EFFECT OF SINTERING AIDS IN TUNDISH VIBRATABLE MASS

Project report submitted in partial fulfillment of the requirement for the degree of

Bachelor of Engineering

By

Srividya Banerjee (3PD14CC025)

Ravindra (3PD12CC014)

Nirmala Rathod (3PD14CC013)

Mohammed Arif (3PD12CC010)

Department of Ceramic and Cement Technology

Kalaburagi-585102, Karnataka
CERTIFICATE
This is to certify that the students of PDA College of Engineering have
successfully completed their project in TRL Krosaki Refractories Ltd .The
following students are:

1. Srividya Banerjee

2. Nirmala Rathod

3. Ravindra

4. Mohammed Arif

The project was undertaken from 9th January to 22nd February 2018. This
project was undertaken purely for academic purpose.

Department Research and Development(monolithic)

Project Title Effect of sintering aids in tundish vibratable mass

This work has been carried out under my supervision and has not been
submitted elsewhere for a degree.

Signature of supervisor

Dr. Arup Kumar Samanta

(Sr General Manager – Monolithics & FCP)

Research and development dept.

TRL Krosaki Refractories Ltd

Belpahar, Odisha
ACKNOWLEDGEMENT
We thank TRL Krosaki Refractories Ltd, Vice President Dr. Tarapada Das for
giving us the opportunity to conduct our project for time duration of six weeks. We
are grateful for the accommodation given to us during this period.

We would like to thank Dr. Arup Kumar Samanta(Head of Monolithics

department) for his constant support and guidance during our project. Apart from
his busy schedule he took out time to go through our project and making various
corrections.

It was pleasure learning about the safety induction classes held under Training
coordinator Mr.Kalpataru Panda. We thank him for his advices which we
followed during our project training period.

Last but not the least we thank our Head of Department, Dr. J U Kennedy for
encouraging us to complete our project.
CONTENTS
1. Introduction

2. Experimental

3. Results and Discussions

4. Conclusions

5. References
Effect of sintering aids in tundish vibratable mass
INTRODUCTION
Monolithics are a series of material where Dry vibratable mass is one of them (Fig – 1). Dry vibratable
(DVM) or disposable tundish liners are used to maintain the molten steel cleanliness and steel
temperature to protect the high alumina permanent tundish lining and allow the easy removal of the steel
skull after casting. These requirements are achieved because of the refractory properties of the disposable
tundish lining which depend on the chemical composition of the dead burned magnesites and the dunite
grains used.

The tundish is the last refractory vessel that the steel encounters before it enters the mold. Figure 2 shows
the process steps in the continuous casting of steel.The application of Dry Vibratable Mass (DVM) in the
tundish disposable lining has influenced most in the production of cleaner steel and energy efficient
casting operation. The free flowing behavior of the material in the annular space between the forma and
back up lining forms a continuous, smooth surface after curing. The hot setting behavior of the dry mass
depends on the granulometry, binder content and curing temperature. During application the packing
density of the dry mass, coating of the additives on curing, and flow tendency during side wall filling up
is dependent on the size distribution of the constituents used in DVM preparation1.

Ramming
mass

Gunning Dry
Mass Vibratable

Monolithics
Refractory Plastic
Mortars masses

Castables

Fig.-1: Major Monolithic materials

The shape of the tundish having more lining surface area per volume of steel in the steel making process
making it even more important that the tundish disposable lining not react with the steel or contaminate
it. The tundish flow patterns are carefully controlled to reduce inclusions in the steel by allowing them to
float into the molten slag covering the steel where they are dissolved, producing even cleaner steel. Steel
chemistry and nonmetallic impurities have a marked influence on the physical and mechanical properties
of steel. Competition from other materials has resulted in steel grades having even narrower composition
ranges2,3 and lower guaranteed contents of critical elements such as C,H,N,O,P and S. Steel cleanness
and purity requirements have also been increased to achieve the outstanding steel properties on a
reproducible basis.

