1. Corrosion phenomenon: Corrosion phenomenon is an important problem faced by refractory materials. When its working temperature exceeds its refractoriness, corrosion will inevitably occur. This corrosion phenomenon often occurs in high-temperature areas such as the furnace wall near the arc area and the furnace bottom at the end of the electrode.
In order to gain a deeper understanding of this phenomenon, we conducted detailed data analysis of furnace bottom temperature measurement patches and thermocouples. The results show that the temperature at the bottom of the furnace bottom electrode reaches a peak, becoming the area with the highest temperature in the entire furnace bottom. At the same time, we also found that if the working end of the electrode is too long, the furnace bottom temperature will rise significantly, thereby exacerbating the risk of corrosion.
This phenomenon poses a serious challenge to our refractory materials, because excessive temperature will directly affect the fire resistance and service life of the material. Therefore, during the design and operation process, we must fully consider the relationship between the electrode length and the furnace bottom temperature to ensure that the refractory material can work normally within its refractory range, thereby avoiding the occurrence of corrosion and ensuring the submerged arc furnace stable operation.
2. Chemical erosion: Chemical erosion refers to a series of complex chemical reactions that occur between refractory materials and furnace materials such as slag, metal melt, dust, exhaust gas, etc. These reactions include various types such as gas-solid reaction, liquid-solid reaction, liquid-liquid reaction and gas-liquid reaction, which together constitute the chemical challenges faced by refractory materials in the furnace environment.
When the working temperature of a refractory material is close to or exceeds its refractory degree, the chemical erosion of metals and other substances will be significantly enhanced. This is because in high-temperature environments, the activity of substances increases, and the rate and intensity of chemical reactions will increase accordingly. At this time, substances such as metal melt are more likely to react with refractory materials, causing changes in their structure and properties, thereby shortening their service life.
In order to meet this challenge, we need to have a deep understanding of the mechanisms and influencing factors of various chemical attacks in order to make more reasonable decisions in terms of material selection and furnace environment control. At the same time, optimizing the composition and structural design of refractory materials to improve their resistance to chemical attack is also the key to ensuring a stable environment in the furnace and extending the service life of refractory materials.
3. Mechanical action: The impact of mechanical action on refractory materials cannot be ignored. In the working layer, when the temperature of the refractory material is higher than its load softening temperature, the mechanical strength of the material will drop significantly and it will become extremely susceptible to external forces. At this time, the mechanical force of metal, slag and other substances is like a heavy blow, constantly exerted on the refractory material, causing it to gradually deform, crack or even break. This mechanical loss can seriously affect the service life of the refractory material and the normal operation of the furnace.
Therefore, we need to pay close attention to the working temperature of refractory materials to ensure that it does not exceed the load softening temperature, thereby reducing losses caused by mechanical action. At the same time, choosing refractory materials with high strength and high wear resistance is also an effective way to reduce mechanical losses. Through these measures, we can better protect the refractory materials, ensure the stable operation of the furnace and extend its service life.
4. Peeling and cracking: Peeling and cracking are serious problems that are prone to occur in refractory materials under certain conditions. When refractory materials are subjected to rapid temperature changes or uneven thermal loads, significant thermal stress will occur within them. If this thermal stress exceeds the structural strength limit of the material, it will cause local damage to the material, manifested as peeling or cracking.
Especially when the furnace is restarted after being shut down for a long time, due to the huge temperature difference between the inside and outside of the furnace, the refractory material is prone to expansion and cracking during rapid heating. In addition, in specific parts such as the taphole chute, the peeling and cracking of refractory materials are also particularly obvious due to long-term thermal shock and mechanical erosion by the metal melt flow.
In order to avoid such problems, we need to carefully select and design refractory materials to ensure they have good thermal shock resistance and structural stability. At the same time, reasonable operation and maintenance are equally important to reduce the thermal stress on the refractory materials, extend their service life, and ensure the safe and stable operation of the furnace.
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