A Method for Steel Ladle Lining Optimization Applying Thermomechanical Modeling and Taguchi Approaches

Successful lining concept design can avoid the premature wear of refractory linings, allow for more economically efficient configuration of refractories, and improve the efficiency of high-temperature processes and save energy. The present paper introduces the Taguchi method combining finite element (FE) modeling for the lining optimization of a steel ladle from thermal and thermomechanical viewpoints. An orthogonal array was applied to design lining configurations for FE simulations. Analysis of variance and signal-to-noise ratio were used to quantitatively assess the impact of factors on thermal and thermomechanical responses. As a result, two optimal lining concepts using commercially available materials were proposed, which showed a substantial decrease in heat loss through the steel shell and thermomechanical load at the hot face of the working lining. The combined application of FE thermomechanical modeling and Taguchi approaches facilitates the selection of proper commercial materials and thicknesses of linings for the given process conditions.