Figure 2. Continuous casting of steel

Both DBM and Dunite contain SiO2, FeO/Fe2O3 and MnO which can reoxidize the steel in the tundish.
The rate of steel reoxidation by these oxides in the tundish linings contacting the steel has been shown to
depend on the amount of fluid silicates present in the disposable lining at molten steel temperatures. Thus
the DBM and dunite chemical compositions are important in producing cleaner steels.

A cross section of a tundish wall is shown in figure 3. Note the disposable tundish liner is thicker at the
slag line to prevent the corrosive slag from reaching the high alumina permanent lining. In the case of
tundish spray the thickness is easily adjusted to fit the wear patterns of the tundish. The thickness is also
carefully controlled to insure the temperature at the spray permanent lining interface does not exceed
~13250 C, to insure that the steel skull and the disposable liner can be dumped easily without damaging
the permanent lining after casting is completed.

The disposable tundish lining must have a low thermal diffusivity to prevent freeze-off during the critical
start up of casting period when the tundish is cold and heat loss from the molten steel must be minimized
in order to maintain the narrow temperature range required to allow the mold to continuously solidify it.
If the molten steel loses too much heat to the cold tundish lining during start up of casting, a dangerous
and costly breakout or freeze off could occur.

Figure 3. Cross section of tundish wall showing disposable tundish lining

The design of both spraying mass and dry vibratable mass based on dead burned magnesite and dunite
and therefore disposable tundish linings must have excellent resistance to hydration when exposed to
water and steam. Hydration of magnesite in disposable tundish liners can create serious safety issues for
the workers in the steel mill, as well as quality issues from hydrogen and oxygen pickup in the steel
passing through the tundish.

Hydration is one of the most important properties for magnesites that are used in disposable tundish
linings. All magnesite will react with water or water vapor to form magnesium hydroxide.

MgO + H2O = Mg(OH)2

The hydration chances is more in case of spraying mass where 26 – 30% water is used to spray the
material. The reaction of magnesite grain with water increases with temperature and is greatly
accelerated when exposed to steam at 100°C. During the drying of tundish sprays and tundish boards
and the curing of the Dry Vibratable Mixes, (DVM), the magnesite tundish linings are exposed to
100°C. The possible reaction of the steam with the magnesite is further enhanced because the magnesite
particle size in disposable tundish linings is typically -50 mesh with significant quantities being under
-325 mesh. The large DBM surface area in contact with water and 100°C steam requires further
increases the need for magnesites with good hydration resistance.

Figure 4 shows4 that temperatures of 400°C or more are required through the full lining thickness to
decompose all the Mg(OH)2 formed in the lining. If any free CaO were present in the lining, the entire
thickness of the lining would have to be heated to a minimum of 600°C to decompose all the Ca(OH)2.

Dry vibratable mixes and tundish boards are dried and cured at approximately 200 - 300°C, thus any
Mg(OH)2 present in the linings will not be decomposed, only the free H2O will be driven off. Tundish
spray is typically dried by blowing ~ 550°C air over the exposed surface until all of the free H2O is driven
off, as indicated when the temperature at the permanent lining/spray interface exceeds ~110°C. At this
time the temperature in the`50-60% of the spray lining thickness near the permanent lining has normally
not exceeded 400° C and still contains all the Mg(OH)2 formed during the drying of the lining.

Figure 4. MgO- H2O and CaO- H2O phase diagrams

Tundish sprays are designed to have low thermal conductivities and this property extends the time
required to dry the linings, (of the free H2O), and makes it impractical to dry long enough to
decompose all the Mg(OH)2 during drying. However, additional Mg(OH2) is decomposed if the
tundish is preheated prior to casting, since preheat temperatures are much hotter, ~1300°C, causing a
greater depth of the disposable tundish lining to be heated over the ~400°C, further reducing the H2O
in the lining.

When casting begins, the 1550°C. molten steel temperature rapidly heats the entire thickness of the
disposable tundish lining to over 400°C.and the H2O(g) from Mg(OH)2 diffuses to the molten steel,
contaminating it by increasing the amount of H and O dissolved .

