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Overcoming the problem of slag blocking failure and taking converter steelmaking to a new level
2025-09-28
Overcoming the problem of slag blocking failure is a key breakthrough in improving the efficiency, purity, and economic benefits of converter steelmaking. The following systematically elaborates on this innovative achievement from three aspects: technical principles, solutions, and industry impact:
Slag blocking plug
1、 The core pain point of slag blocking plug failure
Failure manifestations: premature melting/erosion of slag blocking plug (resulting in slag discharge>3kg/t), insufficient mechanical strength (installation fracture rate>5%), poor matching with steel outlet (slag leakage rate>15%).
Industry losses: An increase in slag discharge per furnace will result in a 2-3% decrease in alloy yield, a 30% increase in the risk of excessive inclusions, and an 8-15 yuan increase in the cost per ton of steel.
2、 Key technological breakthrough path
(1) Innovation in Material Systems
Composite ceramic matrix: Adopting MgO-Al ₂ O ∝ - ZrO2 ₂ three-phase eutectic structure (ZrO ₂ content 18-22%), the refractoriness is increased to 1850 ℃ (traditional material 1600 ℃)
Nano coating technology: Surface spraying of 200 μ m titanium boride coating improves corrosion resistance by 40% (laboratory data)
Transition layer of metal ceramic: achieving thermal expansion coefficient matching between steel core and refractory material through gradient sintering technology (CTE difference<0.5 × 10 ⁻⁶/℃)
(2) Structural optimization design
Fluid dynamics simulation: slag steel two-phase flow simulation based on ANSYS Fluent, optimizing head cone angle (55-60 °) and vent hole distribution
Intelligent warning system: embedded with micro thermocouples (response time<0.5s), real-time monitoring of changes in plug temperature field
(3) Process control upgrade
Accurate casting model: Establish the motion trajectory equation of the slag blocking plug (considering 12 parameters such as ladle inclination angle and tapping speed), and control the casting timing error within ± 0.3s
Laser positioning assistance: ToF laser rangefinder (accuracy ± 1mm) is used to ensure installation coaxiality
3、 Industrial application effectiveness
Actual measurement data of 300t converter in a certain steel plant:
The lifespan of slag blocking has been extended from 8 minutes to 15 minutes
The slag discharge rate has decreased from 4.2kg/t to 1.6kg/t
The endpoint [O] content decreased by 12ppm
economic performance:
Alloy consumption reduced by 1.8kg/t steel
The cost of refractory materials has decreased by 23%
Annual benefits reach 27 million yuan per converter
4、 Technological extension value
Promote standard upgrade: The newly revised "YB/T 5049-2023 Technical Specification for Slag Blocking in Steelmaking" has adopted this technical indicator
Intelligent steelmaking connection: provides key execution unit reliability guarantee for the subsequent unmanned steelmaking system
Cross industry application: technology derived to scenarios such as continuous casting intermediate ladle plug rods, molten iron pretreatment spray guns, etc
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