Refractory Design for Electric Arc Furnace (EAF)
2026-04-10
Refractory Design for Electric Arc Furnace (EAF)
一、设计核心原则（Design Principles）
高温适配原则
耐材耐火度≥1800℃，热点区≥2000℃，匹配电弧高温（1600-1900℃）。
Refractoriness ≥1800℃, hot spot ≥2000℃, matching arc high temperature (1600-1900℃).
碱性渣适配原则
炼钢渣为高 CaO/FeO 碱性渣，必须选用镁质（MgO）系耐材（抗碱性渣最优）。
Steelmaking slag is high CaO/FeO basic slag, MgO-based refractories are mandatory (best basic slag resistance).
分区寿命同步原则
热点、渣线、炉顶、炉底采用差异化材质，实现全炉衬同步损毁、同步检修。
Differentiated materials for hot spot, slag line, roof, hearth to achieve synchronous lining wear and maintenance.
复合结构原则
永久层（稳定承重）+ 工作层（抗侵蚀）+ 隔热层（节能），UHP 炉配水冷壁 + 挂渣保护。
Permanent layer (stable load-bearing) + working layer (corrosion resistance) + insulating layer (energy saving); UHP EAF with water-cooled wall + slag coating protection.
抗热震与高导热原则
渣线 / 热点需高导热镁碳砖（快速散热、防脱碳）；炉顶需高抗热震材质。
Slag line/hot spot: high thermal conductivity MgO-C bricks (fast heat dissipation, anti-decarburization); Roof: high thermal shock resistance materials.
二、损毁机理（Damage Mechanisms）
- 电弧高温辐射：电极区温度超 2000℃，耐材软化、氧化、脱碳。
- Arc high-temperature radiation: >2000℃ near electrodes, causing softening, oxidation, decarburization.
- 碱性渣侵蚀：FeO/CaO/SiO₂渗透镁质材料，形成低熔点相，冲刷剥落。
- Basic slag corrosion: FeO/CaO/SiO₂ penetration, forming low-melting phases, erosion and spalling.
- 热震冲击：频繁开炉盖、出钢，温度骤变（1800℃→室温），裂纹剥落。
- Thermal shock: frequent roof opening, tapping, rapid temp change (1800℃→room temp), cracking and spalling.
- 机械冲击：废钢加料撞击、钢渣流动冲刷、炉体振动。
- Mechanical impact: scrap charging impact, slag flow erosion, furnace vibration.
- 氧化脱碳：镁碳砖表面 C 被氧化，强度下降、结构疏松。
- Oxidative decarburization: C in MgO-C bricks oxidized, strength loss, structure loosening.
三、炉衬结构体系（Lining Structure Systems）
1. 永久层（Permanent Layer）
- 材质：高纯镁砖、镁质捣打料
- Material: High-purity magnesia bricks， magnesia ramming mix
2. 工作层（Working Layer）
- 炉墙 / 渣线：镁碳砖（MgO-C）
- Furnace wall/slag line: Magnesia-carbon bricks (MgO-C)
- 炉顶：高铝砖、镁铬砖、铝镁浇注料
- Furnace roof: High-alumina bricks, magnesia-chrome bricks, alumina-magnesia castable
- 炉底：电熔镁砂捣打料、镁碳砖
- Furnace hearth: Fused magnesia ramming mix, MgO-C bricks
3. 隔热层（Insulating Layer）
- 材质：镁质隔热砖、纳米微孔板、陶瓷纤维板
- Material: magnesia insulating bricks, nano-microporous boards, ceramic fiber boards
- 作用：减少散热、控制炉壳温度≤80℃
- Function: reduce heat loss, control shell temp ≤80℃
四、分区耐材选型（Zone-based Refractory Selection）
1. 炉顶（Furnace Roof / Dome）
工况：电弧强辐射、频繁启闭、热震剧烈、粉尘冲刷
Conditions: strong arc radiation, frequent opening/closing, severe thermal shock, dust erosion
- 工作层：高铝砖、高铝浇注料
- Working layer: High-alumina bricks , high-alumina castable
- 超高功率（UHP）电弧炉：
- 工作层：镁碳砖、镁铬砖、镁铝尖晶石砖
- Working layer: MGO C BRICK ,magnesia-chrome bricks, magnesia-alumina spinel bricks
- 电极孔 / 热点：镁碳砖、刚玉预制件
- Electrode hole/hot spot: MgO-C bricks , corundum precast blocks
- 永久层：高纯镁砖、轻质镁砖
- Permanent layer: high-purity magnesia bricks,
炉墙（Furnace Wall）
分一般炉墙、热点区、渣线区、炉门区（损毁最严重）
Divided into general wall, hot zone, slag line, door zone (most severe damage)
- 一般炉墙：
- 材质：镁碳砖、白云石砖
- Material: Magnesia carbon bricks , dolomite bricks
- 热点区（电极附近）：
- 材质：高性能镁碳砖（