Hydrogen in steel causes cracking and porosity during solidification and thus is very undesirable.
Oxygen leads to inclusions which decrease strength, reduce toughness, produce fatigue, give surface
defects, etc. Thus magnesite hydration can play a major role in reducing the quality of the initial steel
cast.

The most serious problem that can occur due to magnesite hydration is a steam explosion which can blow
molten steel out of the tundish causing danger to the workers nearby, the caster machinery and controls
and the possibility of shutting down the caster. This can occur due to excessive magnesite hydration
causing a large amount steam to be rapidly released as the lining temperature quickly exceeds the 400°C.
Mg(OH)2 decomposition temperature when the molten steel enters the tundish. It can be shown that as
little as 5% Mg(OH)2 in a 38mm thick disposable tundish liner can produce a volume of steam, (at
1550°C steel temperatures), that extends over 10 meters from the liner surface, i.e. steam explosion. The
typical molten steel depth in a tundish is ~1 meter.
Disposable tundish liners use dead burned magnesite as the main refractory grain because it is chemically
stable and will not react with steel. It would be nice to use very high quality 98% DBM, to avoid
reactions some of the DBM impurities undergo with steel, however the minor steel quality gains do not
justify the extra cost. Typical DBM used in disposable tundish liners is in the 90 to 94% MgO range. It is
common for those not close to the tundish liner technology, to assume that tundish sprays, DVM and
tundish boards use similar magnesite as gunning mixes, since they are both disposable refractories.
Tundish liner compositions, however, require some hot strength and should form a minimum amount of
low melting silicate liquid so they can maintain high porosity and insulating properties at their
1100-1550oC service temperature under a ferro-static pressure of up to ~ 1 meter of steel. Just the
opposite of gunning mixes.

The 90-94% MgO DBM offer a wide choice, however a low C/S ratio and low CaO is desired to reduce
the amount of Monticellite CaO.MgO.SiO2, which melts at 1502oC. Alumina impurities lower the
monticellite melting temperatures and increases the volume of CMS liquid and should be minimized if
possible. Iron oxide impurities and SiO2 can reoxidize steel in the tundish. As discussed by Bannenberg,5
et.al. and Lehmann,6 et.al., the Fe2O3, FeO and SiO2 reoxidation of the steel is slowed by a diffusion layer
that forms on the DBM-olivine linings in contact with Al killed steel. This has allowed high quality steels
to be produced for over 10 years with both Fe2O3 and SiO2 at the rather high levels present in high dunite
linings.
.
However, given a choice of either increasing the iron oxide or having more calcium oxide and aluminum
oxide, which form low melting liquid silicates; more iron oxide is usually the better choice for disposable
tundish linings.

It is common to utilize good quality dunite grain with the 90 - 94 DBM to produce disposable tundish
linings with low thermal conductivity and good resistance to hot pressing. The dunite introduces
virtually no calcium oxide or aluminum oxide and thus lowers the C/S ratio of the lining reducing the
amount of low melting silicate that forms.

Apart from different requirements as mentioned above, tundush vibratable mass should have the
following characteristics

(1) Grain size must be designed in such a way so that free falling is there during installation

(2) No lump formation in the material

(3) Should have sufficient strength after curing

(4) It must have optimum strength after secondary heating

(5) No sticking of material with the form work

(6) No crack formation and no falling of material after heat curing

(7) Give sufficient life in terms of casting duration or heats

(8) Easy deskulling at the end of the campaign

Only the design of dry vibratable mass may not fulfill all the requirements. The operational parameters
along with condition of tundish particularly back up lining is most important. Sometime back up of
tundish is not good and it is worn out. This type of back up may cause difficult for deskulling. So before
application of dry vibratable mass the back up must be repaired with suitable castable followed by
heating. In below some of the photos (Fig. 5) are given showing the physical appearance of tundish
before and after application of dry vibratable mass.

