Teams should check parts often and line up shrouds carefully. They need to control heating rates. Using logs and photos helps track wear. Plants with strict maintenance plans have longer part life and fewer leaks.
Ladle Shroud Gasket – Material, Function, Shape & Installation Guide
How to Use the Ladle Shroud Manipulator in Continuous Casting Operations
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Drawing design method and skill of ladle slide gate plate
slide gate plate test report In AK Middletown 225-ton ladle
Recycling slide gate plates to save costs and reduce waste
The top 5 ladle shroud manufacturers in China
The Role of Slide Gate Plates in Steel Industry Efficiency: Exploring the Mechanisms of LS, CS, and LG Series for Optimal Performance

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New generation ladle slide gate system for performance improvement
Thermal Stress Cracking Of Ladle Slide Gate Plate
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The Unseen Champion Of Continuous Steel Casting-Slide Gate
5 Key Factors Behind Ladle Shroud Cracking
How To Extend The Service Life Of Slide Gate Plates In Steel Casting - Henan Yangyu Refractories Co.,Ltd
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Before Enquiry Some Questions You Should Know About Ladle Shroud - Henan Yangyu Refractories Co.,Ltd
The Iso Refractory Trial Report Compared With Vesuvius
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How To Improve The Lifespan Of Slide Gate Plates
The Reason Of Sub Entry Nozzle Clogging And How To Slove It
Why The Tundish Stopper Cracks And How To Improve It
How To Avoid The Sub Entry Nozzle(SEN) Clogging
The Problem In The Application Of Monoblock Stopper Rods
https://youtu.be/EmNn8E3hRdo
https://youtu.be/AJ3Dt9R2Rh8
https://youtu.be/ctppROYzPuc
Facebook
Teams should check parts often and line up shrouds carefully. They need to control heating rates. Using logs and photos helps track wear. Plants with strict maintenance plans have longer part life and fewer leaks.
Ladle Shroud Gasket – Material, Function, Shape & Installation Guide
How to Use the Ladle Shroud Manipulator in Continuous Casting Operations
Refractory shapes and sizes
Operation procedure of dry material for induction furnace
Drawing design method and skill of ladle slide gate plate
slide gate plate test report In AK Middletown 225-ton ladle
Recycling slide gate plates to save costs and reduce waste
The top 5 ladle shroud manufacturers in China
The Role of Slide Gate Plates in Steel Industry Efficiency: Exploring the Mechanisms of LS, CS, and LG Series for Optimal Performance

The difference between magnesia carbon brick and aluminum magnesia carbon brick
Production and application of isostatically pressed refractory materials
New generation ladle slide gate system for performance improvement
Thermal Stress Cracking Of Ladle Slide Gate Plate
The-damage-reasons-to-ladle-sliding-plates-and-the-advantages-and-disadvantages-of-some-slide-gate-plates
The Unseen Champion Of Continuous Steel Casting-Slide Gate
5 Key Factors Behind Ladle Shroud Cracking
How To Extend The Service Life Of Slide Gate Plates In Steel Casting - Henan Yangyu Refractories Co.,Ltd
How To Choose Ladle Shroud From A China Factory
A Few Things You Should Know About The Ladle Nozzle
Wear Reason About The Slide Gate Plate
Before Enquiry Some Questions You Should Know About Ladle Shroud - Henan Yangyu Refractories Co.,Ltd
The Iso Refractory Trial Report Compared With Vesuvius
The drawing regarding kinds of slide gate plate
Slide Gate Plate Price Guide 2025: Complete Pricing Analysis and Buying Tips
Complete Guide to Submerged Entry Nozzle (SEN) in Steel Making
What Is A Ladle Shroud And Its Function - Henan Yangyu Refractories Co.,Ltd
How To Improve The Lifespan Of Slide Gate Plates
The Reason Of Sub Entry Nozzle Clogging And How To Slove It
Why The Tundish Stopper Cracks And How To Improve It
How To Avoid The Sub Entry Nozzle(SEN) Clogging
The Problem In The Application Of Monoblock Stopper Rods
https://youtu.be/EmNn8E3hRdo
https://youtu.be/AJ3Dt9R2Rh8
https://youtu.be/ctppROYzPuc
Facebook
 

The ladle shroud nozzle for continuous casting is also called the protective sleeve. It is an important component connecting the ladle and the tundish. It is connected to the lower shroud of the sliding shroud device at the bottom of the ladle, and the lower end extends into the tundish.
The shroud is an important functional refractory material for maintaining casting and improving steel quality. The length of the shroud is generally 600-1800mm, the pipe diameter is 90-150 mm, and the structure of the ladle shroud nozzle is shown in Figure 2. Its use conditions are harsh and must have the following functions: excellent thermal shock resistance; good mechanical strength; excellent resistance to alternating corrosion of molten steel and slag, high oxidation resistance, and in addition, other suitable properties are required for some special steel grades.more information,please check here

Tundish nozzle
Slide Gate Plate is a critical component in the continuous casting process, used to control the flow of molten steel from the ladle or tundish to the crystallizer. The following is a detailed description:

Role and Function

• Flow Control: The sliding gate plate adjusts the opening size of the nozzle through the sliding mechanism, thereby controlling the flow of molten steel. This is very important for maintaining a constant and controllable casting process.
• Operational Flexibility: The sliding gate plate allows operators to adjust the molten steel flow rate as needed during the casting process to adapt to different production requirements and conditions.
• Emergency Stop: In an emergency, the sliding gate plate can completely close the flow channel and stop the flow of molten steel, thereby preventing accidents and losses.

 
Slide gate plate for Converter
The slide gate plate is made of sintered corundum, fused corundum, fused zirconium corundum, zirconium mullite and other main raw materials. It is combined with new resin, formed by high pressure and fired at high temperature. It has the advantages of high strength, super hard, high temperature resistance and corrosion resistance, and strong thermal stability.
Stopper

Monoblock Stopper is used mainly for flow control on Molten Steel poured from tundish to mould. Monolithic Stopper is installed in the Tundish above the Sub Entry Nozzle and the gap between stopper head and Nozzle decide the throughput requirement of Molten Steel inside the Mould.
Argon can be blown into the tundish through argon inlet to prevent nozzle from Clogging ( specially designed feature wherever it is required we design and customise accordingly)
SPECIAL FEATURES:
o Facility for gas purging
o Anti oxidant properties
o Design and size as per customer’s requirement
o Clogging free casting for long sequence of casting
o Gas purging facilities to prevent alumina clogging (optional)
o Slag zone immersed part re-inforcement with special material for long life
o Argon sealing purging arrangement can be provided on customer’s request
o Wide range of formulation for withstanding oxidation and long sequence casting
o Different assembly methods for assured security even in long sequence casting
o We manufacture Silica free Oxy-bore ladle shroud for less corrosion and long sequence casting

Recycling slide gate plates to save costs and reduce waste

The top 5 ladle shroud manufacturers in China
Production and application of isostatically pressed refractory materials

SEN
首页
重定向声明
adam wang | Archinect
Monoblock Stopper is used mainly for flow control on Molten Steel poured from tundish to mould. Monolithic Stopper is installed in the Tundish above the Sub Entry Nozzle and the gap between stopper head and Nozzle decide the throughput requirement of Molten Steel inside the Mould.
Argon can be blown into the tundish through argon inlet to prevent nozzle from Clogging ( specially designed feature wherever it is required we design and customise accordingly)
https://www.futmetal.com/ 这个网址做了很多别的网页链接
JS Bin - Collaborative JavaScript Debugging
sequence casting
o Different assembly methods for assured security even in long sequence casting
o We manufacture Silica free Oxy-bore ladle shroud for less corrosion and long sequence casting
[URL="https://hyrefr.com/product/ladle-shroud/"]here[/URL].
IntenseDebate - junhuamachinery
5 Key Factors Behind Ladle Shroud Cracking | SMP Maria Mediatrix
The top 5 ladle shroud manufacturers in China · hyrefractory/slide-gate-plate Wiki
HYRE   
ladle shroud
tundish stopper
Sub entry nozzle
The ladle shroud nozzle for continuous casting is also called the protective sleeve. It is an important component connecting the ladle and the tundish. It is connected to the lower shroud of the sliding shroud device at the bottom of the ladle, and the lower end extends into the tundish.
The shroud is an important functional refractory material for maintaining casting and improving steel quality. The length of the shroud is generally 600-1800mm, the pipe diameter is 90-150 mm, and the structure of the ladle shroud nozzle is shown in Figure 2. Its use conditions are harsh and must have the following functions: excellent thermal shock resistance; good mechanical strength; excellent resistance to alternating corrosion of molten steel and slag, high oxidation resistance, and in addition, other suitable properties are required for some special steel grades.more information,please check here

Tundish nozzle
Slide Gate Plate is a critical component in the continuous casting process, used to control the flow of molten steel from the ladle or tundish to the crystallizer. The following is a detailed description:

Role and Function

• Flow Control: The sliding gate plate adjusts the opening size of the nozzle through the sliding mechanism, thereby controlling the flow of molten steel. This is very important for maintaining a constant and controllable casting process.
• Operational Flexibility: The sliding gate plate allows operators to adjust the molten steel flow rate as needed during the casting process to adapt to different production requirements and conditions.
• Emergency Stop: In an emergency, the sliding gate plate can completely close the flow channel and stop the flow of molten steel, thereby preventing accidents and losses.

