Multi-impregnating pitch-bonded Egyptian dolomite refractory brick for application in ladle furnaces

A method of preparation of multi-impregnated pitch-bonded Egyptian dolomite refractory brick for ladle furnace is described. Brick samples were prepared from blend of calcined dolomite mineral and coal tar pitch. The blend was hot mixed and pressed under a compression force up to 151 MPa. Green bricks were baked for 2 h at temperatures up to 1000 °C. Voids in the baked bodies were filled with carbon by multiple impregnations using low-softening point coal tar pitch. Each impregnation step (30 min) was followed by calcination at 1000 °C. Brick samples containing 8–12 wt.% coal tar pitch binder and pressed under 108–151 MPa acquired quantify crushing strength. However, multi-impregnating favored the mechanical strength of the baked brick samples and improved their hydration resistance (>45 days). Dolomite brick samples containing 10 wt.% coal tar pitch and pressed at 108 MPa gave high hydration resistance (more than 60 days in normal condition) compared to the hydration resistance of the commercial bricks (30 days). The prepared brick samples have acceptable density, chemical stability, outstanding resistance and good mechanical properties would meet the requirements of Ladle furnace (LF) for steel making industry. In addition, estimation of production cost of the brick indicates it is competitive with the market price based on durability and service life time aspects.