Soft slag stopper

As a key functional component in steel smelting, slag blocking plugs can achieve cost reduction and efficiency improvement for steel plants from multiple dimensions through technological upgrades and accurate applications, becoming a true "secret weapon". The following is an analysis of its core mechanism of action and specific benefits: Slag blocking plug 1、 How can slag blocking plugs directly reduce costs? Reduce steel loss Intercepting oxide slag: Accurately blocking the slag liquid from mixing into the ladle during the steelmaking process of the converter/electric furnace, avoiding the forced return or downgrading of the molten steel after contamination, and directly reducing the scrap rate. Yield improvement: In traditional processes, about 0.3% to 0.8% of molten steel is lost due to slag entrapment, and the slag stopper can reduce it by more than 50% (based on an annual production of 2 million tons of steel plants, an additional 3000 to 8000 tons of molten steel are recovered each year, worth tens of millions of yuan). Extend the lifespan of refractory materials Excellent slag blocking plugs have strong corrosion resistance, reducing slag erosion damage to the ladle lining and continuous casting intermediate ladle. The refractory material replacement cycle is extended by 20% to 30%, saving millions of maintenance costs annually. Reduce energy consumption Reduce secondary refining caused by insufficient purity of molten steel (such as LF furnace treatment), shorten smelting time by 10% to 15%, and reduce electricity consumption per ton of steel by 5-10 kWh. 2、 How can the slag blocking plug indirectly improve efficiency? Premium brought by quality upgrade The improvement of the purity of molten steel (such as T.O content ≤ 15ppm) can increase the qualification rate of high-grade steel (automotive board, silicon steel, etc.) by 2%~5%, and the selling price per ton of steel can be increased by 100~300 yuan. Reduce the risk of customer claims due to inclusion defects (such as fatigue life issues with bearing steel). Production process optimization Automated matching: The intelligent slag blocking plug is linked with the steel tapping detection system to achieve "one click steel tapping", reducing manual operation errors and production pauses. Continuous casting operation: The thickness of the slag layer in the ladle is stably controlled at ≤ 30mm to avoid blockage of the continuous casting nozzle and increase the number of continuous casting furnaces. 3、 The 'efficiency lever' of technological upgrading Material Innovation Composite ceramic fiber: can withstand temperatures above 1700 ℃, has a lifespan twice that of traditional materials, and reduces single use costs by 40%. Self lubricating coating: reduces steel splashing during insertion and improves operational safety. structural design Cone shaped porous design: Through fluid dynamics optimization, the efficiency of slag layer stripping is improved by more than 90% (traditional slag blocking plugs are only 70%~80%). Detachable structure: Replace damaged parts instead of the whole, further reducing consumable costs. data-driven IoT monitoring: Real time collection of data on slag blocking depth, temperature, etc., optimized insertion timing and angle through AI analysis, increasing the success rate of slag blocking from 85% to 98%. 4、 Typical case: Application effect of a steel plant Background: The steel plant has an annual output of 3 million tons, and the yield of molten steel using the original slag blocking process is 92.5%. After renovation: Adopting high-performance slag blocking plug and intelligent control system. Result: The yield increased to 94.2%, with an annual increase in efficiency of approximately 54 million yuan; Reduce the cost of refractory materials by 2 million yuan per year; The proportion of high-grade steel has increased from 15% to 22%. 5、 Key points of industry promotion Customized adaptation: Adjust the size and material of the slag stopper according to the furnace type and steel grade of the steel plant (such as stainless steel plants that require high chromium slag resistance). Employee training: Standardize operating procedures (such as insertion speed and angle) to avoid human error. Integration with existing systems: It is necessary to be compatible with MES/PLC systems in steel mills to avoid "information silos". Conclusion The slag blocking plug leverages "significant efficiency improvement" through "technological innovation", and its value is not only reflected in direct cost savings, but also reshapes the competitiveness of steel mills through quality upgrades and process optimization. In the future, with the penetration of intelligence and new material technology, slag blocking plugs will evolve from "auxiliary tools" to "core controllers of smelting processes", becoming an invisible pillar for cost reduction and efficiency improvement in the steel industry.

The converter slag stopper is a key equipment used in the steelmaking process to improve the purity of molten steel. Its core function is to prevent slag from entering the ladle during steelmaking. The following system analysis from principle to application: Converter slag blocking plug 1、 Working principle Mechanical barrier mechanism Slag blocking plugs are usually made of refractory materials and have a conical or spherical structure. By accurately placing them at the steel outlet, a physical barrier is formed using the density difference (between molten steel and slag). When the molten steel flows out, the slag stopper floats at the interface of the steel slag and gradually blocks the steel outlet as the liquid level decreases, preventing high oxidation slag (containing FeO, SiO ₂, etc.) from mixing into the molten steel. Dynamic control By optimizing the timing and position of the slag blocking plug (usually when the steel output reaches 90% -95%), combined with the fluid dynamics characteristics of the steel outlet, the vortex effect is reduced to avoid steel slag mixing.

In response to the pain points of low slag blocking efficiency, high material loss, and poor adaptability in converter steelmaking, multiple breakthrough slag blocking plug solutions have been developed in recent years through interdisciplinary innovation in materials science, structural design, and intelligent manufacturing. The following systematically elaborates on technological progress from four dimensions: material formulation, structural optimization, manufacturing process, and intelligent integration: Converter slag blocking plug 1、 Material System Innovation: From Single Refractory to Functional Composite Materials Gradient composite structure design Working layer: ZrB ₂ - SiC ultra-high temperature ceramic (resistant to 1800 ℃ erosion) is used, and in-situ ZrC reinforcement phase is formed through reaction sintering, which improves the corrosion resistance by 5 times (compared to traditional magnesia carbon brick). Buffer layer: Introducing mullite porous ceramics with porosity of 30% -35%, effectively absorbing the thermal shock stress of molten steel and avoiding cracking. Weight layer: tungsten alloy skeleton+lightweight Al ₂ O ∝ hollow sphere composite, achieving accurate and adjustable density of 6.2-6.8 g/cm ³ (suitable for different steel grades).

In the steelmaking process of converter, the gradual replacement of traditional slag blocking balls with slag blocking plugs is an important technological innovation, with the core of improving slag blocking effect, reducing slag discharge, and optimizing steel quality. The following is a detailed analysis of this technological change: Principle: The slag blocking ball relies on a density between the molten steel and the slag (usually 4.2-4.5 g/cm ³), and naturally falls into the steel outlet at the end of the steelmaking process as the steel liquid level drops, using the density difference to block the slag. Disadvantages: Incomplete slag blocking: The spherical shape does not match the shape of the steel outlet, which can easily cause gaps and lead to slag droplets flowing into the ladle. Strong timing dependence: Throwing too early may block the steel outlet, while throwing too late may result in ineffective slag blocking. Inaccurate control: Turbulence inside the furnace may cause the slag blocking ball to shift, and the success rate of slag blocking is only about 70-80%.