Method of installing a refractory lining

A method of installing a refractory lining in a wall of an electric induction furnace, the method comprising the steps of:

• providing a dry refractory material between a liner form placed within the furnace and a furnace wall;
• placing at least one variable frequency/amplitude electric vibrator in operational communication with an element selected from a structural member of the furnace, the liner form, and a vibrator rig placed within the furnace;
• operating at least one variable frequency/amplitude vibrator in a first operational mode having a high amplitude, low frequency vibration such that flow of the dry refractory material is induced and the volume of the dry refractory material is reduced;
• and
• operating at least one variable frequency/amplitude vibrator in a second operational mode having a low amplitude, high frequency vibration such that compaction of the dry refractory material occurs after flow of the dry refractory material is induced.

A method of installing a refractory lining in a wall of an electric induction furnace, the method consisting essentially of the steps of:

• providing a dry refractory material between a liner form placed within the furnace and a furnace wall;
• placing at least one variable frequency/amplitude electric vibrator in operational communication with an element selected from a structural member of the furnace, the liner form, and a vibrator rig placed within the furnace;
• inducing flow of the dry refractory material by operating at least one variable frequency/amplitude vibrator in a first operational mode having a high amplitude, low frequency vibration;
• and
• compacting the dry refractory material by operating at least one variable frequency/amplitude vibrator in a second operational mode having a low amplitude, high frequency vibration after inducing flow of the dry refractory material.

A method of installing a refractory lining in a wall of an electric induction furnace, the method comprising the steps of:

• providing a dry refractory material between a liner form placed within the furnace and a furnace wall;
• placing at least one variable frequency/amplitude electric vibrator having a rotating shaft in operational communication with an element selected from a structural member of the furnace, the liner form, and a vibrator rig placed within the furnace;
• inducing flow of the dry refractory material by operating at least one variable frequency/amplitude vibrator in a first operational mode having a low frequency vibration and a first shaft rotational direction;
• and
• compacting the dry refractory material by operating at least one variable frequency/amplitude vibrator in a second operational mode after inducing flow of the dry refractory material, the second operational mode having a high frequency vibration and a second shaft rotational direction, the said first shaft rotational direction causing the vibrator to vibrate at high amplitude and the second shaft rotational direction causing the vibrator to operate at low amplitude.

A method of installing a refractory lining in a wall of an electric induction furnace, the method comprising the steps of:

• providing a first quantity of a dry refractory material between a liner form placed within the furnace and the furnace wall;
• placing at least one variable frequency/amplitude electric vibrator having a rotating shaft in operational communication with an element selected from a structural member of the furnace, the liner form, and a vibrator rig placed within the furnace;
• inducing flow of the dry refractory material by operating at least one variable frequency/amplitude vibrator in a first operational mode having a high amplitude, low frequency vibration in the first operational mode;
• compacting the dry refractory material by operating at least one variable frequency/amplitude vibrator in a second operational mode having a low amplitude, high frequency vibration after inducing flow of the dry refractory material;
• and
• providing a programmable controller in operational communication with at least one variable frequency/amplitude vibrator, the controller being capable of storing and sending instructions for direction of vibrator shaft rotation, vibrator speed, and time of vibrator operation, a first direction of vibrator shaft rotation causing operation of the vibrator at high amplitude and a second direction of vibrator shaft rotation causing operation of the vibrator at low amplitude.

A method of installing a refractory lining in the floor portion of an electric induction furnace, the method comprising the steps of:

• providing a dry refractory material in the floor portion of the furnace;
• providing at least one variable frequency/amplitude electric vibrator equipped with a vibrating bottom plate;
• and
• compacting the dry refractory material by causing the vibrating bottom plate to engage the dry refectory material when at least one variable frequency/amplitude vibrator is in an operational mode having a low amplitude, high frequency vibration after inducing flow of the dry refractory material.

A method of installing a refractory lining in an electric induction furnace, the method comprising the steps of:

• installing a refractory lining in the floor portion of the furnace;
• providing a dry refractory material between a liner form placed on the floor portion of the refractory lining and the furnace wall;
• placing at least one variable frequency/amplitude electric vibrator in operational communication with an element selected from a structural member of the furnace, the liner form, a vibrator rig placed within the furnace;
• inducing flow of the dry refractory material by operating at least one variable frequency/amplitude vibrator in a first operational mode having a high amplitude, low frequency vibration;
• and
• compacting the dry refractory material by operating at least one variable frequency/amplitude vibrator in a second operational mode having a low amplitude, high frequency vibration after inducing flow of the dry refractory material.

A method of installing a refractory lining in an inductor of an electric channel induction furnace, the method comprising the steps of:

• placing a channel form inside an inductor casing;
• installing at least one bushing spaced at a distance from the interior of the channel form;
• filling the inductor casing with dry refractory material;
• placing at least one variable frequency/amplitude electric vibrator in operational communication with an element selected from the inductor casing and the channel form;
• inducing flow of the dry refractory material by operating at least one variable frequency/amplitude vibrator in a first operational mode having a high amplitude, low frequency vibration;
• and
• compacting the dry refractory material by operating at least one variable frequency/amplitude vibrator in a second operational mode having low amplitude, high frequency vibration after inducing flow of the dry refractory material.

A method of installing a refractory lining in a wall of an electric induction furnace, the method comprising the steps of:

• providing a dry refractory material between a liner form placed within the furnace and a furnace wall;
• placing at least one electric vibrator in operational communication with an element selected from a structural member of the furnace, the liner form, and a vibrator rig placed within the furnace;
• inducing flow of the dry refractory material by operating at least one electric vibrator in a first operational mode having a high amplitude, low frequency vibration;
• and
• compacting the dry refractory material by operating at least one electric vibrator in a second operational mode having low amplitude, high frequency vibration after inducing flow of the dry refractory material.