Nowadays, finding ceramic materials with good physical-chemistry characteristics to make
ceramic cups is no longer a big difficulty. However, the stability of the construction,
the anti-penetration ability and the adaptability of the working profile of the hat face
of the ceramic cup are of critical importance to prolong the campaign life of the ceramic
cup itself and thus the BF hearth. In a lot of cases, the so-called “ceramic cup” is
formed just by one, two or more rings of the standard-shaped ceramic bricks which are
installed closely against the carbon hot face. In these linings, there are many
penetrating linear joints from the hot face to the cold face through the ceramic lining.
Both the overall stability of the construction and the anti-penetration ability of the
lining are very poor. Therefore, the goal of installing a ceramic cup, to protect the
carbon lining from the erosion of hot metal, would be difficult to achieve and the
lifetime of the ceramic cup would not be long no matter what excellent materials were
being used. However, an “Integrated Ceramic Cup” structure for the BF hearth is composed
of special-shaped ceramic blocks which are all interlocked with each other. In such a
construction, there is no linear breakthrough joint from the hot face to the cold face of
the ceramic lining. A ceramic lining with this structure can effectively avoid hot metal
and gases penetrating into and then through the joints of the ceramic lining to attack the
carbon lining behind. As a result, the campaign life of the BF hearth, and also the
campaign life of the blast furnace, would be prolonged. Nowadays the “Integrated Ceramic
Cup” structure has been used in many modern blast furnaces and its significant performance
has been proved.