FIELD OF THE INVENTION
The present invention relates to developing refractory lining and more particularly zonal
refractory lining for hot metal ladles adapted to minimize wear and mouth jam. The present
invention is directed to developing a zonal refractory lining for ladle bottom, side walls and
top or mouth of ladle adapted to ensure a balanced wear throughout the ladle lining by
adopting using different quality bricks and castables at different zones having different
physico-chemical properties to take care of metal impact, erosion/corrosion as well as
abrasion resistance. Importantly, the new refractory lining design for the hot metal ladle
would favour reduced heat loss, easy dismantling in case of metal penetration through
working lining, less mouth jam and easy de-skulling, resulting in improved campaign life,
increased ladle availability, improved productivity at lowered cost of production. Selective
ladle lining design introduced for bottom, safety lining and working lining, comprising
castables and refractory bricks for conical bottom, side walls, slag portion, as well as top
portion and lip of ladle, involving Alumina-Silicon carbide-Carbon (AI2O3-SiC-C bricks) in slag
/mouth zone which are having non-wetting characteristics favoring less jamming and easy
de-skulling as well as use of 70% alumina low cement castable in top 200-250 mm and
spout has stopped dislodging of bricks and as a consequence, the ladle life is increased to
about 810 to 920 heats, from conventional 575-600 heats making hot metal ladles having
such refractory lining configuration capable of wide industrial application in steel plants for
transferring/carrying hot metal from blast furnace to mixers of Steel Making Shop with
enhanced ladle life requiring less repair/maintenance.
BCKGROUND ART
It is well known in the art of iron and steel making that Liquid hot metal (pig iron) is tapped
from blast furnace into ladles called hot metal ladles. These ladles are used to carry liquid
metal from blast furnace to mixers of Steel Melting Shop where hot metal from all the blast
furnaces is mixed for compositional homogeneity and temperature uniformity. This hot
metal is then taken to Basic Oxygen Furnaces or twin hearth furnaces for converting it into
steel.
On an average these ladles carry 3-4 heats per day. The lining design practiced in the
working lining of these conventional ladles is a single quality comprising 42% Al2O3 bricks.

It has been observed with the existing refractory lining for hot metal ladles in steel melting
shop that the average lining life obtained with above mentioned configuration is around 575
- 600 heats with 6-7 intermittent repairs. The wear profile study of these ladles with
conventional lining indicate that faster erosion/wear takes place in following areas:
a) Metal impact area of bottom conical where hot metal strikes.
b) Top portion (slag zone) where metal jam formation occurs and coming out of bricks
when removal of jam is attempted.
c) Lips where from the metal falls into the mixer.
There has thus been a need in the art of refractory lining design of hot metal ladles for
transferring liquid metal from blast furnace to steel making furnace/BOF in melting shop, to
developing a lining configuration and composition which would protect the lining against
abrasive wear, increase erosion/abrasion resistance, prevent metal impact wear and
minimize mouth jamming or easy cleaning of sticking metal and de-skulling, avoid falling
lining, damaged or jammed spout/mouth, prevent metal penetration through working lining
and also facilitate easy dismantling/relining if needed to thereby reduce down time of ladle,
increase ladle availability with increased number of heats and thus reducing cost of
operation.
OBJECTS OF THE INVENTION
The basic object of the present invention is thus directed to developing a refractory lining
composition and configuration for hot metal ladle with enhanced impact and abrasive wear
resistance to ensure longer ladle lining life with increased number of heats.
A further object of the present invention is directed to developing a refractory lining pattern
and composition as well as selective use of lining materials comprising castables and bricks
wherein the ladle bottom, side walls, top portion and lips are all protected against wear,
erosion and abrasion or metal jamming so that uninterrupted handling of successive heats is
possible.

