Abstract: The invention relates to various energy saving measures for use in the smelting, refining and melting of metals, and in particular in the manufacture of steels, alloy steels and ferrous alloys. In such processes fuel consumption is reduced and efficiency improved by using in the oxy-fuel or air-fuel burner a fuel (referred to as an "X-type" fuel) which has an exothermic heat of decomposition or which has only a zero or a very small endothermic heat of decomposition.The invention also relates to an oxy-fuel or air-fuel burner for use in a metallurgical process using an X-type fuel, which burner uses as coolant for the burner walls and tip the fuel used in the burner.

Abstract: A metallurgical ladle including a steel shell and refractory brick lining includes a refractory brick retaining ring formed in segments from a ceramic material, with the segments being releasably secured to the inner surface of the steel shell and overlying the lining brick. The ceramic material preferably is reinforced with metal fiber and preferably has a top surface extending above the open top of the steel shell.

Abstract: The invention relates to a vessel for evaporating molten metal, such as aluminum, in which the vessel comprises boron nitride with or without a compatible refractory material and said vessel having on at least a portion of its surface a coating of titanium-iron-silicon which can easily and effectively be wetted by the molten metal.

Abstract: The amount of electrically conductive material in the bottom floor lining of a conventional aluminum reduction cell is reduced by using a non-conductive lining material in its place. The non-conductive material separates the remaining electrically conductive regions form the sidewall linings of the cell and preferably confines the electrically conductive material to the "anode shadow" region of the cell floor. The non-conductive material preferably comprises a particulate alumina mixture made up of large shapes which firmly compact together and smaller particles which fill the remaining voids. Optionally, the mixture may be bonded together with amorphous alumina, in which case the mixture can also be used for cell wall linings. The linings can be used in reduction cells of conventional design and reduces undesirable magnetohydrodynamic effects as well as pollution hazards caused by conventional carbonaceous cell linings.

Abstract: An enclosure or housing for a furnace structure or the like such as for a reheat furnace of the type used in steel rolling operations, the furnace enclosure being comprised of a self-supporting arch structure preferably of sheet material such as steel and having thermal insulation extending continuously over the inner or concave expanse thereof, the arch structure forming an elongated, arched furnace enclosure which provides improved thermal energy distribution, simplified design, and enhanced overall economy.

Abstract: In an installation for the vacuum heat treatment and subsequent hot isostatic redensification of materials comprising a work space inside a container, heating unit, work-space insulation and an outer chamber with a vacuum connection and a pressure-gas connection, insulation is also provided at the interior of the chamber wall. The chamber is water-cooled.

Abstract: A modified metallurgical converter wherein removable segments or portions are provided in the anticipated areas of highest wear of its refractory lining, and methods for repairing same. Also, a method for improving the service and operational life of such metallurgical converters.

Abstract: An apparatus for lining the interior of a furnace or the like having a hot and a cold face comprising alternating strips of two fibrous materials stacked edgewise to form the insulative module or mat. The first fibrous material exhibiting either greater shrinkage or corrosion resistance than the second fibrous material, and the alternating pattern allowing the lining to be used in conditions which would normally exceed the use characteristics of the second material.

Abstract: Steel tubulars are deposited into an insulated container shortly after the steel tubulars are formed in a seamless hot rolling machine. The tubulars are covered by an insulating blanket and allowed to cool at a selected rate to form desired microstructure in the steel of the tubulars. No external energy supply or controls are necessary to achieve the desired microstructure. The side walls of the container taper outwardly and are made of a sandwiched structure, having spaced apart sheet metal members with a layer of insulation there between. The end walls are similarly constructed. The bottom of the container is lined with granular insulating material to cushion the shock of the tubulars being dropped into the container and to insulate the bottom of the container. Stainless steel mesh is used as a sling and embraces the tubulars to facilitate removing the tubulars from the container after the desired amount of cooling.

Abstract: For improving permeability of a metallurgical vessel bottom provided with permeable refractory elements for controlled injection of a stirring fluid into a molten metal bath, the metallurgical vessel is emptied of its contents, a castable composed of a refractory material compatible with the refractory material of the bottom is deposited in the bottom and spread over the latter, and the castable is left to dry and set, while maintaining in the permeable refractory elements a sufficient pressure to provide a permanent flow of a stirring fluid. A hydraulic magnesian refractory castable used in this method has a content of water of substantially between 8 and 10% by weight.

Abstract: A heat-insulating board comprising a molded refractory material having substantially uniformly distributed therethrough flexible thermoset polymer fibers resistant to decomposition at a temperature up to about 400.degree. F. in an amount sufficient to increase the fracture energy of said board, and compositions for making such board.

