Abstract: The invention is directed to a method of providing a protective coating composition that protects a refractory wall or lining from chemical attack by molten aluminum and molten alkali metals. The method includes the steps of coating a refractory wall or liner with an aqueous protective composition that includes, by weight of the solids, about 20-90% Al2O3 (excluding calcined alumina), about 15-55% SiO2 and about 1-15% of a metallic non-wetting agent; and evaporating the water before contacting the protective coating with the reactive molten metal.

Abstract: The aqueous protective coating composition is provided for easy application to refractory linings and walls. When dried, the protective coating composition provides excellent chemical resistance to molten aluminum alkali metals and vapors. The protective coating composition includes alumina and silica, suitably provided as mullite, calcined alumina, and colloidal silica; and a metallic non-wetting agent.

Abstract: The aqueous protective coating composition is provided for easy application to refractory linings and walls. When dried, the protective coating composition provides excellent chemical resistance to molten aluminum alkali metals and vapors. The protective coating composition includes alumina and silica, suitably provided as mullite, calcined alumina, and colloidal silica; and a metallic non-wetting agent.

Abstract: The invention is directed to a method of providing a protective coating composition that protects a refractory wall or lining from chemical attack by molten aluminum and molten alkali metals. The method includes the steps of coating a refractory wall or liner with an aqueous protective composition that includes, by weight of the solids, about 20-90% Al2O3 (excluding calcined alumina), about 15-55% SiO2 and about 1-15% of a metallic non-wetting agent; and evaporating the water before contacting the protective coating with the reactive molten metal.

Abstract: The invention is directed to a method of providing a protective coating composition that protects a refractory wall or lining from chemical attack by molten aluminum and molten alkali metals. The method includes the steps of coating a refractory wall or liner with an aqueous protective composition that includes, by weight of the solids, about 20-90% Al2O3 (excluding calcined alumina), about 15-55% SiO2, and about 1-15% of a metallic non-wetting agent; and evaporating the water before contacting the protective coating with the reactive molten metal.

Abstract: The aqueous protective coating composition is provided for easy application to refractory linings and walls. When dried, the protective coating composition provides excellent chemical resistance to molten aluminum alkali metals and vapors. The protective coating composition includes alumina and silica, suitably provided as mullite, calcined alumina, and colloidal silica; and a metallic non-wetting agent.

Abstract: A method of repairing the lining of a converter includes disposing a refractory composition onto a worn surface of the converter. The refractory composition includes alumina, silicon carbide, and silica. The method may also include disposing a nozzle into a tuyere, pumping a refractory composition through the nozzle and onto a worn surface of the converter, and allowing the refractory composition to flow onto the worn surface of the refractory.

Abstract: A method for lining a blast furnace or other metallurgical vessel in stages uses a plurality of porous consumable forms and a pumpable casting composition. A form member, including a rigid support frame and a porous consumable form mounted thereto, is installed in a lower portion of the vessel being lined, and is spaced from the vessel wall. Casting composition is then pumped into the space between the consumable form and the vessel wall, and is permitted to harden. Then, another form member is positioned above the first, and casting composition is pumped into the space between the second form member and the vessel wall. This process is repeated, using stacked form members, until the refractory lining is completely installed.

Abstract: A method is provided for installing a refractory lining in a metallurgical vessel having a main opening which is much smaller than the diameter of the vessel. The method is especially useful in a vessel having a circular or otherwise curved cross-section. A form or mold is assembled inside the vessel, leaving a space between the form and the outer shell of the vessel. The form is supported on both sides, to maintain the distance between the form and the outer shell, and to prevent collapse or implosion of the form. Then, a pumpable casting composition having a smooth and easy flow is injected between the form and the shell, and allowed to harden. The use of the pumpable composition significantly shortens the time required to form the liner.

Abstract: A ladle port assembly having a longer use life than a conventional porous plug includes an inner refractory member constructed from a high-fired alumina-containing refractory material, a middle refractory member surrounding the inner member and also constructed from a high-fired alumina-containing refractory material, a plurality of channel openings at an interface between the inner and middle refractory members, an outer refractory member surrounding the middle member, and a steel housing which contains the three refractory members. The high-firing of the inner and middle members increases their durability and hardness, reduces wear during use, and reduces the clogging of the channel openings which, in conventional porous plugs, has been caused by erosion and other forms of wear.

