consists of 15-20 % cement and requires 8-10 % water for proper mixing and suitable
application at site. It is suitable for the place where there is no hot-metal and slag in contact.
It develops he strength after proper mixing with water due to Calcium aluminate binder which
works as a hydraulically setting material.

Low cement / ultra low cement castables

The development of refractory materials went through an enormous evolution during the last
decade. These developments are affected by three principle factors :-

New processes in steel making such as secondary metallurgy, continuous casting etc.
End users demand for consistent decrease of the specific refractory consumption, at a
prolonged service life and repairs at programmed intervals
Stringent applied energy saving at all applications.

The changes in technologies and market demands have resulted in a new groups of refractory
materials which are applied at more severe conditions ever before; such as higher temperatures,
longer residence times of molten metal and steel consequently longer reaction time, stronger
agitations, and higher reliability expectations. Hence new generations of refractories possess
more variable properties and functions are characterized by

The development of functional refractories
Uses of new bond systems such as non-oxides, mono- aluminum Phosphates, resins
etc.
Impregnation techniques and new sophisticated production methods
Vibration casting on either cold or hot residual linings
The use of fine powder technology at the production of
New installation & repair techniques as endless repairs.


Basic advantages of new generation castables:-
Improved strength.
Better compactness.
Low lime content.
Better thermal shock resistance.







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Properties of L.C. & U.L.C. castable based on fused alumina aggregates

Properties L.C.C. U.L.C.C.
Refr. aggregates Fused
alumina
Fused alumina
Al2O3 90 % 91 %
CaO 1.1 % 0.3 %
CCS after 110gC 110 80
CCS after 1000gC 120 150






Wearing profile
Conventional castable Low - cement castable
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Design & construction















Application of castables
Design &
Construction
Application
technique
Selection
Selection of castables
Selection of castables is decided on the basis of service condition i.e. Operating
temperature, mechanical thrust, thermal shock, handling activities and atmospheric
conditions.
Design & Construction

Position of
anchor
Anchor gap
Castable
thickness
Steel Ceramic
Mild
Steel
Stainless
Steel

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Shape & size of the anchor






Position of the anchor:- ( Preferably 90 to each other )



1.13 Application Technique:-
Shuttering :- Perfect shuttering plays an important role for better compact in castable lining
where vibrator is being provided . Hence steel frame sheet shutter with proper lagging is
provided and tight fitting is done for smooth and dense quality castable linine.

Mixing :- Mixing is to done by mixing machine . Selection of maxing machines depends upon
the application are and quantity castable . For less amount of castable hand mixing may be
preferred, but for big amount of castable job electric/diesel connected mixing machine must be
performed .Optimum amount of water as per specified to be used and mixing to be done
property, so as to cast the castable in poper way to get the better result.

Casting:- Castable massed to be poured with the use of proper vibrate so as to avoid the
avoids and the have the dense castable lining. Once the casting is started with proper mixing it
is to be continued till the job is over. In no case there should be any gap in casting . Proper care
is required inmixing and casting both to have the better life of the castable lining




Anchor gap:- ( 2 / 3 of the thickness of custable or 30-40
mm less than thickness of castable. )
Selection of anchors:-
Up to 600 C ---------- Mild steel anchor is preferable
Above 600 C ------- Stainless steel anchor is preferable.
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Curing :- Curing is not required for all castable mass. Castable which generate she at and
sets very needs proper curing.

Pre-heating :-In the castable lining where percentage of open pores are less, moisture gets
logged in close pores.
During heating access vapor pressure and cracks generates & some times explosion occurs . To
avoid all these reactions very slow pre- eating is required and to be following strictly.

Example:- TUNDISH CASTABLE.

A) Material: LC90/LC70
B) Mixing: Mixing machine is required.
C) Water : 4 to 6% as per preferred by supplier.
D) Casting: Vibrator must be used.
E) Curing : 16 to 24 hours by air pressure.
F) Heating: 72 hours preferred. Slow heating to be done and followed strictly.

1.14 Ramming materials: At the initial stage in open hearth process bottom, side wall,
back wall and front wall area of the furnace where rammed with basic ramming materials .
With the introduction of LD vessel process of steel making and to obtain the higher production
rate, maintenance of tap-hole area( Re-sleeving of tap hole block and lip plate area was a
problem. At the basic stage this maintenance job was done manually by using the basic
ramming mass. At the present stage maintenance of this area is done with high pressure
gunning technique during the resleeving of tap hole block and lip plate area, which has reduce
the down time of the vessel, saving of the man power as well as reducing the re-sleeving period
during vessel operation

1.15 Spraying:- This technique was adopted in the maintenance of coke ovens batter.
Spraying is done on the jamb brick joints between flash plate and jamb bricks. Spraying
materials are mixed with 30 to 35% water slurry made and put in a container which is
transported through hose by air pressure 3-4 kg/cm2. Adhesion of slurry is achieved by
suitable binders and plasticizer of the materials.

1.16 Gunniting:- This was introduced in open hearth process at the initial stage in TATA
STEEL . This technique was adopted in Coke ovens battery to fill the wider joints in between
the jamb bricks and silica bricks laming, which is not filled up successfully by spraying
technique. Alive gun id used for this purpose which is being operated by 440 volt power
connection with 4 to 5 kg/cm2 air pressure to transport the gunning mass by hose pipe. 8 to 10
% water is required. Materials and water get mixed at the nozzle tip, air pressure, re-bound loss
of the material etc. Special care is required wjhile doing the gunniting job.