Abstract: A tundish for continuous casting of molten metal having an outer metal casing and, adjacent the casing, a permanent refractory lining is provided with an inner, expendable lining comprising refractory, heat-insulating slabs having an erosion resistant backing layer and an inward facing layer of lower density than that of the backing layer.The density of the facing layer is at least 0.2 g/cm.sup.3 but not more than 85% of the density of the backing layer. The presence of the inward facing layer exerts less chilling effect on the molten metal poured into the tundish than if the slab consisted of the backing layer alone.

Abstract: A crucible for melting metals therein to form an active brazing alloy is made of slip cast silica with an yttria lining on the inside surface thereof.

Abstract: A support plate is used, together with the shell of a vessel for the holding and/or refining of aluminum, in combination with a refractory sheet and a metal heating element container positioned in a graphite block to protect said heating element and to thus extend the life of said heating element. Oxidation of the graphite block is precluded, as is the attack upon the heating element by chlorides passing through the pores of said graphite block.

Abstract: Novel preheatable molded refractory insulating liners and methods of use thereof for lining metallurgical vessels, such as hot tops, ladels, tundishes, troughs and pipes, etc., which serve to transfer molten metals, such as ferrous alloys, are disclosed. The new and vastly improved preheatable liners are suitable for developing effectively the required hot strength needed for casting molten metals at vessel preheat temperatures and casting temperatures. The unique preheatable liners additionally possess the needed hot strength during the range of casting temperatures as are experienced in the metal making industry.

Abstract: Ceramic porous bodies, including ceramic foam filters and smooth-faced ceramic objects, e.g., ceramic foam bricks, ceramic foam melting crucibles, and ceramic foam cores, made in accordance with the present invention are suitable for use with molten metal in general and molten superalloys in particular. The invention also provides a tundish for use with ceramic foam filters to filter metal en route from a metal furnace to a casting mold, and a melting device for use in casting metal which employs a ceramic foam filter as a bottom pour valve for a melting crucible such that the ceramic foam filter valve regulates the flow of molten metal therethrough in order to permit an entire ingot of metal to melt in the melting crucible before any metal begins to pour from the melting device into a casting mold.

Abstract: Novel preheatable molded refractory insulating liners and methods of use thereof for lining vessels, such as hot tops, ladles, tundishes, troughs, and pipes, etc., which serve to transfer molten metals, such as ferrous alloys, are disclosed. The new and vastly improved preheatable liners are suitable for developing effectively the required hot strength needed for casting molten metals at both vessel preheat temperatures and casting temperatures. The unique preheatable liners additionally possess the needed hot strength during the range of casting temperatures as are experienced in the metal making industry.

Abstract: A lanthanide-containing alloy is produced by retaining the melt of this alloy by the use of a container having the inner surface formed of a calcia-based refractory possessing a CaO content of not less than 90% by weight in a non-oxidizing atmosphere.

Abstract: A sidewall for a metallurgical smelting furnace is disclosed. The sidewall is made from a refractory material; an evaporation cooling panel; and a convection cooling panel. The refractory material faces the interior of the furnace. A slot is formed between the evaporation cooling panel and the refractory material such that the convection cooling panel is positioned therebetween. The evaporation cooling panel and the convection cooling panel work together to cool the sidewall of the metallurgical smelting furnace.

Abstract: This invention relates to a method for installing a converter bottom, using not only bottom bricks of commercial brick formats but also shaped and fitting bricks, the largest area on a bottom plate being lined with bottom bricks of commercial brick formats, leaving a space free. After the bottom has been inserted into the converter, shaped bricks are laid one beside the other in the free edge area adjacent to the converter walling, the sides of these bricks facing the converter walling being fitted to the curvature of the converter walling. These shaped bricks are of a size such that a free space exceeding one joint width remains between each shaped brick and the adjacent bottom brick. Fitting bricks true to dimensions are laid in these free spaces.

Abstract: A method of purifying steel in a tundish, especially to remove alumina inclusions, comprises passing the steel through at least one refractory board having apertures through it and introducing inert gas into the steel at the upstream side of the foot of the board to cause a stream of bubbles to flow over the upstream side of the board. One of the boards may comprise a ceramic filter element. The boards may be non-vertical and have integral gas supply means. The apertures may taper, may have axes angled from perpendicular to the board's plane and may have high alumina content surfaces. The upstream side of the board may have an exothermic layer.