Abstract: An adjustable form used for forming or repairing a refractory lining includes an adjustable frame constructed from a plurality of intersecting beams, at least some of which are adjustable, and a form connected to the adjustable frame. The frame can be adjusted in at least one direction and, preferably, in more than one direction. By properly adjusting the frame, the adjustable form can be used to form a refractory lining in different metal containment devices varying in dimensions, and can also be used to repair existing refractory linings. The adjustable form is inserted into a metal containment device at a distance from the floor and walls of the metal containment device, and refractory material is poured into the space between the adjustable form and the metal containment device.

Abstract: A method and apparatus are provided for making steel alloys directly in a tundish. Base steel enters the tundish from a ladle. An alloying chamber having a plurality of inlets is positioned above a tundish drain. An alloying material (for example, a wire including one or more alloying ingredients) is fed into the alloying chamber through a feed pipe originating above the liquid level in the tundish. Molten base steel enters the alloying chamber through the inlets and is mixed with the alloying material to make a steel alloy, which exits through the drain. The method and apparatus are especially suitable for making small order quantities of alloy steel of less than one ladle volume.

Abstract: A two-piece tundish nozzle assembly block is provided for the drain regions of tundish vessels. The two-piece assembly block includes a lower main block firmly mounted in the refractory lining of the tundish, and a selectively removable top sleeve which, together with the refractory lining, protects the lower main block from direct exposure to molten iron or steel. The top sleeve is directly exposed to molten iron or steel passing into the drain. The top sleeve is not strongly bonded in place, and can be easily removed and replaced when worn or damaged. The top sleeve further includes a ramp for channeling molten metal into the drain, and a blocking wall for preventing heavy inclusions from entering the drain.

Abstract: A method and apparatus are provided for making steel alloys directly in a tundish. Base steel enters the tundish from a ladle. An alloying chamber having a plurality of inlets is positioned above a tundish drain. An alloying material (for example, a wire including one or more alloying ingredients) is fed into the alloying chamber through a feed pipe originating above the liquid level in the tundish. Molten base steel enters the alloying chamber through the inlets and is mixed with the alloying material to make a steel alloy, which exits through the drain. The method and apparatus are especially suitable for making small order quantities of alloy steel of less than one ladle volume.

Abstract: A slag stopper assembly for use in a tundish vessel includes a chamber for reducing the flow of slag to the tundish drain and a stopper plunger for regulating the flow of liquid metal through the drain. The chamber includes a central opening for receiving the stopper plunger, and the stopper plunger is retractably movable relative to the chamber through the central opening. In accordance with the invention, a sealing rim is present on the stopper plunger, or on an inner wall of the chamber, or both, in order to reduce the retractable movement of the stopper plunger, reduce the amount of slag which enters the chamber as a result of such movement, and seal off the central opening of the chamber from the tundish drain when the stopper plunger is in a retracted position.

Abstract: A two-piece tundish nozzle assembly block is provided for the drain regions of tundish vessels. The two-piece assembly block includes a lower main block firmly mounted in the refractory lining of the tundish, and a selectively removable top sleeve which, together with the refractory lining, protects the lower main block from direct exposure to molten iron or steel. The top sleeve is directly exposed to molten iron or steel passing into the drain. The top sleeve is not strongly bonded in place, and can be easily removed and replaced when worn or damaged.

Abstract: A tundish baffle having a plurality of fluted openings is provided. The fluted openings interrupt and remove inclusions from molten metal passing through the baffle, using a plurality of obstructive peaks and valleys located at the perimeters of the openings. The fluted openings also include central portions which are not obstructed by the flutes, through which molten metal can flow in a regular fashion.

Abstract: A system for spraying ceramic coatings on surfaces in contact with molten metals in which a constant amount of slurry made from water and ceramic powder is supplied to a pump and a hose for applying the slurry to the surface to be coated. Activation of an air valve delivers air to the hose at a sufficient pressure to spray the slurry on the surface to be coated. Deactivation of the air valve shuts off the pump.

Abstract: A tundish impact pad is provided for use in a tundish vessel. The impact pad has a wavy upper surface which significantly reduces the horizontal surface area in the region of impact where molten iron or steel enters the tundish vessel. This wavy surface substantially reduces the vertical splashing of molten iron or steel entering the vessel, causing a significant reduction in agitation and turbulence within the vessel. The impact pad may exist as a discrete structure or may form an integral part of the structure of the tundish vessel.

Abstract: An impact pad for use in a tundish vessel utilizes outer and inner guides which partially surround the region of impact except in the direction of the one or more tundish drains. Much of the molten iron or steel entering the tundish is directed toward a drain by the inner guide or guides. The inner and outer guides define a channel such that molten iron or steel which splashes or otherwise flows over the inner guides can also be directed toward the one or more tundish drains.