 
Slide gate plate for Converter
The slide gate plate is made of sintered corundum, fused corundum, fused zirconium corundum, zirconium mullite and other main raw materials. It is combined with new resin, formed by high pressure and fired at high temperature. It has the advantages of high strength, super hard, high temperature resistance and corrosion resistance, and strong thermal stability.
Stopper

Monoblock Stopper is used mainly for flow control on Molten Steel poured from tundish to mould. Monolithic Stopper is installed in the Tundish above the Sub Entry Nozzle and the gap between stopper head and Nozzle decide the throughput requirement of Molten Steel inside the Mould.
Argon can be blown into the tundish through argon inlet to prevent nozzle from Clogging ( specially designed feature wherever it is required we design and customise accordingly)
SPECIAL FEATURES:
o Facility for gas purging
o Anti oxidant properties
o Design and size as per customer’s requirement
o Clogging free casting for long sequence of casting
o Gas purging facilities to prevent alumina clogging (optional)
o Slag zone immersed part re-inforcement with special material for long life
o Argon sealing purging arrangement can be provided on customer’s request
o Wide range of formulation for withstanding oxidation and long sequence casting
o Different assembly methods for assured security even in long sequence casting
o We manufacture Silica free Oxy-bore ladle shroud for less corrosion and long sequence casting

Recycling slide gate plates to save costs and reduce waste

The top 5 ladle shroud manufacturers in China
Production and application of isostatically pressed refractory materials

SEN
首页
重定向声明
adam wang | Archinect
Monoblock Stopper is used mainly for flow control on Molten Steel poured from tundish to mould. Monolithic Stopper is installed in the Tundish above the Sub Entry Nozzle and the gap between stopper head and Nozzle decide the throughput requirement of Molten Steel inside the Mould.
Argon can be blown into the tundish through argon inlet to prevent nozzle from Clogging ( specially designed feature wherever it is required we design and customise accordingly)
https://www.futmetal.com/ 这个网址做了很多别的网页链接
JS Bin - Collaborative JavaScript Debugging
sequence casting
o Different assembly methods for assured security even in long sequence casting
o We manufacture Silica free Oxy-bore ladle shroud for less corrosion and long sequence casting
[URL="https://hyrefr.com/product/ladle-shroud/"]here[/URL].
IntenseDebate - junhuamachinery
5 Key Factors Behind Ladle Shroud Cracking | SMP Maria Mediatrix
The top 5 ladle shroud manufacturers in China · hyrefractory/slide-gate-plate Wiki
HYRE   
ladle shroud
tundish stopper
Sub entry nozzle
The ladle shroud nozzle for continuous casting is also called the protective sleeve. It is an important component connecting the ladle and the tundish. It is connected to the lower shroud of the sliding shroud device at the bottom of the ladle, and the lower end extends into the tundish.
The shroud is an important functional refractory material for maintaining casting and improving steel quality. The length of the shroud is generally 600-1800mm, the pipe diameter is 90-150 mm, and the structure of the ladle shroud nozzle is shown in Figure 2. Its use conditions are harsh and must have the following functions: excellent thermal shock resistance; good mechanical strength; excellent resistance to alternating corrosion of molten steel and slag, high oxidation resistance, and in addition, other suitable properties are required for some special steel grades.more information,please check here

Tundish nozzle
Slide Gate Plate is a critical component in the continuous casting process, used to control the flow of molten steel from the ladle or tundish to the crystallizer. The following is a detailed description:

Role and Function

• Flow Control: The sliding gate plate adjusts the opening size of the nozzle through the sliding mechanism, thereby controlling the flow of molten steel. This is very important for maintaining a constant and controllable casting process.
• Operational Flexibility: The sliding gate plate allows operators to adjust the molten steel flow rate as needed during the casting process to adapt to different production requirements and conditions.
• Emergency Stop: In an emergency, the sliding gate plate can completely close the flow channel and stop the flow of molten steel, thereby preventing accidents and losses.

 
Slide gate plate for Converter
The slide gate plate is made of sintered corundum, fused corundum, fused zirconium corundum, zirconium mullite and other main raw materials. It is combined with new resin, formed by high pressure and fired at high temperature. It has the advantages of high strength, super hard, high temperature resistance and corrosion resistance, and strong thermal stability.
Stopper

Monoblock Stopper is used mainly for flow control on Molten Steel poured from tundish to mould. Monolithic Stopper is installed in the Tundish above the Sub Entry Nozzle and the gap between stopper head and Nozzle decide the throughput requirement of Molten Steel inside the Mould.
Argon can be blown into the tundish through argon inlet to prevent nozzle from Clogging ( specially designed feature wherever it is required we design and customise accordingly)
SPECIAL FEATURES:
o Facility for gas purging
o Anti oxidant properties
o Design and size as per customer’s requirement
o Clogging free casting for long sequence of casting
o Gas purging facilities to prevent alumina clogging (optional)
o Slag zone immersed part re-inforcement with special material for long life
o Argon sealing purging arrangement can be provided on customer’s request
o Wide range of formulation for withstanding oxidation and long sequence casting
o Different assembly methods for assured security even in long sequence casting
o We manufacture Silica free Oxy-bore ladle shroud for less corrosion and long sequence casting

Recycling slide gate plates to save costs and reduce waste

The top 5 ladle shroud manufacturers in China
Production and application of isostatically pressed refractory materials

SEN
首页
重定向声明
adam wang | Archinect
Monoblock Stopper is used mainly for flow control on Molten Steel poured from tundish to mould. Monolithic Stopper is installed in the Tundish above the Sub Entry Nozzle and the gap between stopper head and Nozzle decide the throughput requirement of Molten Steel inside the Mould.
Argon can be blown into the tundish through argon inlet to prevent nozzle from Clogging ( specially designed feature wherever it is required we design and customise accordingly)
https://www.futmetal.com/ 这个网址做了很多别的网页链接
JS Bin - Collaborative JavaScript Debugging
sequence casting
o Different assembly methods for assured security even in long sequence casting
o We manufacture Silica free Oxy-bore ladle shroud for less corrosion and long sequence casting
[URL="https://hyrefr.com/product/ladle-shroud/"]here[/URL].
IntenseDebate - junhuamachinery
5 Key Factors Behind Ladle Shroud Cracking | SMP Maria Mediatrix
The top 5 ladle shroud manufacturers in China · hyrefractory/slide-gate-plate Wiki
HYRE   
ladle shroud
tundish stopper
Sub entry nozzle
 

Introduction

Slide gate plates are key functional refractories installed in the ladle or tundish slide gate system to control steel flow during casting. As flow-control components, they are subjected to extreme thermal, chemical, and mechanical stresses: high steel temperatures, erosive flow, oxidation, slag attack, mechanical abrasion, and frequent opening/closing cycles. Their lifespan directly affects casting sequence length, ladle turnaround time, production cost, and operational safety.

Improving slide gate plate life is therefore a critical objective for steel plants as it increases sequence casting lengths, reduces refractory consumption, and enhances steel cleanliness. Achieving long service life requires a combined approach involving raw material selection, plate design, production technology, preheating practices, operational discipline, and metallurgy control. This article provides a detailed and practical guide on how to extend slide gate plate life in modern steelmaking operations.

1. Use High-Quality Raw Materials

The quality and selection of raw materials have the strongest influence on plate performance.

1.1 High-Purity Alumina

Al₂O₃ content above 85–95% is essential for:

• High refractoriness
• Resistance to steel and slag erosion
• Dimensional stability at high temperature

Low impurities reduce unwanted reactions with molten steel and inclusions.

1.2 Carbon and Antioxidants

Carbon enhances oxidation resistance and thermal shock resistance. In high-quality plates:

• Carbon content ranges from 5–20% depending on application.
• Antioxidants such as SiC, Al metal, Si metal, Mg metal, and BN improve stability.

Proper antioxidant blend minimizes oxidation, which is one of the main failure modes.

1.3 Special Additives

To further extend life:

• Zirconia (ZrO₂) improves chemical resistance and wear resistance.
• Spinel-forming materials (MgO·Al₂O₃) help resist corrosion from Ca-treated steels.
• BN coatings are often applied to reduce friction and enhance smooth plate movement.

The raw material design must match steel grade, casting temperature, and sequence length.

2. Use Advanced Manufacturing Technology

Manufacturing processes determine plate density, strength, porosity, and overall durability.

2.1 Isostatic Pressing

Isostatic pressing creates higher density and more uniform microstructure than conventional pressing. Benefits include:

• Lower porosity
• Higher thermal shock resistance
• Improved erosion resistance
• More consistent material performance

Isostatic plates normally last significantly longer, especially in continuous casting applications.

2.2 Optimized Firing Temperature

High-temperature firing produces:

• Strong ceramic bonds
• Lower microcracks
• Higher mechanical strength

Underfired plates degrade quickly because of insufficient bond formation.