Abstract: A lightweight cover provides heat insulation for a heated vessel such as a soaking pit. The cover can be readily assembled in a manner providing for ease of repair plus simplicity of maintenance. The cover has a pair of opposing frame members with ceramic fiber insulation positioned therebetween. The insulation is secured in movable engagement such as a free-floating and swinging engagement. In this mode, compression can be exerted against the insulation to most desirably reduce heat loss otherwise caused by heat induced ceramic fiber shrinkage. Moreover, with this structure a ceramic fiber heat seal can be achieved around edges of the soaking pit.

Abstract: An infrared ray reflective coating for application to insulative materials comprising aluminum particles in an aqueous acidic binder slurry, a hardener, and a coating cement having about 96% of a mixture of Al.sub.2 O.sub.3 and SiO.sub.2.

Abstract: A molten metal handling vessel has an inner, expendable, refractory, heat-insulating lining containing particulate zircon and a binder. The vessel may be used for handling molten ferrous metals e.g. steel, including high manganese steel. The inner lining may be in the form of a shaped article and the vessel may be a tundish for use in continuous casting.

Abstract: Articles and method for containing molten nickel and methods for making the former. The material used is a high density silicon nitride that is very resistant to the corrosive properties of molten nickel alloys. The composition needed to produce such a containing article comprises polycrystalline silicon nitride containing (by weight) about 0.6% to about 8% alumina, about 15% yttria and about 2% to about 5% silica or amorphous silicon nitride containing about 2% to about 6% alumina, and about 15% yttria and about 2% to about 5% silica. The articles are formed by cold pressing and sintering methods. These articles are particularly useful in processes for molding and (RSR.TM.) spinning molten nickel alloys.

Abstract: A rotary hearth adapted to rotate in horizontal plane having a top surface made of a loose granular refractory material, advantageously dead burned dolomite grain.

Abstract: In an apparatus for treating workpieces by means of the igniting of a gaseous mixture in a work chamber for receiving the workpiece, it is proposed that the work chamber and optionally the supply duct for the gaseous mixture, as well as a mixing block for preparing the gaseous mixture which precedes the supply duct, are provided at least in part with a lining of ceramic material in the form of aluminum oxide or zirconium dioxide, in order to intercept the corrosive action exerted by the ignition of the combustion gas-oxygen mixture upon these parts of the apparatus.

Abstract: A leg is fitted through a joint material into each of a pair of vertical openings on a bottom wall of a vacuum tank for refining molten steel, for protecting the vertical openings from molten steel. The abovementioned leg has an annular inner wall formed by piling up through a joint material a plurality of magnesia-chrome fired radial bricks in a plurality of horizontal annular rows arranged one on the other so as to form an inner bore for passing molten steel therethrough. The leg also has an annular outer wall formed by piling up through a joint material a plurality of magnesia-chrome fired radial bricks in a plurality of horizontal rows arranged one on the other so as to cover substantially the entire outer surface of the annular inner wall. The inner surface of the annular outer wall is in contact with the outer surface of the annular inner wall through a joint material.

Abstract: A light weight insulator blanket capable of repetitive use of extended duration as a cover, gasket, or the like for a vessel or conduit used in transporting, storing or processing molten or non-molten metal, particularly iron or steel, and in similar applications, including a principal insulator layer of a light weight, flexible, fibrous ceramic material having one or both surfaces covered by a thick protective layer of a light weight, flexible fibrous metallic material such as high-temperature stainless steel wool, monel metal wool, or a multi-layer knitted or woven material; the layers are securely bound to each other by metallic fastening means such as high temperature stainless steel wire stitching, staples, or rivets.

Abstract: A ladle or other vessel for containing molten metal, for example molten steel, is lined with refractory at least some of which (e.g. in the slag line area) is unfired refractory bonded with a phosphate bond such as a long-chain glassy polyphosphate and containing, at least in the material smaller than 0.15 mm (-100 mesh), a high-lime periclase grain. This type of refractory shows unexpectedly high resistance to erosion and corrosion in the environment of a steelmaking ladle.