MONOLITHICS

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1.17 Cost of Monolithic :- As the manufacturing, storage, handling and transportation
cost of Refractories materials is increasing day by day, we must keep control on wastage of the
materials during the application practices in plant . The cost of refractories materials must be
taken into the account and any losses incurred during applications must be discussed with the
concerned persons so that wastage of materials to be controlled so as to survive and give better
service to the operation.



The figure indicates the approximate cost of the monolithics in our plant :::



A Castable
Super fire creat
Ril cast
Why theat K
Why theat A
Orcast 90 S
LC 70
Approx cost / bag ( 25 kg )
125
125
250
400
400
350
B. Gunniting Material
Guntapite XL
Gopelit
Plistic
Tata ram

1500
1500
2500
1000
C. Spraying material
Brokit
Ref pack Ep 8234
Monocon

150
200
400















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TOTAL REFRACTORIES FOR TUDISH RELINING Cost of CC1 Tundish
:-


S.No Item Qty Unit Cost Total
1.
15.5mm Zirconia Nozzle 4 650 2600
2.
16.0 Zirconia Nozzle 2 600 1200
3.
Turbostop 1 9946 9946
4.
Magnesite Lining ( Tundex ) 1.95T 14184 27658.8
5.
Castable for Nozzle Fixing 025T 15000 3750
6.
* High alumina Suriker Pad .25Nos 4000 1000

Total Cost 45154

Considering striker pad is changed after 4 campaigns

Cost of CC2 Tundish:-

S.No Item Qty Regd Unit Cost Total
1. 16mm Zirconia Nozzle 5 600 3000
2. 15mm Zirconia 1 600 600
3. Tubostop 1 7510 7510
4. Magnesite Board 1 set 13950 13950
5. Castable for Nozzle
fixing
.25T 15000 3750
6 * High alumina Striker
Pad
.25 Nos 4000 1000
7. Refractory Sand 1.St 680 1020
8. Magnesite Pad 1 1492 1492
Total Cost 32300






MONOLITHICS

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C onsiderinh striker pad is changed after 4 campaigns.

HEATING SCHEDULE LC- TO CASTABLE
AMBIENT TO 120C- @ 30C / HR
HOLDAT 120C- 1HR / INCH THICKNESS OF CASTABLE 120C TO 550C-@40C /HR
HOLD AT 550C- 1HR/ INCH THICKNESS 550C TO USE TEMP- 50/ HR


CASTABLES, RAMMING MASSES USED IN L.D. SHOP #1
( TYP:CAL SPECIFICATION )

Chemical analyis % Physical properties H.A
CAST
ABLE
Brand
name
A12o
3Min
Fe2o3
Max
Ca
O
Max
Si
02
Max
C.C.S
Kg/cm2
P.L.C
%
P.C.E
0C
Water
Require
ment
%
Recom
service
temp
OC
60%A
L
Whytheat-
k
( A.C.C )
60 1 4.3 350 1.5 1717 1416 1700
Tata
CastAH-
60
( T.R.L )
60 1 4.7 30.81 517 1.5 910 1600
90%
AL
Whytheat-
A
( A.C.C )
90 0.8 4.7 550 1 1820 79 1750
Orcast-
90S
( O.A.L )
90 0.8 550 1 1800 89 1750
TataCast-
AH 90
( T.R.L )
90 1.5 4.78 2.23 643 1 89 1700
















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Chemical analyis % Physical properties LC
CASTABLE
Brand
name
A12o3
Min
Fe2o3
Max
Ca
O
Max
Si
02
Max
C.C.S
Kg/cm2
P.L.C
%
P.C.E
0C
Water
Require
ment
%
Recom
service
temp
OC
LC
70 %
Accmon
70
( A.C.C )
70 1.5 1.8 1070 1 1804 47--54 1600
Tatacast
LC- 70
( T.R.L)
70 1.5 2 1200 0.5 50--55 1550
Lc90
%
Accman-90
( A.C.C)
90 1 1.7 1200 0.8 1820 42--50 1700
Intoval T-
85
SP-10 (
Repa)
( A.C.C.)
89 0.4 3 1100 1.1 65--80 1750
Taqta
cast
LC-90
(T.R.L)
90 1.5 2 1200 1.5 45.55 1650
Duraflo-865
AM
VESUVIUS
85.6 0.4 1.1 96 1100 0.6 60--65 180











Chemical analyis % Physical properties RAMMING
MASS
Brand
name
A12o3
Min
Fe2o3
Max
Ca
O
Max
MgO
Max
C.C.S
Kg/cm2
P.L.C
%
P.C.E
0C
Wate
r
Requi
re
ment
%
Recom
service
temp
OC
95 %
Mgo
Tataram-
M 96
( T.R.L )
96 2.5 1.41 0.12 323 0.65 40.50 1750
MONOLITHICS

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Question:-

1) What are the advantages of Monolithics ?

2) Explain the steps involve in castable application?

SAFETY:-

Use all PPE with 55 concept
Special attention on over head crane, handling of mixing machine and castable.
































T;AA) YCU T;AA) YCU T;AA) YCU T;AA) YCU
MONOLITHICS

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