A still further object of the present invention is directed to developing a refractory lining
configuration for hot metal ladles adapted to prevent heat loss from ladle by selective
provisioning of ceramic paper for safety lining while retaining molten metal within the ladle
for transfer to steel making furnace.
A still further object of the present invention is directed to developing a refractory lining
configuration for hot metal ladles wherein 50% alumina low cement castables with MS
anchoring is used for lining of shell to increase the durability of lining.
A still further object of the present invention is directed to developing a refractory lining
configuration for hot metal ladles wherein working lining comprising selective alumina bricks
for the bottom conical portion and is adapted to withstand metal impact and is resistant to
erosion.
A still further object of the present invention is directed to developing a refractory lining
configuration for hot metal ladles wherein alumina split bricks are used in between castable
and working lining for easy dismantling in case of metal penetration through working lining.
A still further object of the present invention is directed to developing a refractory lining
configuration for hot metal ladles that favour lesser skull formation and mouth jam and
resultantly stopped dislodging of bricks while removing such jam.
A still further object of the present invention is directed to developing a refractory lining
configuration for hot metal ladles whereby such ladles are adapted to transferring hot metal
weighing more than or equivalent to its capacity consistently due to less increase in tare
weight due to said lining.
A still further object of the present invention is directed to developing a refractory lining
configuration for hot metal ladles adapted to favor increased ladle availability because of
higher campaign life as well as reduction in frequency of breakdown/repairs.

SUMMARY OF THE INVENTION
This according to the basic aspect of the present invention there is provided an Al2O3 and
AI2O3-SiC-C refractory based zonal lining for hot metal ladle adapted to reduce wear and
mouth jam comprising:
(a) Slag zone/mouth area obtained of Al2O3-SiC-C bricks having
Al2O3 (%),min : in the range of 50-60;
Fe2O3 (%), Max. : in the range of 1.0-3.0;
SiC (%),min : in the range of 3.0-6.0;
Residual carbon (%),min : in the range of 6.0-10.0;
CCS (kg/cm2),min : in the range of 400;
HMOR, (kg/cm2) at 1400°C,min: in the range of 35-40;
Ap. Porosity (vol%),max : in the range of 8-10;
Bulk density (g/cm3),min : in the range of 2.65-2.70;
RUL (ta), Min. °C : in the range of 1650-1700;
PLC atl500°C/3hrs, %, max. :±1.5;
Size Tolerance :±1.5% or ± 2mm which is greater;
(b) Top ring and spout obtained of 70% low cement castables; and
(c )Bottom and bottom conical area obtained of 70% Al2O3 bricks comprising:
Al2O3 %(min): in the range of 65-75;
Fe2O3(max): in the range of 1.0 to 4.0;
PCE ( min): in the range of 30-40;
CCS (kg/cm2),min: in the range of 425-475;
Ap. Porosity (vol%),min: in the range of 20-23;
Bulk density (g/cm3),min.: in the range of 2.45-2.65;
PLC at 1500oC/3hrs, (%),max.: in the range of +3.0, Shrinkage: Nil;
RUL (ta), min. (°C): in the range of 1420-1460 °C;
Size Tolerance: ±1.5% or ± 2mm which is greater.

In accordance with a preferred aspect of the invention the Al2O3 and AI2O3-SiC-C refractory
based zonal lining for hot metal ladle as above comprises
(i) bottom lining comprising:
Casting with 50% alumina low cement castable (LCC) 300mm thick at ladle
bottom;
70% alumina bricks as working lining 200mm thick; and
30% alumina split brick 32mm thick, in between the castable and working lining;
(ii) safety lining comprising:
Ceramic fiber paper adjacent to shell;
Vibro-casting with 50% alumina Low Cement Castable (LCC) 60mm thick after
anchoring the shell with mild steel anchors;
30% alumina split bricks 32mm thick in between castable and working lining;
(iii) working lining comprising:
70% alumina bricks in bottom and bottom conical area of ladle, covering 1st to
10th layer of brick lines each 200mm thick;
high RUL(1470°C) and low porosity 45% alumina bricks in side wall covering 11th
to 26th layer of brick lining;
alumina-silicon carbide -carbon(AI2O3-SiC-C) bricks in slag zone covering top six
layers from 27th to 32nd ring;
vibro-casting of top portion and lips with 70% Al2O3 low cement castable 200-
250mm thick;
In the above AI2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle the
characteristics of 70% Alumina Bricks for bottom working lining to withstand metal impact
and erosion resistance, comprise:

AI2O3 %(min): in the range of 65-75;
Fe2O3(max): in the range of 1.0 to 4.0;
PCE ( min): in the range of 30-40;
CCS (kg/cm2),min: in the range of 425-475;
Ap. Porosity (vol%),min: in the range of 20-23;
Bulk density (g/cm3),min.: in the range of 2.45-2.65;
PLC at 1500oC/3hrs, (%),max.: in the range of +3.0, Shrinkage: Nil;
RUL (ta), min. (°C): in the range of 1420-1460 °C;
Size Tolerance: ±1.5% or ± 2mm which is greater.
In the above Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle the
characteristics of 45% Alumina bricks used in working lining for side wall, to increase
erosion resistance, comprise
AI2O3 %,min : in the range of 40-50
Fe2O3, %, Max. : in the range of 1.0-3.0
CaO+MgO, Max. % : in the range of 0.2-0.4
Alkalies, Max. % : in the range of 0.3-0.6
PCE (Orton) , min : 34;
CCS (kg/cm2),min : 340-260;
Ap. porosity (vol%),max : 17-19;
Bulk density (g/cm3),min : 2.25;
RUL (ta), Min. °C : 1470;
PLC 1450°C/2hr, max : ±0.5%;
Size Tolerance : ±1.5% or ± 2mm which is greater;
In the above Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle the
Alumina-Silicon carbide-Carbon (Al2O3-SiC-C) bricks having non-wetting characteristics used
in working lining of slag zone for less mouth jam and easy de-skulling, comprise
Al2O3 (%),min : in the range of 50-60;
Fe2O3 (%), Max. : in the range of 1.0-3.0;
SiC (%),min : in the range of 3.0-6.0;
Residual carbon (%),min : in the range of 6.0-10.0;
CCS (kg/cm2),min : in the range of 400;

HMOR, (kg/cm2) at 1400°C,min: in the range of 35-40;
Ap. Porosity (vol%),max : in the range of 8-10;
Bulk density (g/cm3),min : in the range of 2.65-2.70;
RUL (ta), Min. °C : in the range of 1650-1700;
PLC atl500°C/3hrs, %, max. :±1.5;
Size Tolerance :±1.5% or ± 2mm which is greater;
Advantageously, the Al2O3 and Al2O3-SiC-C refractory based zonal lining for hot metal ladle
of the invention involve working lining with 70% Al2O3 low cement castable comprising
vibro-casting covering top portion and two numbers lips to increase abrasion resistance of
metal and rigidity against pulling and stopping dislodging of bricks while removing jam.
According to an aspect in the Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot
metal ladle of the invention 5mm thick Ceramic fiber paper of safety lining adjacent to shell
is incorporated to reduce the heat loss from shell.
Also, preferably the vibro-casting with 50% LCC in safety lining is anchored with shell by
mild steel anchors for increasing the durability of lining.
Advantageously, the 30% alumina split bricks used in between castable and working lining
is used for easy dismantling in case of metal penetration through working lining.
Importantly, the hot metal ladle with said modified refractory lining configuration is capable
of transferring hot metal consistently more than or equivalent to its capacity due to less
increase in tare weight.
Advantageously also the said modified refractory lining configuration increased the ladle
availability by reduction of repairs and higher campaign life as well as increased number of
heats carried in the range of 817 to 925.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1: is the schematic illustration of the existing lining configuration of the hot metal
ladle showing ladle bottom and side walls comprising refractory bricks lining.

Figure 2: is the schematic illustration of the modified lining configuration for hot metal
ladles according to the present invention comprising 50% alumina based low cement
castable, AI2O3-SiC-C bricks, alumina split bricks etc., adapted to enhance campaign life
with increased number of heats handled by said ladle.
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE
ACCOMPANYING DRAWINGS
The present invention relates to developing modified and improved refractory lining
composition and configuration for steel ladles and more particularly zonal refractory lining
for hot metal ladles adapted to minimize impact wear, erosion/abrasion and mouth jam. The
present invention is directed to developing a zonal refractory lining for ladle bottom, side
walls and tip or mouth of ladle adapted to ensure a balanced wear throughout the ladle
lining by adopting using different quality bricks and castables at different zones having
different physico-chemical properties to take care of metal impact, erosion/corrosion or
heat loss problems experienced in the prior art, enhancing ladle life and number of heats
handled.
Reference is first invited to the accompanying Figure 1 that illustrates the existing lining
design of hot metal ladles capable to handle number of heats and is prone to frequent
failure of refractory lining needing down time to repair/relining.
The details of the conventional refractory lining presently existing are as given below:
Conventional lining :
(a) Bottom:
i) 400 mm casting with 60% Alumina castable;
ii) 150 mm bricks of 42% Alumina working lining;
(b) Side walls:
(i) Safety lining : comprising 60% Alumina castable of 40mm thick plus Fireclay bricks of
40mm thick;