Fig.-5: Appearance of tundish before and after installation of DVM (Right – After application)

In the present study changes of strength and physical appearance of DVM has been carried out in
presence of two sintering aids. Two kinds of sintering aids were selected based on boron compound. The
dose of sintering aids were in between 0.25% to 1.25%.

Raw Materials:
To design either dry vibratable mass (DVM) of spraying mass, magnesite and Olivine are the major base
raw materials.
Magnesite

Although Magnesite is a mineral (MgCO3) in the Refractories industry the term Magnesite is identified
with MgO (magnesia). Magnesite is produced either by calcining the mineral Magnesite after appropriate
beneficiation or by synthetically extracting it from the sea water or brine. Naturally occurring Magnesite
is often associated with dolomite, talc, chlorite, serpentine, mica, pyrite and magnetite. Most deposits are
mined selectively and the ores are often beneficiated. The beneficiation method varies according to the
location but usually includes crushing, screening, washing, Magnetite separation, and heavy media
separation and froth flotation.

The most important process in the production of magnesia from sea water and brines is the precipitation
of magnesium hydroxide from solutions of magnesium salts by the addition of by the addition of a strong
base (calcined limestone or calcined dolomite). The magnesium hydroxide precipitate is then washed,
thickened, filtered and calcined to produce magnesia. In another commercial process, concentrated
magnesium chloride (MgCl2) brine is sprayed into a thermal reactor where hot gases convert it to
magnesia and hydrogen chloride. The magnesia is slurried forming Mg(OH) 2 that is washed, filtered and
calcined to produce magnesia.

For refractory application, dead burnt (>1400) magnesia is used. Naturally occurring DBM is often
associated with higher qualities of silica and iron, while the synthetic magnesites are made by controlled
chemistry with is often associated with desired quantity of silica and calcia to attain higher density. Fused
magnesia is produced by at temperatures >2750OC by fusing magnesia in an electric arc furnace. The
fused magnesite is strength, abrasion resistance and chemical reactivity.

In the monolithic Refractories the greatest use of magnesia is in the gunning maintenance of basic oxygen
furnaces and electric furnaces. In recent years the use of Magnesite in tundish working lining has become
a regular practice and its consumption is increasing with time. The magnesite used in tundish lining does
not need to be of high quality since it is mixed with silicates and clay minerals to obtain the desired
properties and it can tolerate much higher amounts of impurities compared to other applications. Table - 1
shows the chemical analysis and densities of some available magnesites.

Table – 1: Chemical and physical properties for different Magnesites

Source Natural Natural Sea water Brine Brine

Density, g/cc 3.25-3.30 3.30-3.35 3.45-3.47 3.45-3.48 3.28-3.33
Chemical
analysis,%
MgO 85-88 90-91 98-99 95-96 97-98
SiO2 5-5.7 1-1.5 0.2-0.3 0.5-0.6 0.5-0.6
Fe2O3 3-4 5-6 0.2-0.3 0.2-0.4 0.1-0.2
Al2O3 1-2 1-1.5 0.2-0.4 0.2-0.4 0.1-0.2
CaO 2-3 1.5-2 1-1.5 2.2-2.4 1.5-2
Olivine

Dunite was, named after its olivine green color. It is a generic term used to indicate a group of ortho
silicate minerals in a solid solution series, with forsterite (2FeO.SiO2) as end points Olivine is a major
constituent of earth forming rocks. Therefore, it is found in varying quantities of alteration products, such
a serpentine (3MgO.2SiO2.2H2O). Dunite is an olivine containing rock with about 90% olivine. Olivine
has natural properties that support its use for a variety of application, viz, melting point of 1800 oC , low
heat conductivity, good insulating values (60-80% less than magnesite), high refractoriness level
(1760oC), no hydration, i.e., no calcinations is required before use, inert nature, Mohr’s hardness of 6.5-
7.0, specific gravity of 3.27-3.37 and bulk density of 1.5-2.0 g/cm3. Moreover, it is environmentally
friendly (contains no free silica), high chemical and mineralogical stability (due to strong forsterite
mineralogical binding) and high resistance to metal penetration (to both basic and acidic iron oxide-rich
Slags, alkaline oxides, sulfates carbonates and halides). Because olivine is inexpensive, it competes
favorably against higher-priced raw materials of similar chemistry. Olivine competes with magnesite as a
refractory mineral as well as in constables and tundish liners. In refractory incinerators, olivine has
technical advantages over other refractory materials including resistance to Slags attack, temperature and
spalling. Table- 2 shows the chemical composition of refractory- grade olivines.

