Converter Refractory Patching Machine for Steelmaking: A Key Equipment Ensuring Efficient and Stable Operation of Converters
In the modern iron and steel smelting process, the converter is the core equipment for steelmaking. The integrity of the refractory lining of the converter directly determines the service life of the converter, steelmaking efficiency, and molten steel quality. However, under the harsh working conditions of high temperature, strong impact, and chemical corrosion, the refractory lining of the converter is prone to loss problems such as erosion and spalling. To solve this problem, the converter refractory patching machine has emerged. As a key equipment for converter maintenance, it can realize accurate and rapid repair of the damaged parts of the lining, providing a solid guarantee for the continuous and stable production of the converter.
I. Core Functions of the Equipment: Targeted Solutions to the Pain Points of Converter Refractory Loss
The core functions of the converter refractory patching machine revolve around "repairing the lining, extending the converter campaign life, and reducing costs", which can be specifically divided into three categories:
1. Accurate Positioning and Patching to Reduce Local Excessive Loss
The loss degree of different areas of the converter lining varies significantly. For example, parts such as the tap hole, molten pool slag line, and furnace top cap are in direct contact with high-temperature molten steel and furnace slag, so their loss rate is much higher than that of other areas. The traditional manual patching method relies on experience judgment, making it difficult to accurately control the patching position and dosage, which easily leads to "inadequate patching" or "excessive accumulation". In contrast, the refractory patching machine can real-time identify the area and depth of the damaged part of the lining. Combined with the preset patching parameters, it can accurately deliver refractory materials (such as magnesia-carbon brick particles, unshaped refractory castables, etc.) to the damaged parts, realizing "patching wherever there is loss". While avoiding the waste of refractory materials, it ensures that the thickness of the repaired lining is uniform, effectively resisting the impact of subsequent smelting.
2. Efficient and Continuous Patching to Adapt to the Fast-Paced Production of Converters
Modern converter steelmaking mostly adopts the efficient "blowing to the end" mode. The smelting cycle of a single furnace is usually only 30-40 minutes, leaving very little time for lining patching. If the patching efficiency is low, it is easy to cause the converter to stop production and wait, affecting the rhythm of the entire production line. The refractory patching machine can quickly complete the patching operation during the "interval period" after the converter taps and before the next furnace is charged. No manual intervention is required throughout the process, and the patching time for a single furnace can be controlled within 5 minutes, perfectly adapting to the fast-paced production needs of the converter.
3. Stable Patching Quality to Reduce the Quality Risk of Molten Steel
During manual patching, the laying density and flatness of refractory materials are greatly affected by the operator's skills. If there are problems such as looseness and voids in the patched layer, it is easy to cause "furnace penetration" accidents during subsequent smelting, or lead to refractory particles mixing into the molten steel, affecting the purity of the molten steel. The refractory patching machine can ensure that the refractory materials are evenly accumulated and tightly bonded on the surface of the lining. The bulk density of the patched layer can reach more than 2.8g/cm³ (basically the same as the density of the original lining), which greatly reduces the risk of "furnace penetration" and the probability of molten steel contamination, providing an important guarantee for the stable quality of molten steel.
II. Technical Characteristics of the Equipment: "High-Strength Design" Adapting to the Harsh Working Conditions of Converters
High-temperature resistant materials to resist harsh environments
Intelligent control system to realize "unmanned" operation
Flexible movement mechanism to adapt to different converter specifications
Safety protection design to ensure operation safety
IV. Advantages and Development Trends of the Equipment: Assisting the Iron and Steel Industry in Cost Reduction, Efficiency Improvement, and Green Upgrade
Compared with the traditional manual patching, the advantages of the converter refractory patching machine are mainly reflected in three aspects:
Cost Reduction: On the one hand, accurate patching reduces the waste of refractory materials, reducing the refractory consumption per ton of steel by 15%-20%; on the other hand, it extends the converter campaign life (the average campaign life can be increased from 1,500 furnaces to more than 2,500 furnaces), reduces the number of converter overhauls, and can save enterprises millions of yuan in overhaul costs every year.
Efficiency Improvement: There is no need for manual entry into the converter for operation, which avoids the safety risks and efficiency bottlenecks of manual operation, increases the converter operation rate by 3%-5%, and can produce tens of thousands of tons more steel every year.
Quality Improvement: Stable patching quality reduces the risk of molten steel contamination, increases the qualification rate of molten steel by 0.5%-1%, and provides a guarantee for enterprises to produce high-end steel grades.
Conclusion
As the "guardian" of converter production, the converter refractory patching machine not only solves the problems of low efficiency, poor quality, and high risk of traditional manual patching, but also provides important support for iron and steel enterprises to reduce costs, improve efficiency, and upgrade quality. With the continuous advancement of technology, the future converter refractory patching machine will be more intelligent, efficient, and green. It will become one of the key equipment for the iron and steel industry to realize intelligent manufacturing and green development, injecting new impetus into promoting the high-quality development of China's iron and steel industry.
Zhangjiakou Xuanhua Innovake Drilling Machine Co., Ltd. is a joint-stock enterprise specializing in the research and development, production, and sales of metallurgical machinery and equipment for ironmaking and steelmaking.