(ii) Working lining: comprising 42% Alumina bricks with variation in lining thickness as
follows:
a) 1st to 4th layer: 180 mm;
b) 5th to 22nd layer: 135 mm;
c) 23rd to 29th layer: 100 mm;
(iii) Lip lining: Cast with 60% Alumina castable.
The average lining life obtained with this lining is around 575 - 600 heats with 6-7
intermittent repairs. The wear profile study of these ladles with conventional lining indicate
that faster erosion / wear takes place in following areas:
d) Metal impact area of bottom conical where hot metal strikes.
e) Top portion (slag zone) where metal jam formation occurs and bricks come out when
removing the jam.
f) Lips from where from the metal falls into the mixer.
In order to have a balanced wear throughout the ladle lining, a new zonal working lining has
been developed using different quality bricks and castabies at different zones having
different physico-chemical properties to take care of metal impact, erosion/ corrosion as
well as abrasion resistance. Lining thickness has also been modified suitably to meet
requirements of strength and thermal properties.
Reference is now invited to the accompanying Figure 2 that schematically illustrates the
modified and improved refractory lining according to the present invention comprising
selectively disposed ceramic paper, alumina low cement castabies as well as selectively
configured refractory bricks for lining different locations inside the ladle such as the ladle
bottom, conical portion at bottom, the side walls, the top portion and lip, in order to have
longer campaign life/ladle life and increased number of heats.
It would be clearly apparent from the accompanying Figure 2, that the modified lining
design for hot metal ladle comprises:

A Modified Zonal lining developed according to the present invention wherein the respective
zones comprising:
(a) The bottom lining comprising: i) Casting with 50% alumina low cement castable
(LCC):300mm; ii) 30% alumina split bricks: 32mm; and iii) 45% alumina bricks as
working lining: 200mm;
(b) Safety lining comprising : a) Introduction of a new safety lining design using 5 mm
ceramic fibre paper adjacent to shell to reduce the heat loss; b) Vibro-casting with 50%
Alumina Low cement castable (60 mm) after anchoring the shell with mild steel anchor for
increasing the durability of the lining; c) Use of 30% Alumina split bricks (32 mm) in-
between castable and working lining for easy dismantling in case of metal penetration
through working lining.
(c) Working lining comprising : a) Introduction of 70% Alumina bricks in bottom (with
increased thickness 200 mm as against 150 mm used conventionally and bottom conical
area (1st to 10th) to withstand metal impact and erosion resistance.
The characteristics of this lining of 70% Alumina Bricks are as follows:
Al2O3 %(min): in the range of 65-75;
Fe2O3(max): in the range of 1.0 to 4.0;
PCE (min): in the range of 30-40;
CCS (kg/cm2),min: in the range of 425-475;
Ap. Porosity (vol%),min: in the range of 20-23;
Bulk density (g/cm3),min.: in the range of 2.45-2.65;
PLC at 1500oC/3hrs, (%),max.: in the range of +3.0, Shrinkage: Nil;
RUL (ta), min, (°C): in the range of 1420-1460°C;
Size Tolerance: ±1.5% or ± 2mm which is greater.
b) The characteristics of the high RUL (1470°C) and low porosity 45% Alumina bricks used
in11th to 26th layers of side wall, to increase erosion resistance, are as given below:

Al2O3 %,min : in the range of 40-50
Fe2O3, %, Max. : in the range of 1.0-3.0
CaO+MgO, Max. % : in the range of 0.2-0.4
Alkalies, Max. % : in the range of 0.3-0.6
PCE (Orton) , min : 34;
CCS (kg/cm2),min : 340-260;
Ap. porosity (vol%),max : 17-19;
Bulk density (g/cm3),min : 2.25;
RUL (ta), Min. °C : 1470;
PLC 1450°C/2hr, max : ±0.5%;
Size Tolerance : ±1.5% or ± 2mm which is greater;
c) The characteristics of the Alumina-Silicon carbide-Carbon (Al2O3 -SiC-C ) bricks lining
introduced in slag zone/top 6 rings (27th to 34th ring/layer) adapted to ensure less mouth
jam and easy de-skulling are as follows:
Al2O3 (%),min : in the range of 50-60;
Fe2O3 (%), Max. : in the range of 1.0-3.0;
SiC (%),min : in the range of 3.0-6.0;
Residual carbon (%),min : in the range of 6.0-10.0;
CCS (kg/cm2),min : in the range of 400;
HMOR, (kg/cm2) at 1400°C,min: in the range of 35-40;
Ap. Porosity (vol%),max : in the range of 8-10;
Bulk density (g/cm3),min : in the range of 2.65-2.70;
RUL (ta), Min. °C : in the range of 1650-1700;
PLC atl500°C/3hrs, %, max. :±1.5;
Size Tolerance :±1.5% or ± 2mm which is greater;
d) Vibro casting of top portion (200-250 mm) and lips (2 nos) with 70 % Al2O3 low cement
castable introduced in the modified lining configuration according to the present invention in
order to increase abrasion resistance of metal and rigidity against pulling.