Table – 2: Chemical and physical properties for different Olivines

Aaheim, Raubergvika, Raubergvika, Hamilton,

Norway Norway Norway Wash., USA
MgO 48-50 45-48 45-48 45-49
SiO2 41-43 41-43 39-42 39-42
Fe2O3 6.8-7.5 7.6-80 6-8 6-8
Al2O3 <1.0 <1.5 <1.0 <1.0
CaO <0.5 <1.0 <1.0 <1.0
L.O.I 0.5-1.2 0.8-1.2 0.8-1.4 0.5-1.0

EXPERIMENTAL:
In general application of DVM, the range of MgO content is in between 65 – 80% in final product.
Keeping this in mind ~ 75% MgO based DVM was designed based on DBM and Dunite along with
powder resin as binder. The chemical analysis of DBM and Dunite is shown in table – 3. Though Dunite
is available in India, DBM is imported from China and Turkey mainly. With the base material sintering
aids were added starting from 0.25% to 1.5%. The batch formulations are shown in table – 4. Properties
of powder resin and sintering aids are given in table – 5 & 6.

Table-3: Chemical composition of base raw materials

Raw materials MgO(%) Fe2O3 (%) SiO2 (%) CaO (%) Al2O3 (%) BD(g/cc)
DBM 94.8 0.66 1.84 2.22 0.12 3.37
Dunite 48.2 8.88 37.6 1.42 1.67 -
Table-4: Different batch formulation

Batch formulations Sintering Aids (%)

Sintering aids (A) 0.25 0.50 0.75 1.0 1.25
Sintering aids (B) 0.25 0.50 0.75 1.0 1.25

Table-5: Properties of powder resin

Property Value

Softening point (0C) 90 – 105

VM (%) 1.4 – 2.0

FC (%) 50 - 55

Fineness (mesh) 90% passing through 200 mesh sieve

Table-6: Properties of sintering aids

Property Sintering Aids (A) Sintering Aids (B)

B2O3 (%) 99.6 14 - 22

ZnO (%) - 2-3
SiO2 (%) - 56 - 60
Al2O3 (%) - 2.2 – 2.7
Fineness (mesh) 100% passing through 100 mesh 85% passing through 200 mesh

Different batches of 5kgs were made in Hobart Mixer with 5 minute dry mixing. To evaluate different
properties initially all the samples were prepared after curing at 200ºC with 2 hours soaking. The sample
size for each case was 50mm X 50 mm cube. The mould for sample preparation is shown in Fig. – 6

Firing was carried out at 400ºC, 600ºC, 800ºC, 1000ºC, 1200ºC, 1400ºC &1500ºC with 3 hours soaking in
ambient atmosphere. In case of PLC measurement initial length was taken after curing the sample at
200ºC for 2 hours. After firing at different temperatures, physical appearance was observed and CCS was
measured (where it was measurable).

