iron making solutions to extend blast furnace lifetime ... · example where a specific advanced...

BLAST FURNACEPERFORMANCECERAMICS andREFRACTORIES

IRON MAKINGSolutions to extend Blast Furnace life-time

INCREASED LIFETIMEImprove your blast furnace liningSupplying all required refractory products specifically developed to extend BF lifetime. Unparalleled experience in BF design supply for over 50 years and several hundred references, relying on global production capacity with factories positioned worldwide to

serve all areas.

EXPERTISEMore than 50 years of experienceRich experience constitutes our total design capability that is unique and unsurpassed, thanks also to the knowledge gained via companies such as Savoie Refractories and Carborundum.

R&D FOCUSAmong TOP 100 Global InnovatorsR&D is part of the DNA of the Group, ranked as one of the top 100 innovators in the world. For our ceramics and refractory activity we invest strategically in innovation to bring you the most efficient solutions developed at Saint-Gobain Research Provence, our center for R&D in Europe with a specialised team dedicated to Blast Furnace application.

ENGINEERING DESIGN CAPABILITYCustomised SolutionsWe measure our success with your operating results. To enhance your performance, our team of passionate top skilled engineers are ready to develop the best adapted solutions for your needs.

QUALITY SUPPLYInternational and global network of divisions and suppliers allow us to access the best quality inputs for our materials. Innovation focuses on material properties to supply solutions specifically adapted to Blast furnace application.

• Top Quality Grades • Wide Range of Grades

INSTALLATIONMore than 350 references that have built our market recognition

• Supervision • Technical assistance

DESIGNOur engineers tackle your design challenges with forefront equipment at your service with great experience/knowledge.

• Full BF design including Carbon• Thermal Calculations using Ansys, Abaqus, etc.• Repairs

• Large Block Size Capability• Tailor-made Solutions

We have the following certificates:

Quality: DIN EN ISO 9001 Environment: DIN EN ISO 14001 Occupational Safety: OHSAS 18001

FULL SUPPLYFull Inclusive Reline Service

UPPER STACKIn this low temperature area, abrasion by the solid burden is the primary mode of wear. Our silicon carbide has proven to be cost-effective solution.

LOWER STACKAbrasion by the coke burden is still a concern but driven by an increasing temperature, in depth attack by Alkali and Zinc vapor become predominant . Our REFRAX 20 SBF is a worldwide recognized reference for this application

BOSH AND BELLYIn addition to Alkali and Zinc attack, the occurrence of molten iron and slag calls for SiAION bonded materials. We recommended either our silicon carbide Sicanit AI3 or our Corundum based Coranit 3S. The final decision dependes on thermal conductivity requirement (low, to save energy, or high, to promote a protective skull).

TUYERE BELTThe tuyere sourrundings experience high heat load and thermal shock in combination with corrosion by molten iron and slag and intense Alkali and Zinc vapor attacks. Backed by a unique range of refractory materials, including silicon nitride or SIAON bonded shapes and pre-formed no and low cement castables, our engineered tuyere sourrounings will fit best to the specific requirements of your blast furnace operation.

HEARTHTraditionally, blast furnace hearths are lined with high ther-mal conductive carbon-based materials. Placed inside the carbon lining the concept of the SG Ceramic Cup is an example where a specific advanced design and material quality render significant benefit to blast furnace operators in terms of lifetime extension and operational efficiency. Be-ware of cheap copies on the Ceramic Cup. Design (avoid-ing high stress, and items floating off) Material Quality (to ensure slow wear) and correct Installation all need to be correct to ensure good lifetime

Coranit SlagR / Coranit ALMS4 / MS4R / MS10

Refrax 20 SBF / Sicanit AL3 / Coranit 3S

Sicanit AL3Refrax 20 SBF / SiC 85P/ MS2R

Refrax 20 SBF / SiC 85PMS2R / MS6

MonoCoral / MonoGuard/ Sicanit TM

HEARTH LINING Our Philosophy - Enhancing Perfomance

“Saint-Gobain has pioneered and promoted “Ceramic Cup” technology since 1982. We have learned a lot over last four decades. We are now into our third generation of design (sialon bonded corundum – “Coranit”) and have recently developed a new improved quality called “Coranit SlagR.”

Detailed feedback from users has shown that the “Coranit” grade wears very gradually over the lifetime of the hearth. 400mm thickness has been shown to last 9 years or more. Af-ter the Ceramic Cup has worn, the carbon then wears quite rapidly until an equilibrium is reached whereby the hot face is sufficiently cooled to allow a self-protecting “skull” to form.

Operators are then able to maintain a stable “skull” to achieve required campaign life-time. It has been observed on many occasions however that when the protective “skull” is lost the carbon can be worn away very rapidly re-sulting in dangerous situations. The Ceramic Cup does not depend on a “skull” to achieve its intended lifetime.