It is thus possible by way of the present invention to developing a zonal refractory lining for
ladle bottom, side walls and top or mouth of ladle adapted to ensure a balanced wear
throughout the ladle lining by adopting using different quality bricks and castables at
different zones having different physico-chemical properties to take care of metal impact,
erosion/corrosion as well as abrasion resistance and increasing the campaign life and
number of heats handled needing fewer repair. Importantly, the new refractory lining
design for the hot metal ladle would favour improved resistance to impact wear, erosion and
corrosion/abrasion resistance, reduced heat loss, easy dismantling in case of metal
penetration through working lining, less mouth jam and easy de-skulling, resulting in
improved campaign life, increased ladle availability, improved productivity at lowered cost of
production and thus favoring wide industrial application in iron and steel industries.

We claim:
1. Al2O3 and Al2O3-SiC-C refractory based zonal lining for hot metal ladle adapted to
reduce wear and mouth jam comprising:
(a) Slag zone/mouth area obtained of Al2O3-SiC-C bricks having
AI2O3 (%),min : in the range of 50-60;
Fe2O3 (%), Max. : in the range of 1-0-3.0;
SiC (%),min : in the range of 3.0-6.0;
Residual carbon (%),min: in the range of 6.0-10.0;
CCS (kg/cm2),min : in the range of 400;
HMOR, (kg/cm2) at 1400°C,min: in the range of 35-40;
Ap. Porosity (vol%),max: in the range of 8-10;
Bulk density (g/cm3),min: in the range of 2.65-2.70;
RUL (ta), Min. °C : in the range of 1650-1700;
PLC atl500°C/3hrs, %, max.:±1.5;
Size Tolerance :±1.5% or ± 2mm which is greater;
(b) Top ring and spout obtained of of 70% low cement castables; and
(c ) Bottom and bottom conical area obtained of 70% Al2O3 bricks comprising:
Al2O3 %(min): in the range of 65-75;
Fe2O3(max): in the range of 1.0 to 4.0;
PCE ( min): in the range of 30-40;
CCS (kg/cm2),min: in the range of 425-475;
Ap. Porosity (vol%),min: in the range of 20-23;
Bulk density (g/cm3),min.: in the range of 2.45-2.65;
PLC at 1500oC/3hrs, (%),max.: in the range of +3.0, Shrinkage: Nil;
RUL (ta), min. (°C): in the range of 1420-1460°C;
Size Tolerance: ±1.5% or ± 2mm which is greater.

2. Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in claim
1 comprising
(i ) bottom lining comprising:
Casting with 50% alumina low cement castable (LCC) 300m thick at ladle
bottom;
70% alumina bricks as working lining 200mm thick; and
30% alumina split brick 32mm thick, in between the castable and working lining;
(ii) safety lining comprising:
Ceramic fiber paper adjacent to shell;
Vibro-casting with 50% alumina Low Cement Castable (LCC) 60mm thick after
anchoring the shell with mild steel anchors;
30% alumina split bricks 32mm thick in between castable and working lining;
(iii) working lining comprising:
70% alumina bricks in bottom and bottom conical area of ladle, covering 1st to
10th layer of brick lines each 200mm thick;
high RUL(1470°C) and low porosity 45% alumina bricks in side wall covering 11th
to 26th layer of brick lining;
alumina-silicon carbide -carbon(AI2O3-SiC-C) bricks in slag zone covering top six
layers from 27th to 32nd ring;
vibro-casting of top portion and lips with 70% Al2O3 low cement castable 200-
250mm thick;