RESULTS & DISCUSSION:

The physical appearance of samples after heat curing at 2000C is shown in Fig. – 7. CCS of all the
samples were measured along with the sample having no sintering aids (marked as “C”). The results are
shown in Fig.- 8.
Fig.-6: Mould for sample preparation Fig.-7: Appearance of samples after curing at 2000C

Sintering Aids - A Sintering Aids - B

120

100

80
CCS IN KG/CM2

60

40

20

0
0 0.25 0.5 0.75 1 1.25 1.5
SINTERING AIDS (%)
Fig.-8: Variation in CCS with different amount of sintering aids (at 2000C)

It is very interesting to observe the variation of CCS in presence of sintering aids. In both the cases there
is decreasing strength in presence of sintering aids. In general, sintering aids help to sinter the material at
relatively higher temperature and therefore increasing in strength. But presence of sintering aids in DVM
giving negative results i.e decreasing in CCS at 2000C. There is sudden decrease in strength even in
presence of 0.25%. The decreasing in strength is continuing with increasing amount of sintering aids. But
with sintering aids beyond 1% there is no significant decrease in strength is observed for sintering aids –
B. Whereas there is still decrease in strength is observed with increasing amount of sintering aids – A. But
in both the cases the decreasing is not significant with increasing amount from 0.5 to 1.25% against the
decrease in strength from 0% to 0.25%. The mechanism for decreasing strength in presence of sintering
aids need details analysis. In DVM, powder resin is the source for strength development after curing at
2000C through polymerization of resin. Presence of sintering aids may affect the degree of polymerization
by changing the pH of the system. Any change in pH of the system in presence of sintering aids may
affect the degree of polymerization.
The physical appearance of samples after firing at 4000C is shown in Fig. – 9 and variation in CCS is
shown in Fig. – 10. In case of sintering aids B there is almost no strength after firing at 4000C but samples
having sintering aids – A was relatively better in appearance as well as in strength. In presence of both the
sintering aids CCS is very low which is in between 0.25 Kg/cm2 to 2.5 Kg/cm2. Though the CCS after
firing at 4000C is very low but there is increasing strength with increasing amount of sintering aids – A.
But in case of sintering Aids – B, there is further decrease in CCS with increasing amount of sintering
aids – B.

Fig.-9: Appearance of sample after firing at 4000C (Left – Sintering Aids A & Right – Sintering Aids B)

2.5

2 Sintering Aids - A
CCS in Kg/cm2

1.5 Sintering Aids - B

0.5

0
0 0.25 0.5 0.75 1 1.25
SINTERING AIDS (%)

Fig.-10: Variation in CCS with increasing amount of sintering aids (at 4000C)
Fig.-11: Appearance of sample after firing at 6000C (Left – Sintering Aids A & Right – Sintering Aids B)

The same observation is found when samples were fired at 6000C & 8000C. The physical appearance of
samples after firing at 6000C is shown in Fig – 11 whereas the same is shown after firing at 8000 C in Fig
– 13. Both at 6000C and at 8000C the effect of sintering aids in not significant. But sintering aids A gives
slightly better strength than sintering aids – B at 6000C (Fig. 12).

While observing the variation in strength at 8000C with increasing amount of sintering aids there is
decreasing trend or same both for sintering aids A & B (Fig. 14) as because the strength is so low there
may be issues for measurement. But it is clear that there is no effect of sintering aids either A or B on
strength of DVM after firing at 8000C.

0.3

0.25 Sintering Aids - A

Sintering Aids - B
CCS in Kg/Cm2

0.2

0.15

0.1

0.05

0
0 0.25 0.5 0.75 1 1.25 1.5
SINTERING AIDS (%)

Fig.-12: Variation in CCS with increasing amount of sintering aids (at 6000C)
Fig.-13: Appearance of sample after firing at 8000C (Left – Sintering Aids A & Right – Sintering Aids B)

0.6
Sintering Aids - B
0.5
Sintering Aids - A
CCS in Kg/cm2

0.4

0.3

0.2

0.1

0
0 0.25 0.5 0.75 1 1.25 1.5
SINTERING AIDS (%)

Fig.-14: Variation in CCS with increasing amount of sintering aids (at 8000C)

The appearance of sample after firing at 10000C is good for both the sintering aids (Fig. 15). It indicates
that some liquid phase may form at this temperature which gives relatively better strength. But again the
effect of sintering aids – A is more effective than sintering aids – B whatever may be the amount (Fig.
16). For sintering aids – B there is no significant increase in strength when the amount is 0.5% and more.
But for sintering aids – A there is continuous increase in strength. Both the aids are having boron
compound but their melting point is different. In case of sintering aids – A melting point is low compare
to sintering aids – B and therefore it gives better strength at 10000C and above.
Fig.-15: Appearance of sample after firing at 10000C

