Holistic view of the insulating layer on the thermal efficiency of a steel ladle lining

The lining design of steel ladles has a major impact on the performance of these metallurgical vessels. For instance, their better thermal performance is mainly related to the refractory materials applied in the lining, which requires continuous quality and cost optimizations. In this study, different refractory linings were investigated in order to understand their effect on the thermal performance of the steel ladle, that is, on the control of the average steel and shell temperatures, effect on the amount of stored energy in the refractory lining and on the cycling energy consumption. The influence of distinct configurations of insulating materials (position, thickness, and types) on those parameters was investigated by heat transfer simulations using numerical tools. The results pointed out the insulating materials efficiency on reducing the shell temperatures and increasing the average steel temperature. However, the benefits of applying the insulator with thicknesses over 21 mm or applying it at the bottom are less significant. The application of the foam insulator at unusual positions showed promising results, such as between the safety and working layer and at the hot face. The former position enhanced the performance during pre‐heating whereas the latter significantly increased the steel temperature (34°C). Consequently, the study pointed out new designs for the project of steel ladle linings, improving their efficiency, targeting solutions for saving energy, and reducing the environmental impacts. The insulating layer role on the thermal efficiency of steel ladles. Heat transfer modeling of the energy consumption in steelmaking process. Disruptive refractory design to save energy in steel ladles.