2.3 Strict Quality Control

Key tests include:

• Apparent porosity
• Bulk density
• Cold crushing strength
• Flexural strength
• Oxidation resistance
• Thermal shock resistance

Consistent production is essential to achieving predictable life cycles.

3. Improve Plate and System Design

Beyond materials, engineering design of plates plays a major role.

3.1 Proper Plate Thickness

Thicker plates withstand longer sequences but must fit system specifications. Overly thin plates fail easily; overly thick plates may cause improper movement or temperature gradients.

3.2 Larger Bore and Optimized Geometry

Optimizing bore diameter, shape, and taper reduces:

• Steel velocity
• Turbulence
• Erosion at the plate’s critical hot face

Some designs use a conical bore to stabilize flow and minimize wear.

3.3 Better Alignment and Contact Surface

Improper alignment between upper and lower plates causes:

• Uneven wear
• Groove formation
• Steel leakage risks

Precision machining of contact surfaces is essential to long service life.

4. Proper Preheating Practices

Preheating slide gate plates is one of the simplest yet most effective ways to extend their life.

4.1 Benefits of Proper Preheating

• Reduces thermal shock during first steel impact
• Drives out residual moisture
• Minimizes cracking and microfractures
• Enhances oxidation resistance

4.2 Best Preheating Practices

• Minimum 800–1000°C for ladle slide gates
• Slow and uniform heating
• Avoid direct flame impact on plate surfaces
• Maintain proper soak time before tapping

Extreme temperature jumps shorten plate life dramatically.

5. Metallurgical Factors That Affect Plate Life

Operational metallurgy heavily influences erosion and oxidation rates.

5.1 Steel Temperature

Higher temperatures increase:

• Erosion rates
• Chemical attack
• Thermal shock risk

Optimizing tapping and casting temperature directly contributes to longer plate life.

5.2 Calcium Treatment Practice

Calcium treatment modifies inclusions but the resulting slag reacts differently with plates. Excessive Ca addition may:

• Accelerate erosion
• Increase chemical penetration

Coordinating Ca addition strategies with refractory design is essential.

5.3 Slag Composition

High FeO and MnO slags are aggressive to slide gate plate materials. Lowering oxidizing slag components helps prevent chemical wear.

6. Operational Practices and Maintenance

Even the best materials fail early if operational practices are poor.

6.1 Smooth Opening and Closing

Abrupt movement or forceful operation causes:

• Mechanical abrasion
• Misalignment
• Premature wear

A well-maintained slide gate mechanism ensures smooth movement.

6.2 Correct Torque Settings

Proper tightening torque:

• Prevents plate deformation
• Ensures uniform contact pressure
• Reduces risk of leakage

Torque must be set according to equipment manufacturer specifications.

6.3 Cleanliness During Assembly

Before installation:

• Remove dust, moisture, or foreign materials
• Ensure surface flatness
• Apply BN or graphite lubrication as required

Even small debris can compromise plate contact and reduce service life.

7. Using Compatible Refractory Components

Slide gate plate life is also influenced by associated refractories, such as:

• Nozzles (upper/lower)
• Ladle well blocks
• Collector nozzles
• Ladle shrouds

Incompatible combinations may cause:

• Mismatch in expansion rates
• Thermal stress concentration
• Different erosion patterns

Using a fully matched system from the same manufacturer often yields longer life.

8. Regular Inspection & Failure Analysis

To continuously improve slide gate plate life, plants must analyze failure modes:

Common Failure Mechanisms

1. Thermal shock cracking
2. Chemical erosion from slag/steel
3. Oxidation-induced damage
4. Mechanical abrasion
5. Misalignment wear
6. Grooving or channel formation

By identifying root causes, engineers can adjust:

• Materials
• Designs
• Operating practices
• Preheating procedures

Continuous improvement is the key to reaching optimal service life.

9. Selecting a Reliable Slide Gate Plate Supplier

A long-lasting slide gate system requires a stable supplier who provides:

• High-purity materials
• Strong R&D capability
• Isostatic pressing technology
• Consistent quality control
• Technical support at the steel plant
• Ongoing improvement programs

Supplier partnership is essential; it is not just procurement but co-engineering cooperation.

Conclusion

Improving the life of slide gate plates requires a holistic approach that integrates material science, manufacturing technology, operational practices, and metallurgical control. Raw material purity, isostatic pressing, optimized design, proper preheating, stable casting conditions, and strict operational discipline all contribute to longer life.

By coordinating refractory suppliers, steelmaking engineers, and maintenance teams, steel plants can significantly extend plate service life, reduce refractory consumption, enhance casting stability, and improve overall productivity. Long-term success comes from continuous monitoring, failure analysis, and refinement of both process and materials.

Before Enquiry Some Questions You Should Know About Ladle Shroud - Henan Yangyu Refractories Co.,Ltd

The Iso Refractory Trial Report Compared With Vesuvius

The drawing regarding kinds of slide gate plate

Slide Gate Plate Price Guide 2025: Complete Pricing Analysis and Buying Tips

Complete Guide to Submerged Entry Nozzle (SEN) in Steel Making

What Is A Ladle Shroud And Its Function - Henan Yangyu Refractories Co.,Ltd

How To Improve The Lifespan Of Slide Gate Plates

The Reason Of Sub Entry Nozzle Clogging And How To Slove It

Why The Tundish Stopper Cracks And How To Improve It

How To Avoid The Sub Entry Nozzle(SEN) Clogging

The Problem In The Application Of Monoblock Stopper Rods

https://youtu.be/EmNn8E3hRdo

https://youtu.be/AJ3Dt9R2Rh8

https://youtu.be/ctppROYzPuc

Facebook

The ladle shroud nozzle for continuous casting is also called the protective sleeve. It is an important component connecting the ladle and the tundish. It is connected to the lower shroud of the sliding shroud device at the bottom of the ladle, and the lower end extends into the tundish.
The shroud is an important functional refractory material for maintaining casting and improving steel quality. The length of the shroud is generally 600-1800mm, the pipe diameter is 90-150 mm, and the structure of the ladle shroud nozzle is shown in Figure 2. Its use conditions are harsh and must have the following functions: excellent thermal shock resistance; good mechanical strength; excellent resistance to alternating corrosion of molten steel and slag, high oxidation resistance, and in addition, other suitable properties are required for some special steel grades.more information,please check here

Tundish nozzle
Slide Gate Plate is a critical component in the continuous casting process, used to control the flow of molten steel from the ladle or tundish to the crystallizer. The following is a detailed description:

Role and Function

·        Flow Control: The sliding gate plate adjusts the opening size of the nozzle through the sliding mechanism, thereby controlling the flow of molten steel. This is very important for maintaining a constant and controllable casting process.
·        Operational Flexibility: The sliding gate plate allows operators to adjust the molten steel flow rate as needed during the casting process to adapt to different production requirements and conditions.
·        Emergency Stop: In an emergency, the sliding gate plate can completely close the flow channel and stop the flow of molten steel, thereby preventing accidents and losses.
 
Slide gate plate for Converter
The slide gate plate is made of sintered corundum, fused corundum, fused zirconium corundum, zirconium mullite and other main raw materials. It is combined with new resin, formed by high pressure and fired at high temperature. It has the advantages of high strength, super hard, high temperature resistance and corrosion resistance, and strong thermal stability.
Stopper

Monoblock Stopper is used mainly for flow control on Molten Steel poured from tundish to mould. Monolithic Stopper is installed in the Tundish above the Sub Entry Nozzle and the gap between stopper head and Nozzle decide the throughput requirement of Molten Steel inside the Mould.
Argon can be blown into the tundish through argon inlet to prevent nozzle from Clogging ( specially designed feature wherever it is required we design and customise accordingly)
SPECIAL FEATURES:
o Facility for gas purging
o Anti oxidant properties
o Design and size as per customer’s requirement
o Clogging free casting for long sequence of casting
o Gas purging facilities to prevent alumina clogging (optional)
o Slag zone immersed part re-inforcement with special material for long life
o Argon sealing purging arrangement can be provided on customer’s request
o Wide range of formulation for withstanding oxidation and long sequence casting
o Different assembly methods for assured security even in long sequence casting
o We manufacture Silica free Oxy-bore ladle shroud for less corrosion and long sequence casting

Recycling slide gate plates to save costs and reduce waste

 
The top 5 ladle shroud manufacturers in China
Production and application of isostatically pressed refractory materials
 
SEN
首页
重定向声明
adam wang | Archinect
Monoblock Stopper is used mainly for flow control on Molten Steel poured from tundish to mould. Monolithic Stopper is installed in the Tundish above the Sub Entry Nozzle and the gap between stopper head and Nozzle decide the throughput requirement of Molten Steel inside the Mould.
Argon can be blown into the tundish through argon inlet to prevent nozzle from Clogging ( specially designed feature wherever it is required we design and customise accordingly)
https://www.futmetal.com/ 这个网址做了很多别的网页链接
JS Bin - Collaborative JavaScript Debugging
sequence casting
o Different assembly methods for assured security even in long sequence casting
o We manufacture Silica free Oxy-bore ladle shroud for less corrosion and long sequence casting
[URL="https://hyrefr.com/product/ladle-shroud/"]here[/URL].
IntenseDebate - junhuamachinery
5 Key Factors Behind Ladle Shroud Cracking | SMP Maria Mediatrix
The top 5 ladle shroud manufacturers in China · hyrefractory/slide-gate-plate Wiki
HYRE   
ladle shroud
tundish stopper
Sub entry nozzle
[url]https://hyrefr.com/[/url]
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5 Key Factors Behind Ladle Shroud Cracking

Operators often see cracks and damage in ladle shrouds, long nozzles, and refractory parts. This happens because of a few main reasons:
·        Fast temperature changes can cause thermal shock and peeling.
·        Mechanical stress comes from handling, hitting, or working forces.
·        Hot slag and molten steel can wear down and get into the parts.
·        Material problems like tiny holes or mistakes made during making.
·        Issues with design, how things line up, or how they fit together.
Knowing these reasons helps teams stop corrosion, breaks across the part, and chemical damage. This helps ladle shrouds last longer.