We can design your BF Hearth using the fol-lowing PHILOSOPHY:Hot-Face of Ceramic Cup, with just enough thickness of carbon behind to allow a protec-tive “skull” to build-up. No point in having too thick carbon as it will quickly wear to the equi-librium point.

In a perfect world the operator is able to achieve an eternal hearth lifetime by maintaining forever the protective “skull.” In this case, there is no need for Ceramic Cup. Unfortunately, we do not live in a “perfect world”. Operators get the benefit of maybe 10 years lifetime on the Ce-ramic Cup before needing to stabilise the “skull” (and avoid water leakages, variable raw mate-rials, unplanned stoppages, large-dense dead-man formation, productivity variations etc.). It is this assurance that operators are given when adopting SG Ceramic Cup technology.”

HEARTHBrick Solution

Designed to boost the performance of BF, withstanding the severe conditions inside Blast Furnace hearth. Applicable also in other parts of BF that face extreme conditions. Heat flow from the hearth wall/bottom are in the ratio of approxi-mately 80:20. With a Ceramic Cup wall the thermal conductivity of the Coranit is around 3.5 W/mK at 1000C whereas many super-micropore carbons are over 20W/mK. Heat flow at hearth wall drops from around 15 W/m² with carbon to 5w/m² with a Coranit Ceramic Cup. It is clear that heat flow reduction is good for the environment, good for economy!

CERAMIC CUP WALLPioneering this solution since 1982, recently achieved a 3rd generation of materials that present enhanced the charac-teristics.

Sialon Bonded Corundum BrickCoranit SlagR Improved Mechanical Stability Better Slag/Iron Resistance Excellent Abrasion ResistanceCoranit AL Iron / Slag Corrosion Resistant Good Abrasion Resistance Alkali Corrosion Resistance

CERAMIC CUP PADBest solutions to protect the bottom of the blast furnace, with materials that are highly resistant to Iron.

High Alumina Brick MS4 Mullite / MS4R Both MS4 and MS4R are well suited for hearth pad application being iron resistant and stable MS4 being the classical mullite recipe. Both have numerous references in circular and herring bone design.

TUYERE BELT and BOSHBig Block SolutionBig Block tailor-made that can be customised according to your needs. There is no universal quality that has been ac-cepted as recognised solution for tuyere belt, carbonaceous materials as well as SiC or Al2O3 are used but we suggest our three top performing materials. Each operator can decide the best solution depending on what he considers to be the main wear mechanism for his BF (refractoriness, slag/iron attack, oxidation attack, alkali attack, abrasion etc.)”.As for Bosh application, Sicanit AL3 (sialon bonded SiC) with improved alkali and oxidation resistance or Coranit 3S (sialon bonded corundum) are most often chosen, the latter when low thermal conductivity is required. Refrax 20 SBF or MS2R can also be chosen for lower stack..

TUYERE BELTMonoCoralThe original Ultra-Low Cement Corundum Big Block with 89% alumina. Almost 100 references for tuyere and counting

Sicanit TMNovel large block sialon bonded SiC. Similar properties of small brick sialon bonded SiC but avoiding mortar joints and complications of installation and multiple complex brick items.

MonoGuardImproved Corundum Big Block, increased Iron and Slag resistance, high strength and stability.