1.8

1.6
Sintering Aids - A
1.4
Sintering Aids - B
1.2
CCS in Kg/cm2

0.8
0.6

0.4
0.2
0
0 0.25 0.5 0.75 1 1.25 1.5
SINTERING AIDS (%)

Fig.-16: Variation in CCS with increasing amount of sintering aids (at 10000C)

There is same behavior in strength after firing the sample at 12000C to 15000C. At 14000C there is
significant increase in strength of the material in presence of sintering aids – A. Even with increasing
amount of sintering aids – A there is increasing in strength. But in presence of sintering aids – B,
significant increase in strength is not observed. Even the strength is similar with higher amount of
sintering aids – B. It clearly indicates that sintering aids – A is having better sinter ability than sintering
aids – B.
Physical appearance of samples after firing at 12000C is shown in Fig. – 17 and variation of strength is
shown in Fig. – 18.
Fig.-17: Appearance of sample after firing at 12000C

2.5 Sintering Aids - A

CCS in Kg/Cm2

2 Sintering Aids - B
1.5

0.5

0
0 0.25 0.5 0.75 1 1.25 1.5
SINTERING AIDS (%)

Fig.-18: Variation in CCS with increasing amount of sintering aids (at 12000C)

Fig.-19: Appearance of sample after firing at 14000C (Left – Sintering Aids A, Right – Sintering Aids B)
80
70
60

CCS in Kg/Cm2
50
40
Sintering Aids - A
30
20 Sintering Aids - B
10
0
0 0.25 0.5 0.75 1 1.25 1.5
SINTERING AIDS (%)

Fig.-20: Variation in CCS with increasing amount of sintering aids (at 14000C)

Fig.-21: Appearance of sample after firing at 15000C (Left – Sintering Aids A, Right – Sintering Aids B)

The same behavior is observed while firing the samples at 15000C. There is continuous increase in
strength in presence of sintering aids – A but for sintering aids – B it is more or less same and there is no
effect on quantity of sintering aids – B (Fig. 22)

In Fig. 23 to 27 variation of strength is shown with fixed amount of sintering aids along with material
having no sintering aids. In all cases the strength is very low in between the temperature range of 4000C
to 12000C. Beyond 12000C there is significant increase in strength in presence of sintering aids – A
whatever may be the quantity. But for sintering aids – B increase in strength is not significant.
The increasing strength of the samples having sintering aids – B and having no sintering aids is similar
which indicates there is no effect on sintering of DVM in presence of sintering aids – B. Whatever
increase in strength is observed beyond 1200 C is due to normal sintering of the material.
160

140

120

100
CCS in Kg/cm2

80
Sintering Aids - A
60 Sintering Aids - B

40

20

0
0 0.25 0.5 0.75 1 1.25 1.5
SINTERING AIDS (%)

Fig.-22: Variation in CCS with increasing amount of sintering aids (at 15000C)

120

100
0.25% Sintering Aids (A)

80 0.25% Sintering Aids (B)

CCS in Kg/cm2

No Sintering Aids
60

40

20

0
0 200 400 600 800 1000 1200 1400 1600
Temp in OC

Fig.-23: Variation in CCS with temperature (Sintering Aids – 0.25%)

120
0.5% Sintering Aids (B)
100
No Sintering Aids
CCS in Kg/cm2

80 0.5% Sintering Aids (A)

60

40

20

0
0 200 400 600 800 1000 1200 1400 1600
Temp in OC

Fig.-24: Variation in CCS with temperature (Sintering Aids – 0.5%)

120

0.75% Sintering Aids (A)

100
0.75% Sintering Aids (B)
80
CCS in Kg/cm2

No Sintering Aids

60

40

20

0
0 200 400 600 800 1000 1200 1400 1600
Temp in OC

Fig.-25: Variation in CCS with temperature (Sintering Aids – 0.75%)

