Document MomJJ6B25BnKeyeavaEjp9Q59

Weirton Steel Company Weirton, M. Va. October 17 J. A. Fierce cc:'Mr. Walter Sllman, M.3.Detrick Co., Pittsburgh Mr. James Thomas, M.H.Detrick Co., Pittsburgh cc: R.A.Buchholz (2) J.A.Fierce j Chicago Office (2) File L.L.Gill /' 1------ ^ / 58 PERSONNEL INTERVIEWED: Mr. Ludwig, Assistant Supt. Sinter Plant Following a preliminary inspection with Mr. Buchholz on the 15th, I net Mr. Thomas of the M. a. Detrick Co. at Weirton today to inspect the condition of the refractory lining of the new sinter line Ignition hood, the line being down for repairs for the second time since starting operation!in June 1958. The primary purpose of the repair at this time was to remove excessive accumulation of build-up which was strongly adhered to the lower parts of the ANCHOR and ANCHOR DASH lining and to repair a hole which had developed in the lining over one of the side burners. It had been noted earlier during operations that some of the castable packing used around burner blocks was running out and these holes were also filled with a competitive super plastic fixe brick which was the only type of material used in any ef these present repairs. The Koppers erection drawing for this furnace was not explicit as to the type of castable to be used around the burners although there was a verbal understanding that it was to be H-W HIGH ALUMINA CASTABLE. H-W 85 LIGHTWEIGHT CASTABLE was supplied for other parts of the unit and the performance ef the material around the burner blocks leaves considerable question as to just what was used in that location. Samples could not be obtained. Because of the considerable emphasis being placed on sinter lines over the country, the purpose of this visit was to help evaluate refractory' performance. The ANCHOR DASH brick in the roof looked excellent and leave nothing to be desired. The same is true for the upper side walls and end walla above the burners. The hole in the one side wall mentioned above was merely due to the loss of two whole brick in some unexplained manner. - continued - Weirton Staal Co. -2 - October 17, 1958 There was 3oaa evidence of catting out in the lower wells in several locations: 1. below the heck wall burners which are angled down. This is an indication of localized overheating due to direct impingement of the combustion cone. 2. Some evidence of concentrated wear in the corners which would seam to be caused by recirculating gases, that is, eddy currents. It was estimated that approximately 7" of brickwork remained from an original thickness of from 10 to 12" in the areas of greatest veer. A once a year replacement cycle in such spots might logically he estimated. KORUN&AL was recommended both to Mr. Ludwig and to the M. H. Detrick Co. as the best material for upgrading quality. When we observed the unit operating on the 15th, there was consider able evidence that extensive physical daitge had been done to the lower edges of the furnace when it was down at an earlier date for removal of accumulated build-up. Numerous of the large right angle ANCHOR tile had the corners broken off and exhibited other evidences of damage. This was not surprising to us when we watched the removal of the build-up with pickaxes on the 17th. The build-up was quite vitrified and had adhered strongly to the 6CX alumina brick although actual penetration was not great. KORUNDAL tile in this area would decrease the adherence but we also suggested that e neutral monolithic material he trowelled or gunned cn at the time of each slag removal. This would act as a parting layer and prevent damage to the refractory. We recmaaended THXRMDLITH for troweling and CHROH8PAC for gunning. JAP/ds