Abstract: An under-heater type furnace for maintaining a molten metal at a high temperature, comprising a refractory vessel made of an integral castable material for containing the molten metal, a heat insulating layer made of a ceramic fiber material and fixed outside of the refractory vessel for covering thermally the refractory vessel, a heater, a protective tube made of ceramics and having a closed end and an open end for housing the heater and protecting the heater from the molten metal in the refractory vessel, the refractory vessel having a first support at a lower side portion thereof and a second support at an opposite side portion thereof, the first support having a tapered opening wall which is outwardly widened, a sealing material disposed between the tapered opening wall and the protective tube for fixing the protective tube relative to the vessel, the second support supporting the closed end of the protective tube in such a manner that the closed end of the protective tube can freely move relative to the

Abstract: Unfired refractory structural member in the form of a plate for the expendable lining of metallurgical vessels, especially for tundishes used in continuous steel casting, and comprising magnesia sinter and possibly olivine with a grading of 30-45% by weight under 0.09 mm, and 55-70% by weight 0.09 to 4 mm, including 20-40% by weight over 1 mm; cork or granulated ceramic fibers as a pore-forming material; an inorganic binder; and possibly other additives. This refractory structural member has good strength, a small ignition loss, a low content of volatile hydrogen-containing substances, a favorable peeling behavior, and good resistance to slag and molten steel.

Abstract: Ladles and the like into which hot metal is teemed are refractory lined to withstand the high-temperature effects of the hot metal. Prior to teeming of the hot metal into the ladle, the ladle is heated by applying a flame to the interior thereof, which flame is provided by a burner that directs the flame through a ladle cover plate having a substantially flat surface covered with heat-insulating refractory material, which surface is brought into sealing engagement with the ladle. This seal minimizes the amount of heat energy that escapes from the ladle to render the preheating operation more efficient. The rim of the ladle, which contacts in sealing engagement the heat-insulating refractory material of the ladle cover plate, causes wear and damage to the heat-insulating refractory material.

Abstract: A lightweight cover provides heat insulation for a heated vessel such as a soaking pit. The cover can be readily assembled in a manner providing for ease of repair plus simplicity of maintenance. The cover has a pair of opposing frame members with ceramic fiber insulation positioned therebetween. The insulation is secured in movable engagement such as a draped and swinging engagement. In this mode, compression can be exerted against the insulation to most desirably reduce heat loss otherwise caused by heat induced ceramic fiber shrinkage. Moreover, with this structure a ceramic fiber heat seal can be achieved around edges of the soaking pit.

Abstract: A method for flame spraying of gunite on the lining of metallurgical units, comprising a delivery of a mixture of a refractory material and fuel in a central axisymmetric flow and a delivery of oxygen in an annular flow concentric with the flow of the refractory material and fuel, a heating and fusion of the refractory material in a high-temperature flame, and applying particles of the refractory material to the surface of the lining. Oxygen is delivered in a tapering annular flow rotating about its axis. The ratio between the rotation momentum of the oxygen flow and the momentum of the flow of the refractory and fuel is maintained in the range of 0.3 to 3.0.

Abstract: A core for blow-forming the lining of a vessel for molten metal, which core is provided with a main body having blow-in holes and an exhaust port, the side face and the lower faces of said body having the same dimensions and shapes as those of the inside of the lining of said vessel for molten metal, a flange mounted approximately horizontally in the outer direction at the periphery of the upper end of said main body, a plurality of supports which are actuated downwardly from said flange, and airtight and shock absorbers mounted beneath said flange, a lining method which uses said core, and a lining composition used in said lining method.

Abstract: A method of producing molten iron in which iron oxide is fed together with carbon to an oxygen-top-blown melt from below through blocks whose pores permit the particles to be entrained into the melt in a carrier gas, the pores preventing penetration of the molten metal.

Abstract: A suspended nose construction for high temperature furnaces providing refractory replacement from the cold side of the refractory has a plurality of wedge-shaped refractories arranged to form a wedge row along the length of the nose adjacent, on at least one side, a plurality of rectangular-shaped refractories arranged to form a straight row along the length of the nose. The converging sides of the wedge-shaped refractories converge toward the cold side of the refractory. Both the wedge refractories and the rectangular refractories are suspended in pairs by suspension means from an exterior support structure, the suspension means and support structure providing space allowing removal of the refractories in pairs from the cold side of the nose construction. The suspended nose construction according to this invention provides for removal and replacement of a small number of refractories in the nose without disturbing the major portion of the nose construction.

Abstract: A molten metal stirring apparatus stirs molten metal by sucking the molten metal into a riser linked to a melting furnace beneath the surface of molten metal in the melting furnace, and returning the molten metal in the riser into the melting furnace. The apparatus includes an electric heater for heating the riser and provided in the vicinity of the position reached by the molten metal drawn into the riser. A changeover valve is linked to the upper end of the riser. A vacuum source, for reducing the pressure inside the upper end of the riser, is connected to the changeover valve. A duct, leading exhaust gas from the melting furnace to the upper end of the riser, is connected to the changeover valve. A heater for heating the riser is provided coaxially with and on the outer periphery of the riser.

