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8 November 2017

NLMK Kaluga reduces refractory consumption by 25% thanks to its new ladle-lining scheme

Ladles are used to transport hot metal from the steelmaking furnace to the casting area. They are lined with refractories to reduce heat losses and protect them from high temperatures when in contact with hot metal and slag.

Previously, steel-pouring ladles at NLMK Kaluga were lined with refractory bricks. The new pilot scheme involves the use of liquid refractory concrete, which is poured between a special molding and the backup lining of the ladle walls and dried. This refractory scheme is an advanced global practice.

Sergey Shalyaev, CEO of NLMK Kaluga, said: “NLMK Group's Kaluga site was the first one to introduce steel casting ladle with cast refractories and we hope that this solution will be scaled out across the entire Group. The new lining scheme significantly increases the service life of the ladle working layer and reduces the specific consumption of refractory materials by 1/4. The estimated annual economic gains of the project will amount to close to 29.1 million rubles. This was made possible through well-coordinated and efficient work of experts and employees of NLMK Kaluga, part of NLMK Long Division".

The plant purchased new equipment and upgraded the infrastructure for steel ladles enhancement. In mid-October the EAF shop went into testing. After the experimental pouring of concrete, in late October steel-casting ladle No. 1 received the first heat from the EAF.

NLMK Kaluga is transferring all eight steel-casting ladles of the EAF shop to castable lining. The project is scheduled for completion in February 2018.