Many properties can be identified through color differentiation, contrast analysis, and value-based segmentation. Specifically, it is relatively straightforward to assess the degree of wear, the displacement at the glass-refractory interface, or the location of the see-through boundary. To ensure accuracy, verification is conducted alongside visual inspection. The scanning method was developed to enhance the precision of evaluating corroded samples, rather than for microstructural analysis. It's important to note that the magnification achievable with a standard A4 flatbed scanner is limited, typically ranging from 600 to 1200 dpi, which depends on the optical resolution of the device.
According to the traditional cinder test procedure, finely ground abrasive materials are applied to the refractory sample block under furnace test conditions. A hollow cylinder is then cemented onto a square-bottom parallelepiped plate. Each mandrel is coated with 15 grams of container glass, with the goal of minimizing material usage. To achieve more accurate results, the remaining glass surfaces were scanned using the newly developed scanning technique, eliminating the need for older, time-consuming planar measurement methods. Additionally, surface penetration was also evaluated.
The process involves several steps: first, scanning the sample; second, performing image processing; third, calibrating the stereo image and converting pixel measurements into real-world units; fourth, measuring the surface of the selected area using techniques such as contrast adjustment and threshold setting. The depth of penetration is then statistically analyzed by taking multiple measurements across the impregnation zone. Using standard deviation, an accurate assessment of seepage uniformity can be made, and the average level of impregnation can be determined.
The PRI product demonstrates a large surface area of remaining glass in all samples. Moreover, the extent of seepage is restricted to only a small portion of the dried material. The absence of corrosion in the refractory material at the glass interface, even along the glass surface line, may be attributed to the low degree of impregnation. The sample was placed in an electric oven, heated to 1400°C over 14 hours, soaked at that temperature for 24 hours, and then cooled to room temperature within the furnace. The soaking temperature was chosen to simulate actual operational conditions. During the testing phase, the sample was cut in half to allow for cross-sectional inspection of the glass-refractory interface. To reliably quantify the glass erosion resistance of the refractory material, the cross-sectional area of the remaining glass was measured.
The ladle test confirmed the technical feasibility of the new alkali spray material (NB-GM) for slag line repairs, particularly for the product. Further research was conducted to identify the most suitable product and equipment. The initial industrial test was carried out in the laboratory, where the material was sprayed onto the MgO-C slag line. The results showed a weight loss of 5.5% after drying at 110°C, a bulk density of 2.69 g/cm³, and a porosity of 319%. The compressive strength was 31 MPa. This material demonstrated superior performance compared to conventional alkaline spray products.
The RH-OB vents project introduced new materials that significantly reduce the total consumption of aluminum (external) and alkaline (internal) materials used for repairs, compared to traditional spray-off products. Ongoing tests focus on automated spraying equipment, especially for practical applications. These materials perform just as effectively as the previously used common materials. The first comprehensive tests of these new materials were highly informative, clearly showing improved performance over traditional spray materials. Two similar studies have further confirmed the future trends of LC-GM (aluminum) and NB-GM (magnesium) materials. The new optimized equipment offers the best masonry operations, with no dust or rebound, achieving a masonry rate of 5 to 6 tons per hour. The new product, especially the aluminum spinel monolith, is better suited for full-scale ladle masonry.
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