Key Takeaways

·        Quick temperature changes can cause thermal shock. This can crack ladle shrouds. Heating slowly and checking the temperature can stop this damage.
·        Mechanical stress from moving and using parts can cause cracks. Storing parts carefully and handling them right helps lower this risk. Installing them the correct way also helps.
·        Hot slag can wear down and get into refractory materials. This makes them weaker. Using strong materials and checking slag conditions can protect the parts.
·        The quality of materials is important. Good raw materials and careful making of parts help stop cracks. Having the right amount of porosity makes parts stronger and better at handling shock.
·        Good design and alignment lower stress and stop leaks. Smooth shapes and tight fits help keep ladle shrouds and nozzles strong. Checking them often also helps.

1. Thermal Shock

Temperature Changes

When the temperature changes quickly, it puts stress inside refractory materials. During ladle preheating, the working layer gets hot on one side and stays cool on the other. This big difference in temperature causes strong pulling stress at the top of the working layer. Sometimes, this stress can get as high as 39.06 MPa. Damage often starts at the top and near the sidewall burner nozzles. If the ladle heats up too fast, alumina-magnesia castables get stiffer but weaker. The material turns more brittle and can break more easily. When steel is poured, the ladle shroud faces sudden heat, which also builds up stress.
Tip: Teams should watch temperature changes during preheating and pouring. Using thermal imaging cameras can help find hot spots and uneven heating. These signs show where cracks might happen.

Crack Formation

Thermal shock cracks show up a lot in high-temperature furnace linings and steel ladles. These parts go through fast heating and cooling many times. When the temperature changes too quickly, the refractory grows or shrinks more than it can handle. If the material is brittle, especially under 1100°C, cracks form easily. Big parts, uneven heating, and outside forces make cracking worse. Changes in the material’s structure can also raise the risk.isostatical pressed refractory
·        Common scenarios for thermal shock cracking:
1.      Ladle preheating with fast temperature rise.
2.      Steel pouring with sudden molten metal exposure.
3.      Quenching or cooling steps in steelmaking.
4.      High-temperature furnace linings in steel, cement, glass, and ceramics.
Thermal shock can cause early failure with small and large cracks. Operators often see pieces breaking off, falling apart, and cracks along the ladle shroud and nozzle. Checking often and tracking temperature changes helps teams stop damage before it gets worse. Using materials that handle thermal shock better and heating slowly can help lower the chance of cracks. Slide gate plate

2. Mechanical Stress

Handling Damage

Mechanical stress often starts when workers do not handle parts carefully. Sometimes, workers drop or hit the ladle shroud by mistake. This can chip, crack, or even break it before use. Teams may forget how important good storage is. If the storage area is wet or rough, the refractory gets weaker. This makes it easier to crack later.
Operators should do these things to stop handling damage:
·        Keep ladle shrouds in dry, clean places.
·        Teach workers to lift and move parts the right way.
·        Check each part for chips or cracks before using it.
·        Heat the ladle shroud slowly so it does not crack.
Tip: Handle parts with care and heat them slowly. This helps stop early cracks and makes the ladle shroud last longer.

Operational Impact

Mechanical stress keeps happening when the equipment is used. Taking off coatings or moving the ladle shroud can hurt the refractory. Forces between the upper nozzle and ladle bottom can cause stress. These forces come from heat changes, steel shell growth, and heavy loads.
These types of mechanical stress often cause cracks or bending:
·        Pulling forces from blocked thermal expansion.
·        Pushing forces that make the part bend for good.
·        The steel shell grows wider and faces thermal shock.
The table below shows how these forces can hurt the structure: Operators who know about these stresses can pick better materials. They can also install parts better and lower the chance of cracks. Checking often and lining up parts right helps keep steelmaking equipment strong.
Ladle Shroud Gasket – Material, Function, Shape & Installation Guide
How to Use the Ladle Shroud Manipulator in Continuous Casting Operations
Refractory shapes and sizes
 
Operation procedure of dry material for induction furnace
Drawing design method and skill of ladle slide gate plate
slide gate plate test report In AK Middletown 225-ton ladle
Recycling slide gate plates to save costs and reduce waste
The top 5 ladle shroud manufacturers in China
The Role of Slide Gate Plates in Steel Industry Efficiency: Exploring the Mechanisms of LS, CS, and LG Series for Optimal Performance

The difference between magnesia carbon brick and aluminum magnesia carbon brick
Production and application of isostatically pressed refractory materials
New generation ladle slide gate system for performance improvement
Thermal Stress Cracking Of Ladle Slide Gate Plate
The-damage-reasons-to-ladle-sliding-plates-and-the-advantages-and-disadvantages-of-some-slide-gate-plates
The Unseen Champion Of Continuous Steel Casting-Slide Gate
5 Key Factors Behind Ladle Shroud Cracking
How To Extend The Service Life Of Slide Gate Plates In Steel Casting - Henan Yangyu Refractories Co.,Ltd
How To Choose Ladle Shroud From A China Factory
A Few Things You Should Know About The Ladle Nozzle
Wear Reason About The Slide Gate Plate
Before Enquiry Some Questions You Should Know About Ladle Shroud - Henan Yangyu Refractories Co.,Ltd
The Iso Refractory Trial Report Compared With Vesuvius
The drawing regarding kinds of slide gate plate
Slide Gate Plate Price Guide 2025: Complete Pricing Analysis and Buying Tips
Complete Guide to Submerged Entry Nozzle (SEN) in Steel Making
What Is A Ladle Shroud And Its Function - Henan Yangyu Refractories Co.,Ltd
How To Improve The Lifespan Of Slide Gate Plates
The Reason Of Sub Entry Nozzle Clogging And How To Slove It
Why The Tundish Stopper Cracks And How To Improve It
How To Avoid The Sub Entry Nozzle(SEN) Clogging
The Problem In The Application Of Monoblock Stopper Rods


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Senior X PLATFORM
Ladle Shroud Gasket – Material, Function, Shape & Installation Guide
How to Use the Ladle Shroud Manipulator in Continuous Casting Operations
Refractory shapes and sizes

Operation procedure of dry material for induction furnace
Drawing design method and skill of ladle slide gate plate
slide gate plate test report In AK Middletown 225-ton ladle
Recycling slide gate plates to save costs and reduce waste
The top 5 ladle shroud manufacturers in China
The Role of Slide Gate Plates in Steel Industry Efficiency: Exploring the Mechanisms of LS, CS, and LG Series for Optimal Performance

The difference between magnesia carbon brick and aluminum magnesia carbon brick
Production and application of isostatically pressed refractory materials
New generation ladle slide gate system for performance improvement
Thermal Stress Cracking Of Ladle Slide Gate Plate
The-damage-reasons-to-ladle-sliding-plates-and-the-advantages-and-disadvantages-of-some-slide-gate-plates
The Unseen Champion Of Continuous Steel Casting-Slide Gate
5 Key Factors Behind Ladle Shroud Cracking
How To Extend The Service Life Of Slide Gate Plates In Steel Casting - Henan Yangyu Refractories Co.,Ltd
How To Choose Ladle Shroud From A China Factory
A Few Things You Should Know About The Ladle Nozzle
Wear Reason About The Slide Gate Plate
Before Enquiry Some Questions You Should Know About Ladle Shroud - Henan Yangyu Refractories Co.,Ltd
The Iso Refractory Trial Report Compared With Vesuvius
The drawing regarding kinds of slide gate plate
Slide Gate Plate Price Guide 2025: Complete Pricing Analysis and Buying Tips
Complete Guide to Submerged Entry Nozzle (SEN) in Steel Making
What Is A Ladle Shroud And Its Function - Henan Yangyu Refractories Co.,Ltd
How To Improve The Lifespan Of Slide Gate Plates
The Reason Of Sub Entry Nozzle Clogging And How To Slove It
Why The Tundish Stopper Cracks And How To Improve It
How To Avoid The Sub Entry Nozzle(SEN) Clogging
The Problem In The Application Of Monoblock Stopper Rods
 

1. Introduction

In modern continuous casting operations, the tundish nozzle plays a crucial role in regulating molten steel flow from the tundish into the Submerged Entry Nozzle (SEN) or directly into the mold. Its reliability and flow-control stability directly impact mold level fluctuation, inclusion removal, casting speed, steel cleanliness, and overall process efficiency. Among various nozzle types, the isostatic tundish nozzle—also known as the isostatically pressed tundish nozzle—has emerged as a high-performance solution due to its superior density, strength, and anti-erosion characteristics. These nozzles leverage advanced isostatic pressing technology to achieve uniform microstructure and enhanced service life, thereby supporting high-productivity and high-quality steelmaking.

