Blast furnace tap hole clays can be extremely sophisticated refractory products. The correct selection is affected by several blast furnace operating factors. The complexity of these formulations mirrors the multitude of often conflicting properties and characteristics that are demanded from the modern day tap hole clay, e.g. refractory properties, plasticity, erosion stability and the suitability to form a compact leak-proof plug. However, the tap hole clay manufacturer not only has to address these 'service' requirements but increasingly there is pressure to meet demanding health and safety as well as environmental standards. The finished product may not look that impressive when stacked on a pallet but this material represents the culmination of significant knowledge and experience in terms of materials technology design. It is our experience that quite often products need to be modified, even custom designed to adapt to a specific furnace or operating practice. Also it is not always the largest furnace representing the biggest challenge. The paper describes challenges for the complete product chain from raw material selection, production to final application and how to overcome especially operational difficulties.
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