How to increase ladle plug life?
How to increase ladle plug life?
· Longer plug helps to increase the life of the plug but the plug needs to be of the same thickness as that of the ladle bottom.
· Material of better quality and composition especially with better abrasion and thermal shock resistant is desirable.
· Upgrading the surrounding block. The bock protects the plug and the premature of the block failure will cause wear from the sides rather than from the hot face.
· Reduced flow rate will decrease stress on the plug. The rate of wear of the plug is proportional to the gas flow rate.
· A larger diameter plug is beneficial.
· A larger block with more protection is useful if the block wear is responsible for the accelerated wear rate.
· Choosing the right balance of hole (slit vs circular vs porous). The wear characteristics are different for different designs. Choosing the right design is key in reducing the wear rate.
How to prevent plug breakouts?
· Decreasing the formation of aggressive slag – Process control like reducing excess oxygen lancing and eliminating bottom jam.
· Discarding poor installation techniques: Proper installation standard techniques are important in preventing plug breakouts. (Eg-The quality and thickness of mortar used is important as steel can infiltrate easily through thicker layer).
· Improving plug quality- The material must possess excellent abrasion, thermal shock, and high-temperature resistant properties.
· Better visual inspection- laser measurement and visual inspection by trained professionals can cut down the breakout frequency.
· Improving the tie-down system. The solid design ensures no movement of the plug during service