This article provides a comprehensive technical overview of the isostatic tundish nozzle, including its definition, manufacturing principles, material properties, performance advantages, design features, and application recommendations for steel plants.

---

2. What Is an Isostatic Tundish Nozzle?

An isostatic tundish nozzle is a tundish refractory component manufactured using cold isostatic pressing (CIP) technology to achieve a highly uniform, high-density, high-strength structure. It is typically installed at the bottom of the tundish and serves as the primary outlet for molten steel flow. Its functions include:

• Controlling molten steel flow rate

• Providing stable connection with slide gate plates or stopper rod systems

• Resisting erosion and chemical attack from steel and slag

• Maintaining dimensional accuracy during long-sequence casting

Compared with conventional vibration-molded or press-formed nozzles, isostatic nozzles present:

• Significantly higher density

• Lower apparent porosity

• Better thermal shock resistance

• Longer service life

• Lower probability of cracking or chipping

• Improved flow-stability, reducing mold level fluctuation

Isostatic tundish nozzles are now widely used in billet, bloom, and slab casters, particularly industries demanding long casting sequences and high steel cleanliness, such as automotive steel, silicon steel, pipeline steel, and bearing steel.

---

3. Principles of Isostatic Pressing Technology

3.1 Definition of Isostatic Pressing

Isostatic pressing is a forming method in which powder materials are compacted under equal pressure from all directions. Unlike conventional pressing methods that apply pressure only from one axis, isostatic pressing ensures uniform compaction and consistent density distribution.

3.2 Manufacturing Process of Isostatic Tundish Nozzle

The typical process includes:

1. Raw material selection and batching

   • High-purity alumina (Al₂O₃)

   • Zirconia (ZrO₂) or stabilized zirconia

   • Chromia or alumina-graphite compositions for specific grades

   • High-temperature binders and antioxidants

2. Powder mixing and granulation

   • Ensures uniform distribution of fine particles and additives

3. Molding using CIP method
   The mixed material is sealed in a flexible mold and placed in a pressure vessel.
   Hydrostatic pressure of 100–400 MPa is applied uniformly.

4. Drying and cold machining

   • Ensures dimensional accuracy and smooth inner bore

5. High-temperature firing

   • Typically at 1500–1700°C depending on the composition

   • Achieves sintering, increases density and microstructural bonding

6. Final inspection and machining

   • Tolerances are tighter compared with conventional products

   • Surface quality superior, reducing erosion initiation sites

3.3 Advantages of Isostatic Pressing in Tundish Nozzle Production

• Uniform density distribution prevents structural weak points.

• Reduced porosity limits slag and steel penetration.

• Higher mechanical strength, both cold and hot.

• Improved thermal shock resistance due to dense and homogeneous microstructure.

• Better erosion resistance against molten steel turbulence and chemical attack.

---

4. Materials Used in Isostatic Tundish Nozzles

The material compositions vary based on the steel grade, casting time, and tundish design. Typical materials include:

4.1 Alumina–Carbon (Al₂O₃–C)

• High thermal conductivity

• Good thermal shock resistance

• Often used for billet or round caster nozzles

• Added graphite improves slag resistance

4.2 Zirconia–Graphite (ZrO₂–C)

• Very high corrosion resistance

• Suitable for high-cleanliness steel

• Excellent erosion resistance in long-sequence casting

4.3 Alumina–Zirconia–Carbon (AZC)

• Strong structural stability

• Balanced resistance to erosion and thermal stress

• Widely used in slab caster nozzles

4.4 Stabilized Zirconia (MgO-PSZ, CaO-PSZ, etc.)

• Ultra-high refractoriness

• Exceptional resistance to thermal cycling

• Premium solution for critical casting operations

The material choice significantly influences performance, and isostatic technology further enhances inherent material properties.

---

5. Structural Design Features

Isostatic tundish nozzles are designed with special geometries to maintain stable flow and reduce stress concentration:

5.1 Bore Shape and Flow Control

Common bore shapes include:

• Straight bore

• Venturi bore

• Non-circular (oval or slot-type) depending on flow requirements

• Converging–diverging designs to optimize velocity profile

Venturi and converging designs help stabilize flow and minimize turbulence entering the SEN.

5.2 Outer-body Structure

• Multi-layer composite structures: inner erosion-resistant layer + outer insulating layer

• Reinforced shoulders to accommodate mechanical stress

• Anti-crack chamfers and optimized transition radii

5.3 Dimensional Tolerances

Isostatic nozzles maintain very tight tolerances:

• Bore dimensional tolerance ≤ ±0.2 mm

• Ovality minimized

• External surface roundness improved

This precision contributes to more predictable flow and better compatibility with slide gate or stopper mechanisms.

---

6. Performance Advantages

Isostatic tundish nozzles outperform conventional nozzles in several critical areas:

6.1 Enhanced Mechanical Strength

• High cold crushing strength

• High hot modulus of rupture

• Minimal deformation under thermal load

This significantly reduces fracture and chipping incidence.

6.2 Superior Thermal Shock Resistance

Dense microstructure minimizes thermal gradient damage, making the nozzle more resistant to:

• Rapid heating during tundish preheating

• Sudden temperature changes during casting

• Flame impingement and steel penetration

6.3 Excellent Erosion and Corrosion Resistance

Especially important when casting:

• High-alloy steels

• Ultra-low sulfur steels

• High-oxygen or aggressive slag systems

Zirconia-based isostatic nozzles can easily handle long sequences exceeding 16–20 hours.

6.4 Longer Service Life and Stability

The lifetime of an isostatic tundish nozzle is typically:

• 2–3× that of conventional pressed nozzles

• More stable flow rate throughout casting

• Less risk of bore enlargement or clogging

6.5 Reduced Casting Risks

• Lower risk of cracking

• Lower probability of nozzle blockage

• Reduced casting interruptions and breakouts

• More stable mold level, improving slab quality

These benefits directly contribute to higher productivity and quality consistency.

---

7. Applications in Continuous Casting

Isostatic tundish nozzles are used in:

7.1 Slab Casters

• Automotive steel

• Silicon steel

• High-strength low-alloy (HSLA) steel

• Pipeline grades

7.2 Billet and Bloom Casters

• Long-sequence mass production

• High-temperature operations

• High wear-resistance requirements

7.3 Special Steel Casting

• Bearing steel

• Stainless steel

• Casting requiring ultra-clean conditions

Their durability and stability reduce maintenance and downtime across all these areas.

---

8. Factors to Consider When Selecting an Isostatic Tundish Nozzle

8.1 Casting Time and Steel Grade

Long casting sequences require high zirconia content.

8.2 Tundish Operation Parameters

• Preheating method

• Slide gate configuration

• Stopper rod control system

8.3 Slag Composition & Erosion Conditions

Aggressive slags demand improved corrosion resistance materials.

8.4 Budget and Lifecycle Cost

While isostatic nozzles have higher initial cost, lifecycle savings are substantial.

---

9. Conclusion

The isostatic tundish nozzle represents a significant advancement in tundish refractories for continuous casting. By combining high-purity materials with isostatic pressing technology, these nozzles achieve unmatched uniformity, strength, erosion resistance, and thermal shock stability. Their precise dimensions and microstructural consistency ensure smooth molten steel flow, reduced turbulence, and improved casting stability.

For steel plants seeking improved process reliability, longer nozzle life, and higher product quality—particularly in demanding steel grades and long-sequence casting—the isostatic tundish nozzle is an essential and highly effective solution. As steelmaking continues to evolve toward cleaner, more efficient, and more automated operations, isostatically pressed nozzles will remain a core technology supporting the next generation of continuous casting performance.More information please visit Henan Yangyu Refractories Co.,Ltd

1. Introduction

In modern continuous casting operations, the tundish nozzle plays a crucial role in regulating molten steel flow from the tundish into the Submerged Entry Nozzle (SEN) or directly into the mold. Its reliability and flow-control stability directly impact mold level fluctuation, inclusion removal, casting speed, steel cleanliness, and overall process efficiency. Among various nozzle types, the isostatic tundish nozzle—also known as the isostatically pressed tundish nozzle—has emerged as a high-performance solution due to its superior density, strength, and anti-erosion characteristics. These nozzles leverage advanced isostatic pressing technology to achieve uniform microstructure and enhanced service life, thereby supporting high-productivity and high-quality steelmaking.

This article provides a comprehensive technical overview of the isostatic tundish nozzle, including its definition, manufacturing principles, material properties, performance advantages, design features, and application recommendations for steel plants.

