PRODUCTION AND EQUIPMENT
DEVELOPMENT OF WASTE-FREE TECHNOLOGY
FOR PERICLASE-CARBON REFRACTORY PRODUCTION
A. G. Valuev,
Yu. L. Klesov,
Yu. A. Borisova,
E. V. Murashko,
and N. A. Bosyakova
Translated from Novye Ogneupory, No. 1, pp. 17 – 19, January 2011.
Original article submitted June 24, 2010.
Results are provided for a study of product nonconformity during manufacture of periclase-carbon ladle
refractories and refractory scrap as a potential raw material source. Optimum charge compositions are given
with addition of secondary refractories and a production scheme for the manufacture of periclase-carbon re
fractory objects taking account of existing technology in the OOO Ogneupor magnesium-dolomite refractory
workshop. Pilot batches of objects are produced for industrial tests, confirming a lack of deterioration in oper
Keywords: waste-free technology, periclase-carbon refractories, secondary refractories, product nonconfor-
mity, refractory scrap, steel-pouring ladle.
In order to reduce the expenditure on manufacturing
periclase-carbon refractories, combined use of raw material
and more rational application of raw material resources un-
der conditions of the magnesia-dolomite refractory work-
shop (MDRW) of OOO Ogneupor work has been carried out
during which a study has been made of the quality of poten
tial of secondary refractory raw material resources.
Repeated use of waste formed during production and use
of refractories, is an important reserve of the economy. In
view of the fact that the proportion of raw material in the cost
of periclase-carbon refractories reaches 70%, as a result of
using refractory waste produced during their manufacture it
may possible to obtain a significant economic effect. An ad
ditional stimulus for developing waste-free technology for
manufacturing periclase-carbon refractories under MDRW
conditions are the following factors: a lack of a natural raw
material base; exhaustion of developed magnesite deposits
within Russia; a sharp increase in cost of magnesia raw ma
terial on the world market; worsening of the ecological situa
tion due to forming dumps of refractory production waste .
Sources of secondary periclase raw material for OOO
Ogneupor are unsuitable MDRW products and refractory
scrap forming after replacing the lining of OOO MMK heat
ing units. Since metallurgy lays down high specifications for
purity of periclase powder, and evaluation of the suitability
of technogenic raw material, it is necessary to lay down spec-
ifications comparable with the requirements for primary raw
In the MDRW the main form of product is objects for lin-
ing steel-pouring ladles of the oxygen converter workshop
(OCW) and electric steel smelting. Increased specifications
are laid down for these objects with respect to external form
and size. Objects not conforming to standard documentation,
and placed on separate pallets, are identified as unsuitable
product. With respect to chemical composition an unsuitable
product is a valuable raw material, which is indicated by data
presented in Table 1.
Refractory scrap after replacing the lining of OAO MMK
heating units enters a section of OOO Ogneupor where is
sorted from rubbish, metal, liberated from slag residues, and
used subsequently for preparing unmolded refractories, i.e.
powders and mixes. In studying the chemical composition of
sorted scrap it has been established that it is also a valuable
raw material, but due to contamination with metal and slag
before use it requires very careful treatment, and with man
ual removal of not only the slag zone, but also the impreg
nated zone. It may be seen from Table 2 that the chemical
composition of scrap after additional manual treatment is
more stable and approaches the chemical composition of se
ries ladle periclase-carbon objects.
After studying the chemical composition of secondary
refractories laboratory studies have been carried out for de
Refractories and Industrial Ceramics Vol. 52, No. 1, May, 2011
1083-4877/11/05201-0009 © 2011 Springer Science+Business Media, Inc.
OAO Magnitogorsk Metallurgical Combine, Magnitogorsk, Russia.