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Smooth solutions for steel ladle

Seven Cast

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Seven Shot

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Seven Flow

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Seven Refractories has supplied a variety of safety and working linings for ladles up to 400 tons capacity.

For the different steel ladle zones and wear mechanisms, Seven Refractories offers a variety of castable materials for vibrating, self-flowing and shotcrete applications.

The benefits of this advanced technology are:

  • ladle lifetime expansion
  • performance increase in heats
  • better resistance to steel and slag
  • compatibility with all types of covering powders
  • chemical attack resistance
  • abrasion resistance
  • thermal shock resistance
  • mechanical strength
  • ease of installation
  • potential cost reduction
  • decreased leakage and infiltration risks
  • smaller maintenance repairs instead of total ladle relining
  • reduced material wastage in comparison with the full demolition of a brick lined ladle
  • potentially higher productive volume due to a thinner refractory layer
  • potentially “endless” lining

 

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    Green advantages

    Reduce the quantity of materials destined to landfill increasing the shares of unshaped in the steelmaking application. Solutions for steel ladle such as monolithic sidewall or maintenance with continuous applications of shotcrete increase the life cycle of the steel ladles and reduce the number of repairs, reducing also the quantity of bricks that have to be disposed in the landfill.

    The trials conducted on monolithic ladles have shown that with a combined technology of monolithic sidewall and sequential shotcrete repairs the performance (measured in number of heats) can be doubled.

    There are also advantages when it comes to waste reduction and recycling.

    2 main features show the benefits of monolithic lining for steel production:

    Extension of ladle campaign reducing the quantity of sets of bricks for relining

      Reduction of the waste connected to the demolition of the ladle and the end of the campaign

      The portion of the lining that hasn’t worked will be kept as backbone for the new material to be casted on top of it

      Reduction of CO2 emission related to heating up of steel ladle after each campaign, using carbon-free refractory materials (based on pure Al2O3 and Spinel)

    Smooth Solutions for Steel Ladles

    Some of the most modern steel plants in the world are successfully supplied with Smooth Solutions by Seven Refractories.

    Over the past years, advanced monolithic solutions have also become more and more attractive in price when compared with traditional brick installations. As a partner of major steel producers, Seven Refractories has developed technically superior alternatives to bricks.

    With Smooth Solutions, a considerable expansion in lifetime and a performance increase in heats could be achieved. Customers benefit from our advanced technology and potential cost reduction.

     

    Steel Ladle Products

    Alumina-spinel monolithic refractories have been used in steel ladles since the beginning of the 1990’s, but only nowadays the utilization of those materials is becoming a common practice. This concept gives an answer to the different wear patterns due to its unique characteristic in terms of physical and chemical properties.

    Seven Refractories has developed several optimized products for different steel ladle zones depending on the dominant wear mechanism:

    Benefits

    High resistance to steel and slag contact, compatibility with all types of covering powders, abrasion resistance, high mechanical strength, all coupled together with an enhanced ease of installation, make Seven Smooth Solutions the preferred material for the requirements of modern steel plants.

    Joint-free refractory linings substantially improve safety during steel ladle operations as they decrease the risk of leakage and infiltration. While traditional bricks are completely removed at the ladle campaign end, a potentially “endless lining” needs only smaller maintenance repairs.

    When the ladle walls are installed with monolithic refractories instead of bricks a potentially thinner layer could be the result. This may increase the productive inner volume of the ladle.

    Seven Smooth Solutions can also be applied as self-flowing materials where vibrating mixes cannot be easily applied or where casting is not technically suitable.


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    Seven Flow | Seven Cast | Seven Shot help to improve the following:

    • Impact of intense stirring in vacuum degasser and secondary metallurgy processes
    • Increased tapping temperature and exothermic reactions by alloying and hot spots by thermal heating
    • Stability of the mineral oxide compounds against reduction or deoxidation
    • Corrosion resistance and penetration of aggressive composition slags into the lining pores
    • Steel shell elastic deformation by liquid steel charging, transport and tilting
    • Thermal shock in any situation
    • Increased liquid steel residence time
    • Ultra-low carbon steel requirements preventing carbon pickup from the lining wall

     

    Benefits of a modern castable for steel ladle linings:

    • Enables potential ‘endless repair’ practices
    • Helps safeguard the steel quality
    • Ensures safety during operation due to absence of gases during heating up
    • Limitation of lining cracks and steel penetration to the safety lining
    • High thermal and thermo-mechanical stability
    • Increase of erosion and corrosion resistance
    • Improved resistance to thermal spalling
    • Enhanced the thermal cycling
    • Reduction in refractory consumption
    • Reduction in waste material
    • No CO2 emission during heating up due to the water-based binder
    • Contribution to environmental protection

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    COMPLETE CUSTOMER SERVICE

    • Preliminary study and investigation for the entire project
    • Design and architecture including bill of materials and thermal calculation
    • Full range of products for lining and maintenance
    • Supply of mixers, gunning machines, pumps, etc.
    • Training on mixing, gunning, and maintenance techniques
    • Training on equipment usage
    • Supervision and monitoring by experienced technicians
    • Global research & development
    • Technical advice by experts
    • Monitoring and targeting of results