---

2. What Is an Isostatic Tundish Nozzle?

An isostatic tundish nozzle is a tundish refractory component manufactured using cold isostatic pressing (CIP) technology to achieve a highly uniform, high-density, high-strength structure. It is typically installed at the bottom of the tundish and serves as the primary outlet for molten steel flow. Its functions include:

• Controlling molten steel flow rate

• Providing stable connection with slide gate plates or stopper rod systems

• Resisting erosion and chemical attack from steel and slag

• Maintaining dimensional accuracy during long-sequence casting

Compared with conventional vibration-molded or press-formed nozzles, isostatic nozzles present:

• Significantly higher density

• Lower apparent porosity

• Better thermal shock resistance

• Longer service life

• Lower probability of cracking or chipping

• Improved flow-stability, reducing mold level fluctuation

Isostatic tundish nozzles are now widely used in billet, bloom, and slab casters, particularly industries demanding long casting sequences and high steel cleanliness, such as automotive steel, silicon steel, pipeline steel, and bearing steel.

---

3. Principles of Isostatic Pressing Technology

3.1 Definition of Isostatic Pressing

Isostatic pressing is a forming method in which powder materials are compacted under equal pressure from all directions. Unlike conventional pressing methods that apply pressure only from one axis, isostatic pressing ensures uniform compaction and consistent density distribution.

3.2 Manufacturing Process of Isostatic Tundish Nozzle

The typical process includes:

1. Raw material selection and batching

   • High-purity alumina (Al₂O₃)

   • Zirconia (ZrO₂) or stabilized zirconia

   • Chromia or alumina-graphite compositions for specific grades

   • High-temperature binders and antioxidants

2. Powder mixing and granulation

   • Ensures uniform distribution of fine particles and additives

3. Molding using CIP method
   The mixed material is sealed in a flexible mold and placed in a pressure vessel.
   Hydrostatic pressure of 100–400 MPa is applied uniformly.

4. Drying and cold machining

   • Ensures dimensional accuracy and smooth inner bore

5. High-temperature firing

   • Typically at 1500–1700°C depending on the composition

   • Achieves sintering, increases density and microstructural bonding

6. Final inspection and machining

   • Tolerances are tighter compared with conventional products

   • Surface quality superior, reducing erosion initiation sites

3.3 Advantages of Isostatic Pressing in Tundish Nozzle Production

• Uniform density distribution prevents structural weak points.

• Reduced porosity limits slag and steel penetration.

• Higher mechanical strength, both cold and hot.

• Improved thermal shock resistance due to dense and homogeneous microstructure.

• Better erosion resistance against molten steel turbulence and chemical attack.

---

4. Materials Used in Isostatic Tundish Nozzles

The material compositions vary based on the steel grade, casting time, and tundish design. Typical materials include:

4.1 Alumina–Carbon (Al₂O₃–C)

• High thermal conductivity

• Good thermal shock resistance

• Often used for billet or round caster nozzles

• Added graphite improves slag resistance

4.2 Zirconia–Graphite (ZrO₂–C)

• Very high corrosion resistance

• Suitable for high-cleanliness steel

• Excellent erosion resistance in long-sequence casting

4.3 Alumina–Zirconia–Carbon (AZC)

• Strong structural stability

• Balanced resistance to erosion and thermal stress

• Widely used in slab caster nozzles

4.4 Stabilized Zirconia (MgO-PSZ, CaO-PSZ, etc.)

• Ultra-high refractoriness

• Exceptional resistance to thermal cycling

• Premium solution for critical casting operations

The material choice significantly influences performance, and isostatic technology further enhances inherent material properties.

---

5. Structural Design Features

Isostatic tundish nozzles are designed with special geometries to maintain stable flow and reduce stress concentration:

5.1 Bore Shape and Flow Control

Common bore shapes include:

• Straight bore

• Venturi bore

• Non-circular (oval or slot-type) depending on flow requirements

• Converging–diverging designs to optimize velocity profile

Venturi and converging designs help stabilize flow and minimize turbulence entering the SEN.

5.2 Outer-body Structure

• Multi-layer composite structures: inner erosion-resistant layer + outer insulating layer

• Reinforced shoulders to accommodate mechanical stress

• Anti-crack chamfers and optimized transition radii

5.3 Dimensional Tolerances

Isostatic nozzles maintain very tight tolerances:

• Bore dimensional tolerance ≤ ±0.2 mm

• Ovality minimized

• External surface roundness improved

This precision contributes to more predictable flow and better compatibility with slide gate or stopper mechanisms.

---

6. Performance Advantages

Isostatic tundish nozzles outperform conventional nozzles in several critical areas:

6.1 Enhanced Mechanical Strength

• High cold crushing strength

• High hot modulus of rupture

• Minimal deformation under thermal load

This significantly reduces fracture and chipping incidence.

6.2 Superior Thermal Shock Resistance

Dense microstructure minimizes thermal gradient damage, making the nozzle more resistant to:

• Rapid heating during tundish preheating

• Sudden temperature changes during casting

• Flame impingement and steel penetration

6.3 Excellent Erosion and Corrosion Resistance

Especially important when casting:

• High-alloy steels

• Ultra-low sulfur steels

• High-oxygen or aggressive slag systems

Zirconia-based isostatic nozzles can easily handle long sequences exceeding 16–20 hours.

6.4 Longer Service Life and Stability

The lifetime of an isostatic tundish nozzle is typically:

• 2–3× that of conventional pressed nozzles

• More stable flow rate throughout casting

• Less risk of bore enlargement or clogging

6.5 Reduced Casting Risks

• Lower risk of cracking

• Lower probability of nozzle blockage

• Reduced casting interruptions and breakouts

• More stable mold level, improving slab quality

These benefits directly contribute to higher productivity and quality consistency.

---

7. Applications in Continuous Casting

Isostatic tundish nozzles are used in:

7.1 Slab Casters

• Automotive steel

• Silicon steel

• High-strength low-alloy (HSLA) steel

• Pipeline grades

7.2 Billet and Bloom Casters

• Long-sequence mass production

• High-temperature operations

• High wear-resistance requirements

7.3 Special Steel Casting

• Bearing steel

• Stainless steel

• Casting requiring ultra-clean conditions

Their durability and stability reduce maintenance and downtime across all these areas.

---

8. Factors to Consider When Selecting an Isostatic Tundish Nozzle

8.1 Casting Time and Steel Grade

Long casting sequences require high zirconia content.

8.2 Tundish Operation Parameters

• Preheating method

• Slide gate configuration

• Stopper rod control system

8.3 Slag Composition & Erosion Conditions

Aggressive slags demand improved corrosion resistance materials.

8.4 Budget and Lifecycle Cost

While isostatic nozzles have higher initial cost, lifecycle savings are substantial.

---

9. Conclusion

The isostatic tundish nozzle represents a significant advancement in tundish refractories for continuous casting. By combining high-purity materials with isostatic pressing technology, these nozzles achieve unmatched uniformity, strength, erosion resistance, and thermal shock stability. Their precise dimensions and microstructural consistency ensure smooth molten steel flow, reduced turbulence, and improved casting stability.

For steel plants seeking improved process reliability, longer nozzle life, and higher product quality—particularly in demanding steel grades and long-sequence casting—the isostatic tundish nozzle is an essential and highly effective solution. As steelmaking continues to evolve toward cleaner, more efficient, and more automated operations, isostatically pressed nozzles will remain a core technology supporting the next generation of continuous casting performance.More information please visit Henan Yangyu Refractories Co.,Ltd

Stopper rods are a type of shaped refractory material used in continuous casting machines. They ensure the stability of the molten steel level in the crystallizer, control the linear flow rate of molten steel, and guarantee the surface and internal quality of the cast billet. In actual production, stopper rods play a crucial role in the stability of steelmaking. Problems with stopper rods, such as corrosion, fracture, or nodule formation, can cause excessive fluctuations in the molten steel level in the crystallizer, and in severe cases, lead to premature shutdown or forced shutdown of the continuous casting machine.

Analysis of stopper rod fracture problem

A steel plant’s slab continuous casting machine frequently experienced stopper rod breakage during casting, severely impacting normal production. Statistics showed that stopper rod heads broke off during tundish baking or at the start of casting in 20% of cases. The remaining incidents involved stopper rod heads breaking off during casting or the rod breaking off 650-700mm below the top edge, with a “V”-shaped fracture (see Figure 1). In 2021, there were 12 stopper rod incidents, averaging one per month. Each incident resulted in unplanned downtime of the continuous casting machine, requiring tundish rebaking, machine standby, and restarting casting, disrupting normal production plans. Therefore, resolving the stopper rod problem is urgently needed to stabilize continuous casting machine production and reduce cost losses.

Statistical classification of stopper rod accidents suggests that the main factors affecting stopper rod breakage and stopper rod head detachment are thermal shock, strength, and stopper rod design and installation issues.