140

120 1% Sintering Aids (A)

1% Sintering Aiods (B)
100 No Sintering Aids
CCS in Kg/cm2

80

60

40

20

0
0 200 400 600 800 1000 1200 1400 1600
Temp inOC

Fig.-26: Variation in CCS with temperature (Sintering Aids – 1%)

160

140
1.25% Sintering Aids (A)
120 1.25% Sintering Aids (B)

100 No Sintering Aids

CCS in Kg/cm2

80

60

40

20

0
0 200 400 600 800 1000 1200 1400 1600
Temp in OC

Fig.-27: Variation in CCS with temperature (Sintering Aids – 1.25%)

1.6 sintering aid (A)
1.4 sintering aid (B)
1.2
1
Shrinkage %

0.8
0.6
0.4
0.2
0
0 0.25 0.5 0.75 1 1.25 1.5
% Sintering aids

Fig.-28: Shrinkage of the material after firing at 12000C

3 sintering aid (A)

2.5 sintering aid (B)
Shrinkage %

1.5

0.5

0
0 0.2 0.4 0.6 0.8 1 1.2 1.4
% Sintering aid

Fig.-29: Shrinkage of the material after firing at 14000C

sintering aid (A)
4
sintering aid (B)
3.5
3
Shrinkage %

2.5
2
1.5
1
0.5
0
0 0.25 0.5 0.75 1 1.25 1.5
% Sintering aid

Fig.-30: Shrinkage of the material after firing at 15000C

Shrinkage of all the materials measured at 12000C, 14000C and 15000C are shown in Fig. 28, 29 & 30.
There is direct relationship between shrinkage and strength development of the material. In case of
sintering aids A there is always higher shrinkage at all temperatures which indicates better sintering of the
material. In case of sintering aids – B there is not significant increase in shrinkage with increasing amount
at all temperature. Slight increase in shrinkage with increasing temperature is due to normal sintering of
the material.

CONCLUSIONS:
Dry vibratable mass is widely used in tundish working lining as it has several advantages over the
spraying mass. Since resin is the binder for this material it is important to design this material with other
sintering aids so that some strength will be there at intermediate temperature during secondary heating.
Two sintering aids were added in the present material with the amount of 0.25% to 1.25% to observe the
effect of strength improvement at different temperatures. It has been observed that there is decrease in
strength of existing material in presence of both the sintering aids while curing at 2000C where resin gives
strength through polymerization. The presence of sintering aids may affect the pH of the system followed
by the degree of polymerization. In between 4000C to 12000C there was almost no strength for all the
materials but sintering aids A gives slightly better strength at 10000C. Beyond 12000C there is significant
increase in strength in presence of sintering aids – A upto 15000C. Higher the firing temperature higher
the strength is observed for sintering aids A but for sintering aids B no significant improvement in
strength is observed with the firing temperature as well as with in increasing amount of it. From this study
it is clear that sintering aids – A is effective to improve the strength of DVM at intermediate temperature.
The dose of the additive depends upon the temperature of secondary heating and duration. However, 0.5
to 1% dose of sintering aids is optimum for this material.
REFERENCES

1. Study on the Properties and Performance of Dry Vibratable Mass for Tundish Lining- Aachen
2012. Dr. Raghunath Prasad Rana, Atanu Suvrajit Bal, Smita Satapathy, Dr. Sukumar Adak, Dr.
Arup Kumar Chattopadhyay.
2. G. Provost et.al. , Aachen Colloquium on Refractories Clean steel Refractories (1994)
3. H. Jocobi, Aachen Colloquium on Refractories Clean Steel Refractories
4. Phase diagrams for ceramists, E. Levin, et.al.1994
5. N. Bannenberg – 38 th Aach Int. Colloquium on Refractories, 1994
6. J. Lehmann, et.al. Advances in Refractories for the Metallurgical Industries II Montreal, 1996