3. Al2O3 and AI2O3-S1C-C refractory based zonal lining for hot metal ladle as claimed in
anyone of claims 1 or 2 wherein the characteristics of 70% Alumina Bricks for bottom
working lining to withstand metal impact and erosion resistance, comprise:
Al2O3 %(min): in the range of 65-75;
Fe2O3(max): in the range of 1.0 to 4.0;
PCE ( min): in the range of 30-40;
CCS (kg/cm2),min: in the range of 425-475;
Ap. Porosity (vol%),min: in the range of 20-23;
Bulk density (g/cm3),min.: in the range of 2.45-2.65;
PLC at 1500oC/3hrs, (%),max.: in the range of +3.0, Shrinkage: Nil;
RUL (ta), min. (°C): in the range of 1420-1460 °C;
Size Tolerance: ±1.5% or ± 2mm which is greater.
4. AI2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in
claims 1 to 3 wherein the characteristics of 45% Alumina bricks used in working lining for
side wall, to increase erosion resistance, comprise
Al2O3 %,min : in the range of 40-50
Fe2O3, %, Max. : in the range of 1.0-3.0
CaO+MgO, Max. % : in the range of 0.2-0.4
Alkalies, Max. % : in the range of 0.3-0.6
PCE (Orton), min : 34;
CCS (kg/cm2),min : 340-260;
Ap. porosity (vol%),max : 17-19;
Bulk density (g/cm3),min : 2.25;
RUL (ta), Min. °C : 1470;
PLC 1450°C/2hr, max : ±0.5%;
Size Tolerance : ±1.5% or ± 2mm which is greater;
5. Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in
claims 1 to 4 wherein the Alumina-Silicon carbide-Carbon (Al2O3-SiC-C) bricks having non-
wetting characteristics used in working lining of slag zone for less mouth jam and easy de-
skulling, comprise

AI2O3 (%),min : in the range of 50-60;
Fe2O3 (%), Max. : in the range of 1.0-3.0;
SiC (%),min : in the range of 3.0-6.0;
Residual carbon (%),min : in the range of 6.0-10.0;
CCS (kg/cm2),min : in the range of 400;
HMOR, (kg/cm2) at 1400°C,min: in the range of 35-40;
Ap. Porosity (vol%),max : in the range of 8-10;
Bulk density (g/cm3),min : in the range of 2.65-2.70;
RUL (ta), Min. °C : in the range of 1650-1700;
PLC atlS00°C/3hrs, %, max. :±1.5;
Size Tolerance :±1.5% or ± 2mm which is greater;
6. Al2O3 and Al2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in
claims 1 to 5 wherein working lining with 70% Al2O3 low cement castable comprising vibro-
casting covering top portion and two numbers lips to increase abrasion resistance of metal
and rigidity against pulling and stopping dislodging of bricks while removing jam.
7. Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in
claims 1 to 6 wherein 5mm thick Ceramic fiber paper of safety lining adjacent to shell
incorporated to reduce the heat loss from shell.
8. Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in
claims 1 to 7 wherein vibro-casting with 50% LCC in safety lining is anchored with shell by
mild steel anchors for increasing the durability of lining.
9. Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in
claims 1 to 8 wherein 30% alumina split bricks used in between castable and working lining
is used for easy dismantling in case of metal penetration through working lining.
10. Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in
claims 1 to 9 wherein hot metal ladle with said modified refractory lining configuration is
capable of transferring hot metal consistently more than 80 ton due to less increase in tare
weight.

11. Al2O3 and Al2O3-SiC-C refractory based zonal lining for hot metal ladle as claimed in
claims l to 10 wherein said modified refractory lining configuration increased the ladle
availability by reduction of repairs and higher campaign life as well as increased number of
heats carried in the range of 817 to 925.
12. Al2O3 and AI2O3-SiC-C refractory based zonal lining for hot metal ladle comprising
castables and bricks adapted to reduce wear and mouth jam substantially as
hereindescribed with reference to the non limiting illustrative drawings.

The present invention relates to zonal refractory lining for hot metal ladles adapted to
minimize wear and mouth jam. The zonal refractory lining is adapted to ensure a balanced
wear throughout the ladle lining, using materials having different physico-chemical
properties to take care of metal impact, erosion/corrosion and abrasion resistance.
Importantly, the lining reduced heat loss, easy dismantling in case of metal penetration
through working lining, less mouth jam and easy de-skulling, favoring improved campaign
life, increased ladle availability, at lowered production cost. The ladle lining comprised
castables and refractory bricks involving Alumina-Silicon carbide-Carbon (Al2O3-SiC-C
bricks) in slag /mouth zone as well as use of 70% alumina low cement castable in top 200-
250 mm and spout. Consequently, the ladle life is increased to about 817 to 925 heats,
compared to conventional 575-600 heats favoring wide industrial application of such
ladles/linings in steel plants for transferring/carrying hot metal from blast furnace to mixers
of Steel Making Shop.