Thermal shock problem

An analysis of the stopper rod’s body and head material design, as well as its manufacturing process, indicates that the currently used stopper rod material meets the process requirements. The steel plant primarily uses carbon structural steel, high-carbon steel, and some medium-carbon alloy steel, which have minimal erosion on the stopper rod. The stopper rod does not have a slag line, and the erosion of the stopper rod head is not severe. After 15 hours of normal steel pouring, the flow control at the stopper rod head is good, and the erosion is uniform. The material design is generally reasonable. However, the fracture surface of the broken stopper rod head is 50-60 mm, with a clean break. The primary issue to address is the stopper rod manufacturing process, which requires adjustments and improvements. The uneven composition of the raw materials used in manufacturing the stopper rod, leading to stress, is the direct cause of the stopper rod fracture.

The baking process of the tundish was monitored on-site, revealing a problem with low baking efficiency. The tundish baking used converter gas with a calorific value of approximately 1300 × 4.1868 kJ/m³, lasting 3 hours. During baking, the stopper rod was open, the baking temperature was 1000 °C, and the tundish was not sealed, resulting in significant flame overflow. Poor stopper rod baking leads to uneven thermal stress in the stopper rod refractory material, thus causing microcracks. Since the stopper rod operates in an extreme environment during casting, even small defects are magnified.

Strength issue

The problem of stopper rod fracture at the slag line typically occurs 1-2 heats after the tap changer is replaced during steel casting, after bonding recovery, and during the tundish quick change process. Analysis suggests that the stopper rod develops cracks and eventually fractures when it is closed during the steel casting process due to lateral and longitudinal forces.

Analysis of the strength of the stopper rod body revealed that its strength is low in the hot state, making it prone to breakage under the influence of molten steel or stress. Therefore, the strength of the stopper rod body needs to be strengthened.

Design and installation of stopper rod

The installation of the stopper rod on site was monitored and analyzed as follows: ① There are problems with the stopper rod design. When the stopper rod is open during steel pouring, it protrudes 200 mm above the tundish cover. According to the normal design, a protrusion of 50 mm above the tundish cover is sufficient. The stopper rod is too long, and in an emergency, it will be subjected to enormous external forces when closed, making it prone to breakage, especially at the slag line where the stopper rod diameter changes, making this area even weaker. ② There are problems with the stopper rod installation. The main issue is that the stopper rod is installed offline. The tundish loading process may cause shaking damage. The stopper rod installation requires a “bite,” and the presence of this “bite” causes lateral forces when the stopper rod is closed, leading to cracks in the stopper rod head or weaker parts. Furthermore, during the steel pouring process, the operator switched the mode from automatic to manual and then forcefully pressed the brake to close the stopper rod, further exacerbating the damage.

Improvement measures

Improvement of stopper rod breakage problem

In response to the above problems, we consider improving the stopper rods currently in use. The specific solutions are as follows: (1) Under the premise of meeting production requirements, we will make minor adjustments to the material to appropriately improve the thermal shock performance of the stopper rods and strengthen the neck strength of the stopper rods. The adjustment idea is to introduce SiC micro powder into the feed of the stopper rods in the tundish production, focusing on the head of the stopper rod and the slag line position, and to design a composite structure for the stopper rods to improve the comprehensive mechanical properties of the stopper rods and reduce the coefficient of linear expansion. When 5% SiC micro powder is added, the room temperature and high temperature flexural strength of the magnesium carbon rod head material are 8.2 MPa and 9.4 MPa, respectively, and the average coefficient of linear expansion is 7.1×10-/℃. No obvious cracks were observed after 3 thermal shock cycles at 1100 ℃. (2) Adjustment of the length of the stopper rod. The stopper rods currently in use are too long, reaching 1750 mm, which increases the difficulty of the stopper rod manufacturing and will also amplify the lateral force generated by the flow of molten steel during use, causing the rod body to break after being stressed. Based on the site conditions, the length of the stopper rods will be adjusted to 1650 mm. (3) Optimize the stopper head by changing the shape of the stopper head from spherical to conical to improve the flow control accuracy of the stopper. At the same time, change the size of the stopper head from 60 mm to 45 mm.

Improved plug installation method

Currently, the stopper rods are installed in the repair area, and vibrations during the transport of intermediate packages can adversely affect them. The existing stopper rod installation process should be improved by changing from offline installation to online installation before the intermediate package is baked, reducing the impact of intermediate package transportation. Additionally, before debugging the stopper rods, check the opening and closing beam for deformation and observe whether the stopper rods are straight. During installation and debugging, eliminate any “biting” and ensure strict alignment to prevent the stopper rods from breaking due to lateral forces during flow control.

Optimization of the baking process for stopper rods

To address thermal shock issues, the stopper rod baking procedure was optimized. When closing the tundish offline, the rim should be sealed tightly, and strict sealing is required before baking to improve the baking effect. The stopper rod should be closed when the tundish begins baking; it should be opened after half an hour of baking to facilitate the baking of the stopper rod and the water inlet. The tundish baking procedure was revised to specify a reasonable baking time. Prolonged baking shortens the tundish’s lifespan and may even render it unusable. The furnace must not be shut off during baking; otherwise, the tundish will be disposed of as unusable. The gas valve opening must be strictly controlled according to the tundish baking curve to ensure the temperature rises to above 1000℃ during the 1-2 hour baking period.

Improve the operation of stopper rods during the initial casting and steel pouring processes.

Instead of the existing practice of “checking the stopper” during the intermediate bread baking process, the practice will be changed to stopping baking before pouring and checking the stopper. If there is a small deviation in the stopper, it will be fine-tuned to reduce the negative impact caused by stopping baking and making forceful adjustments to the stopper during the baking process.

During the processes of changing the sprue nozzle, restoring bonding, and quick replacement of the tundish, the mode is first switched from “automatic” to “manual”. The operator holds the stopper rod handle, and the stopper rod closes by its own weight. Then the operator presses the handle to close the stopper rod and proceeds with the subsequent operations.

Implementation process and results

The above measures will be implemented in two steps: First, improve the tundish baking process, strengthen the tundish sealing, and improve the stopper baking effect, while improving the stopper installation and operation; second, optimize the stopper, with the manufacturer designing improved stopper drawings, manufacturing molds and stoppers, and conducting on-site testing when conditions permit.

The improved stopper rod was tested on-site. The process of baking, pouring and casting of the stopper rod was tracked. The stopper rod was required to be lifted out each time the machine was stopped. The steel grades cast included Q235, Q345, 45# and 50#. The condition of the stopper rod head was observed. The flow control was good and the stopper rod head was uniform.

The implementation of the above measures has achieved certain results. The number of continuous casting machine shutdown accidents caused by stopper rod breakage has gradually decreased. In 2022, the steel plant experienced only 2 stopper rod breakage accidents, a decrease of 10 compared to 2021, and the use of stopper rods has become more stable.

in conclusion

By controlling the trace additives added during the production of stopper rods and optimizing the rod shape, the thermal stability and flow control accuracy of the stopper rods can be improved, which is beneficial for stabilizing the liquid level in the crystallizer, reducing the number of stopper rod opening and closing cycles, and improving the performance of the stopper rods.

Through improvements and optimizations in on-site stopper installation, baking, and use, the breakage problems caused by thermal shock and mechanical damage to the stoppers have been reduced, making the use of tundish stoppers more stable.More information,please visit 

Henan Yangyu Refractories Co.,Ltd

In continuous casting operations, the ladle shroud is a critical refractory component used to protect molten steel from atmospheric reoxidation as it flows from the ladle to the tundish. However, many operators overlook a much smaller but equally important part of the system: the ladle shroud gasket.
Despite its simple appearance, the gasket plays a vital role in ensuring a stable, leak-free, and safe casting process.

This article provides a detailed, professional overview of what the ladle shroud gasket is, how it works, and why it is essential for achieving high-quality steel and stable casting performance.

1. What Is a Ladle Shroud Gasket?

A ladle shroud gasket is a specially designed sealing component placed between the ladle nozzle well block and the ladle shroud connecting plate.
Its primary purpose is to ensure an airtight, secure, and mechanically stable connection when attaching the ladle shroud to the ladle.

In simpler terms, the gasket:

• creates a seal between the ladle and the ladle shroud

• prevents steel leakage during shroud mounting

• protects the joint from thermal and mechanical stresses

• ensures the ladle shroud is aligned and firmly locked in position

Though small and inexpensive, the gasket is a critical safety component because failure at this junction can cause:

• atmospheric reoxidation

• steel leakage

• shroud misalignment

• casting disruption

• safety hazards for personnel

2. Why Is the Gasket Necessary? Technical Function

The ladle shroud gasket provides several important technical functions:

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2.1 Sealing Function (Leak Prevention)

When molten steel flows at temperatures above 1550°C, even minor gaps between the ladle and shroud connection can cause:

• steel leakage

• gas aspiration

• turbulent flow

The gasket eliminates these gaps by creating a compressive seal, ensuring the joint remains tight during casting.

2.2 Mitigation of Mechanical Stress

During casting:

• the ladle shroud is pressed against the ladle nozzle

• the system experiences continuous vibration

• mechanical stress increases due to steel flow pressure

The gasket acts as a flexible buffer, absorbing vibration and preventing damage to the refractory surfaces.

2.3 Thermal Compensation

Because the ladle and shroud heat up at different rates, thermal expansion can introduce gaps.

A gasket compensates for these differences by:

• maintaining uniform contact

• preventing crack formation

• improving thermal stability of the joint

2.4 Protection Against Atmospheric Reoxidation

Any gas infiltration near the joint increases the oxygen level in steel flow.