Abstract: A method of forming an insulation module for insulating the walls of a furnace, the method including forming holes at spaced intervals in a cold face of a mat of ceramic insulation material, applying a liquid adhesive to the cold face, vibrating the adhesive to cause the adhesive to penetrate into the holes of the mat, and providing a backing panel on the cold face.

Abstract: A molten iron containing vessel includes a refractory fireproof inner lining of dolomite bricks and bauxite bricks. The lining includes magnesia bricks positioned between the dolomite and bauxite bricks, thereby avoiding contact reactions between the dolomite and bauxite. A gas permeable brick member extends through an end portion of the vessel for injecting a gas into the molten iron contained therein.

Abstract: A drapable, consumable, heat retention shield for hot metal cars has a fibrous refractory sheet disposed between two metallic lattices, the lattices connected by fastening means to retain the sheet to form a panel having a bottom wall, upstanding side walls and a flange extending outwardly from the side walls. In one embodiment the metallic lattices substantially cover the fibrous refractory sheet, while in another embodiment cross strips of metallic lattices are used with a combustible supporting frame provided about the periphery of the fibrous refractory sheet to support the same.

Abstract: A consumable heat retention shield for retaining the heat of the interior lining of a hot metal car includes a combustible framework having a bottom wall, upstanding walls and a flange, with the surface thereof that is to be directly exposed to the hot metal car covered with a layer of refractory material, with the shield being manually positioned on the hot metal car by workmen, and the shield consumable upon pouring of molten metal upon the shield and through the mouth of the hot metal car. Preferably, the shield has a metallic filler material in a cavity thereof to provide additional weight to the shield, which metallic filler material is compatable with the molten metal charged to the hot metal car.

Abstract: A brickwork construction is disclosed as specifically useful for making the gas distribution chamber of a shaft kiln. In this construction the collapse of the wall into the shaft kiln is prevented by using bricks which are thinner at one end than the other and are laid to make a wall in which there is a straight inner surface to the shaft kiln and an arched side to the gas distribution chamber.

Abstract: The metal shell of a furnace or cupola is cooled by means of water flowing down over the exterior surface of the metal shell. In order to reduce heat loss and thus decrease the energy consumption, the interior surface of the metal shell is lined with a fired refractory shape. The thermal conductivity of the refractory material and its thickness are selected such that the amount of refractory material remaining upon reaching equilibrium conditions will be sufficient to maintain the mechanical and structural integrity of the lining. Refractory materials of different conductivities may be selected for various locations in the furnace depending upon the temperatures to be encountered.

Abstract: The present invention relates to lining units used to protect surfaces exposed to intensive wear by solids, gases and liquids.The lining unit is a metallic shell formed with a pipe of rectangular cross section, containing a metallic plate and a wear-resistant composite material, the shell, the metallic plate and the composite material being diffusion-joined one to another.

Abstract: A blast furnace having a refractory lining of concrete components each having a volume of at least 0.2 m.sup.3, and comprising an alumina-containing cement or slag, chromium oxide of very fine particle size and fired aluminum oxide of somewhat larger particle size, together functioning as a cement for a refractory aggregate, provides great resistance to the heat and abrasive conditions existing inside of a blast furnace.

Abstract: A runner for hot metal as from a blast furnace is formed from a series of interconnected modular units which are prefabricated from refractory based materials in layers of different densities resulting in a calculable exposure life determined by the density and the amount and temperature of the molten metal handled by the runner. The modular units are formed from a mixture including aluminum oxide, clay, refractory cement and phosphoric acid that has a known life dicated by the density of compaction of the layers of the material in the finished product.

Abstract: The heat insulating lining of the metallurgical vessel includes a permanent layer in a refractory material and a consumable layer arranged in the interior of the vessel and intended to be in direct contact with the liquid metal. This layer consists of a mixture of inorganic particles and of mineral and/or organic fibers embedded in an organic and/or inorganic binder. Between the permanent layer and the consumable layer is fitted a relatively compressible layer of an inorganic and/or organic fibre base resistant to the temperature pertaining at the contact of the consumable layer, these fibres being partially embedded in an organic and/or inorganic binder.

Abstract: A teapot ladle has an interior lining of low thermal capacity, low thermal conductivity refractory material which in contact with molten metal poured into the ladle forms an erosion resistant surface, and means for retaining the lining in place when the ladle is tilted.The lining material comprises inorganic fibrous material, particulate refractory material and an organic binder and the retaining means may be a refractory or metal ring which clips over the outer wall of the ladle and the inner wall of the lining, a series of clips or a rod shaped to fit over the top of the ladle and hold the lining in one place at one point on its perimeter.