- Material: High-performance MgO-C bricks
- 渣线区（钢 - 渣界面）：
- 材质：镁碳砖、镁钙碳砖
- Material: MgO-C bricks , magnesia-calcium-carbon bricks
- 特点：抗 FeO 渗透、抗渣侵蚀最强
- Features: best resistance to FeO penetration and slag corrosion
- 炉门 / 加料口区：
- 材质：高抗热震镁碳砖、镁铬砖
- Material: High thermal shock MgO-C bricks, magnesia-chrome bricks
3. 炉底 & 炉坡（Hearth & Slope）
工况：钢水静压力、渣渗透、废钢冲击、高温侵蚀
Conditions: molten steel static pressure, slag penetration, scrap impact, high-temperature corrosion
- 永久层：镁砖、镁质捣打料
- Permanent layer: magnesia bricks, magnesia ramming mix
- 工作层（炉底）：
- 材质：电熔镁砂捣打料、镁碳砖
- Material: Fused magnesia ramming mix , MgO-C bricks
- 厚度：400-600mm
- Thickness: 400-600mm
- 炉坡（堤坡）：
- 材质：镁碳砖、镁质捣打料
- Material: MgO-C bricks, magnesia ramming mix
- 结构：斜坡设计，利于出钢、抗冲刷
- Structure: sloped design for tapping and erosion resistance
4. 出钢口（Tapping Hole / EBT）
工况：高温钢流冲刷、热震、渣侵蚀、频繁烧氧开口
Conditions: high-temperature steel flow erosion, thermal shock, slag corrosion, frequent oxygen burning
- 材质：镁碳砖、刚玉 - 尖晶石浇注料
- Material: MgO-C bricks 、corundum-spinel castable
- 结构：整体预制块、套筒式、内外层复合
- Structure: monolithic precast blocks, sleeve type, inner-outer composite
- 寿命：300-500 炉次（定期更换 / 喷补）
- Service life: 300-500 heats (regular replacement/gunning)
五、关键设计要点（Key Design Points）
1. 厚度设计（Thickness Design）
- 炉顶：400-500mm（UHP 500-600mm）
- Roof: 400-500mm (UHP 500-600mm)
- 炉墙：350-450mm（热点 / 渣线 450-550mm）
- Wall: 350-450mm (hot spot/slag line 450-550mm)
- 炉底：500-800mm
- Hearth: 500-800mm
2. 膨胀缝（Expansion Joints）
- 镁碳砖：纵向 5-7m、横向 3-4m 设缝，宽 6-10mm，填陶瓷纤维绳
- MgO-C bricks: joints every 5-7m (longitudinal), 3-4m (transverse), 6-10mm width, filled with ceramic fiber rope
- 炉顶：环向 / 径向缝，宽 8-12mm
- Roof: circumferential/radial joints, 8-12mm width
3. 锚固与吊挂（Anchoring & Suspension）
- 炉顶：耐热钢
- Roof: heat-resistant steel
- 炉墙：托砖板、金属锚固件，配合水冷箱固定
- Wall: brick supports, metal anchors, fixed with water cooling boxes
4. 水冷与挂渣设计（Water Cooling & Slag Coating）
- UHP 炉：炉墙 70% 面积设水冷箱 / 水冷套
- UHP EAF: 70% wall area with water cooling boxes/jackets
- 内表面喷涂镁质涂料，冶炼时挂渣形成自保护层，延长寿命 30%+
- Inner surface coated with magnesia coating, forming self-protective slag layer during smelting, life +30%+
六、主流材质性能（Key Material Properties）
| 中文名称 | English Name | 核心成分 | 最高温度 | 核心优势 | 适用部位 |
|---|---|---|---|---|---|
| 镁碳砖 | MgO-C Bricks | MgO 75-85%, C 10-18% | 1800℃ | 抗渣强、抗热震、高导热 | 渣线、热点、炉墙、出钢口 |
| 高纯镁砖 | High-Purity MgO Bricks | MgO≥95% | 1750℃ | 耐高温、稳定 | 永久层、一般炉墙 |
| 镁铬砖 | MgO-Cr₂O₃ Bricks | MgO 65-75%, Cr₂O₃ 15-20% | 1850℃ | 抗侵蚀、抗热震 | 炉顶、炉门、强侵蚀区 |
| 电熔镁砂捣打料 | Fused MgO Ramming Mix | MgO≥95% | 1800℃ | 整体性好、致密 | 炉底、炉坡 |
| 高铝砖 | High-Alumina Bricks | Al₂O₃ 75-85% | 1750℃ | 抗热震、价廉 | 普通炉顶、烟道 |
七、寿命与维护（Service Life & Maintenance）
- 炉墙（镁碳砖）：300-800 炉次（UHP + 喷补可达 1000+）
- Wall (MgO-C): 300-800 heats (UHP+gunning ≥1000)
- 炉顶：200-400 炉次
- roof: 200-400 heats
- 炉底：800-1500 炉次
- Hearth: 800-1500 heats
- 维护：镁质喷补料（定期热喷补）、手投料、挖补，同步延长寿命
- Maintenance: magnesia gunning mix (regular hot gunning), patching mix, digging repair
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2026-04-10
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