An intact gasket ensures:

• airtight sealing

• minimal exposure to atmosphere

• improved steel cleanliness

This is especially important for aluminum-killed and ultra-low oxygen steels.

3. What Materials Are Used for Ladle Shroud Gaskets?

Gaskets are usually made from high-temperature resistant, flexible, compressible materials.

Common materials include:

3.1 Ceramic Fiber Paper / Board

• Excellent temperature resistance

• Good compressibility

• Economical

• Suitable for most steels

3.2 Graphite-Based Gaskets

• High thermal shock resistance

• Good sealing properties

• Chemical inertness

• Common in high-temperature operations

3.3 Non-Asbestos Fiber Gaskets

• Environmentally friendly

• Good strength and flexibility

• Moderate temperature resistance

3.4 Vermiculite-Reinforced Gaskets

• High mechanical integrity

• Used for long casting sequences

• Superior erosion resistance

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4. Shapes and Designs of Ladle Shroud Gaskets

Different shroud manufacturers use different gasket designs depending on the connection mechanism.

4.1 Flat Ring Gasket

• Most common design

• Simple, reliable, and easy to install

4.2 Stepped or Profiled Gasket

• Follows the contour of the nozzle plate

• Enhances sealing capability

• Reduces risk of side leakage

4.3 Double-Layer Gasket

• Used when extremely tight sealing is required

• Improves thermal insulation

4.4 Customized Cut Gaskets

• For special ladle shroud geometries

• Laser-cut or die-cut for precision

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5. How the Gasket Is Installed

Proper installation is crucial to gasket performance.

Installation Steps:

1. Clean the ladle nozzle seating surface

2. Align the gasket with the mounting holes

3. Place the gasket evenly without folds

4. Position the ladle shroud mounting plate

5. Apply correct clamping force

Common Installation Mistakes to Avoid:

• Misalignment causing side leakage

• Uneven clamping pressure

• Damaged or torn gasket

• Using low-quality gaskets that degrade quickly

6. Factors Affecting the Life and Performance of the Gasket

6.1 Casting Temperature and Steel Grade

High-alloy steels increase thermal load.

6.2 Shroud Alignment

Misalignment increases mechanical stress on the gasket.

6.3 Gasket Material Quality

Higher-grade materials last significantly longer.

6.4 Installation Conditions

Dust, slag, or dirt reduce sealing efficiency.

6.5 Casting Sequence Length

Long sequences require enhanced gasket strength and thermal resistance.

7. Benefits of Using High-Quality Ladle Shroud Gaskets

Using premium-quality gaskets results in:

• Improved ladle shroud stability

• Better steel cleanliness (lower oxygen pickup)

• Reduced risk of steel leakage

• Longer connection life

• Fewer casting interruptions

• Higher overall safety

In high-precision steelmaking operations—such as automotive, electrical steel, or stainless production—proper gasket selection is essential.

Conclusion

The ladle shroud gasket may be a small component, but its importance in continuous casting cannot be overstated. As the interface between the ladle and ladle shroud, it plays a crucial role in ensuring tight sealing, thermal stability, mechanical integrity, and high steel cleanliness. Proper material choice, correct installation, and alignment are key to achieving a stable and smooth casting process.More information ,please visit Henan Yangyu Refractories Co.,Ltd

The monoblock stopper rod is a critical flow-control component in the continuous casting process. Installed in the ladle or tundish slide-gate system, the stopper rod regulates molten steel flow by adjusting the opening area between the nozzle seat and its controlled orifice. Because it is directly exposed to high-temperature steel, aggressive slag chemistry, thermal shock, and mechanical load, its performance significantly influences casting stability, steel cleanliness, and product quality.

Understanding the structural characteristics, materials, degradation mechanisms, and operational best practices of the monoblock stopper rod is essential for achieving long casting sequences and minimizing risk of nozzle leakage or flow instability. This article summarizes the key technical tips every steel plant should know.

1. Understand the Structure and Working Principle of the Monoblock Stopper Rod

A monoblock stopper rod is a single-piece, integrated ceramic system designed to precisely control molten steel flow. It typically consists of:

1. Tip (Working end)

   • Exposed directly to molten steel

   • Requires high erosion resistance and thermal shock stability

   • Often

2. Body (Shaft)

   • Transfers mechanical force to the tip

   • Must be strong yet lightweight to reduce arm load

   • Usually alumina-graphite with high flexural strength

3. Up

   • With

   • Requires good dimensional tolerance and mechanical integrity

The key working principle is:

• The stopper rod moves vertically to adjust the annular opening between the rod tip and nozzle seat.

• This controls steel flow rate, jet length, and casting meniscus stability.

• Smooth movement is essential to avoid flow surges and inclusion entrapment.

2. Choose the Proper Material System Based on Casting Requirements

Material

2.1 High-Zirconia Carbon (ZrO₂-C)

• Excellent corrosion resistance against aggressive steels

• Very stable against Al-killed steel environments

• Preferred for long-sequence slab or bloom casting

2.2 To

• Good thermal shock resistance

• To

• Economical and widely used

2.3 Low-Carbon or Carbon-Free Systems

• Reduce carbon pick-up and CO bubble generation

• Improve steel cleanliness for ultra-low-inclusion grades

• Critical for interstitial-free and automotive steels

2.4 Tips for material selection

• For stainless steel → use high-ZrO₂ systems

• For high-aluminum steels → ensure anti-oxidation coatings

• For long casting campaigns → use high-density, isopressed products

3. Pay Attention to Stopper Rod–Nozzle Seat Interaction

The interface between the stopper rod tip and nozzle seat is the most critical point in casting flow control.
Problems in this area can lead to:

• Leakage

• Turbulent flow

• Uncontrolled casting speed

• Accelerated clogging

• Inclusion entrapment

Best practices:

• Ensure precise geometry to achieve a uniform annular gap.

• Avoid thermal mismatch between stopper rod and nozzle.

• Use anti-oxidation, anti-slag-wetting coatings to reduce buildup.

• Maintain alignment between stopper rod and nozzle bore.

A misalignment of even 1–2 mm can cause severe turbulence and steel quality defects.

4. Understand the Main Failure Mechanisms

A monoblock stopper rod faces multiple types of degradation. Knowing these mechanisms helps prevent premature failure.

4.1 Oxidation

Graphite in the refractory oxidizes when exposed to air or oxygen-rich slag.
→ leads to porosity growth, strength reduction, and erosion.

4.2 Slag Erosion

Basic slags (CaO-rich) or acidic slags (SiO₂-rich) dissolve refractory surfaces.
→ anti-slag coatings are essential.

4.3 Thermal Shock

The rod experiences rapid temperature change when first immersed.
→ high-modulus graphite and fine-structure alumina reduce spalling.

4.4 Mechanical Load & Wear

Vibration or actuator misalignment causes tip abrasion.
→ requires strong bonding and consistent density.

4.5 Steel–Refractory Reaction (especially in Al-killed steel)

Al₂O₃ deposition at the interface can cause:

• Increased resistance to movement

• Flow instability

• Premature clogging

5. Control Operational Conditions to Extend Stopper Rod Life

Proper operation can increase stopper rod campaign life by 30–50%.

5.1 Preheating

Gentle, controlled preheating prevents thermal shock.

5.2 Correct Argon Injection (if applicable)

• Too low → clogging increases

• Too high → turbulence and re-entrainment

• Optimal → improves steel cleanliness and flow stability

5.3 Smooth Actuator Motion

A jerking motion causes:

• Flow surges → inclusions

• Wear on the nozzle seat

• Risk of breakthrough

Modern electro-servo stopper actuators provide better stability.

5.4 Accurate Stopper Position Calibration

Misalignment can:

• Cause eccentric wear

• Increase clogging

• Lead to molten steel leakage

6. Optimize Stopper Rod Geometry for Your Casting Mode

Different casting processes require different stopper geometries.

6.1 Long strand slab casting

• Use elongated tips for deeper penetration

• Prefer high-ZrO₂ systems

6.2 Billet and bloom casting

• Shorter tapered designs for fast response

• Require high thermal shock resistance

6.3 High-speed casting lines

• Aerodynamic designs to reduce flow separation

• Optimized surface coatings

7. Maintenance and Inspection Tips

To ensure consistent casting performance:

Before casting:

• Check for cracks, tip defects, surface spalling

• Confirm actuator calibration

• Verify coating uniformity

During casting:

• Monitor stopper movement behavior

• In

After casting:

• Examine the rod and nozzle seat for:

  • Buy

  • Clogging deposits

  • Chemical attack zones

Documenting the damage provides guidance for future material optimization.

Conclusion

The monoblock stopper rod is a mission-critical flow-control component in continuous casting. Proper understanding of its materials, design principles, failure mechanisms, and operational considerations can significantly enhance casting stability and steel quality. By selecting high-performance materials, optimizing rod–nozzle interaction, controlling thermal and chemical environments, and maintaining precise operational control, steel plants can extend campaign life and achieve superior metallurgical results.More information,please visit HYRE
leaks.

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