Silicon Carbide (Sialon) BrickSicanit AL3

Corundum (Sialon) BrickCoranit 3SSilicon Carbide (Nitride) BrickRefrax 20 SBF

BOSH

Values MS4 MS4R

Typical Chemical AnalysisAl2O3

Fe2O3

Na2O+K2O

72,5%0,3%0,7%

Al2O3

Fe2O3

Na2O+K2O

71%0,7%0,4%

Bulk Density 2,5 g•cm-3 2,65 g•cm-3

Apparent Porosity 18% 16%

Cold Crushing Strength 120 MPa 70 MPa

Permanent Change of Dimension after firing 3 hours at 1500 °C +0,5% +0,1%

Thermal Conductivity at 1000 °C 2,2 W•m-1

•K-1 2,25 W•m-1•K-1

MATERIAL VALUES

Values Coranit AL Coranit SlagR

Typical Chemical Analysis Al2O3

Nitrogen89%4,8%

Al2O3

Nitrogen77%6.0%


Apparent Porosity 14% 11,5%


Permanent Change of Dimension after firing 3 hours at 1500 °C 0% 0


•K-1 3,9 W•m-1•K-1

Values MonoCoral MonoGuard

Typical Chemical Analysis

Al2O3

Fe2O3

SiO2

CaOSiC

89,5%0,3%7,0%0,5%

---

Al2O3

Fe2O3

SiO2

CaOSiC

87%0,3%

---0,2%4,0%



Permanent Change of Dimension after firing 3 hours at 1500 °C +1% ---


•K-1 4,0 W•m-1•K-1

Values Sicanit AL3 Sicanit TM

Typical Chemical AnalysisSiC

Nitride MatrixNitrogen

Al2O3

71%27%6,2%

13,3%

SiCNitride Matrix

NitrogenAl2O3

75%---

3,7%---


Apparent Porosity 15,5% 16%


Permanent Change of Dimension after firing 3 hours at 1500 °C 0% ---

Thermal Conductivity at 1000 °C 15 W•m-1

•K-1 10 W•m-1•K-1

Coranit 3SAl2O3

Nitrogen78%6,0%

3,24 g•cm-3

12%

250 MPa

0%

3,2 W•m-1•K-1

Refrax 20SBFSiC

Nitride MatrixNitrogen

Al2O3

78%17%7 %---

2,62 g•cm-3

17%

165 MPa

---

18.5 W•m-1•K-1

REFERENCES CERAMIC CUPOver 92 References for Ceramic Cup

Year Customer Location Country BF-N. Hearth (m) Bottom Ceramic Cup

2018 Thyssen Krupp Stahl Schwelgern Germany 1 13,6 Coranit SlagR

2017 Voest Alpine Stahl Linz Austria A 12 MS4 Coranit AL

2016 ArcelorMittal Bremen Germany 2 12 MS4 Coranit AL

2016 PW / NLMK Lipetsk Russia 6 12,3 Coranit AL

2016 ArcelorMittal Eisenhüttenst. Germany 5A 9,75 MS4 Coranit AL

2015 Tata Corus Ijmuiden Ijmuiden Netherland 7 13,8 MS4, MS10 Coranit AL

2013 Jindal Steel Power Ltd Raigarh India 1 6,5 MS4R MonoCoral

2013 Dillingen Rogesa Dillingen Germany 4 11,2 48% Al2O3 Coranit AL

2012 HKM Huckingen Germany B 11 MS4 Coranit AL

2011 Bhilai steel Bhilai India 8 13,4 MS4R Coranit AL

2011 Hyundai Danjin South Korea 3 14,8 70%Al2O3 48%Al2O3 Coranit AL

2011 Thyssen Krupp Stahl Schwelgern Germany 2 14,9 48% Al2O3 Coranit AL

2010 ArcelorMittal Krivoi Rog Ukraine 6 9,75 MS4R Coranit AL

2008 Thyssen Krupp Stahl Hamborn Germany 9 10,2 MS10 Coranit AL

2008 Enakievo Iron & Steel Enakievo Ukraine 3 9,1 MS4R, MS10 Coranit AL

2008 Hyundai Danjin South Korea 2 14,8 70%Al2O3, 48%Al2O3 Coranit AL

2008 Shagang ZhangJiagang China New BF 15,3 Coranit AL

2008 Hyundai Danjin South Korea 1 14,8 70%Al2O3, 48%Al2O3 Coranit AL

2009 ArcelorMittal Tubarão Brazil 2 8Mulfrax

301MSE,M 601

Coranit AL

2007 ArcelorMittal Fos France 2 12,3 MS4R, MS10 Coranit AL

2007 Dillingen Rogesa Dillingen Germany 5 12 MS4, MS10 Coranit AL

REFERENCES TUYERE BELT138 References for Tuyere Belt since 1986

Order in Customer Location Country BF-no. Hearth (m) Tuyeres

2018 Thyssen Krupp Stahl Schwelgern Germany 1 13,6 MonoCoral

2017 ArcelorMittal Bremen Germany 2 12 SICANIT TM SICANIT AL3

2017 DK Recycling Duisburg Germany 3 5,5 SICANIT TM

2016 EKO Stahl Eisenhüttenst. Germany 5A 9,75 MonoGuard

2016 Voest Alpine Stahl Linz Austria 6 8 MonoGuard

2014 Voest Alpine Stahl Linz Austria 5 8 MonoGuard

2014 JSW Dolvi Dolvi India 1 13,8 MonoCoral

2014 SG PAM Pont à Mous-son France 3 5,68 MonoCoral

2014 Voest Alpine Stahl Linz Austria A 12 MonoGuard

2013 ArcelorMittal Newcastle S.Africa 5 10,14 MonoCoral

2013 Voest Alpine Donawitz Donawitz Austria 1 8 MonoCoral

2013 Jindal Steel Power Ltd Raigarh India 1 6,5 MonoCoral

2013 Dillingen Rogesa Dillingen Germany 4 11,2 MonoGuard

2012 HKM Huckingen Germany B 11 MonoCoral CORANIT

2011 Bhilai steel Bhilai India 8 13,4 REFRAX 20SBF


2011 Thyssen Krupp Stahl Schwelgern Germany 2 14,9 MonoCoral

CORANIT

2011 Arcelor Mittal Asturias Gijon Spain B 11,7 MonoCoral

2010 Bhushan Steel Ltd Orissa India 2 13 REFRAX 20SBF

2010 DK Recycling Duisburg Germany 3 5,5 MonoCoral

2010 ArcelorMittal Temirtau Kazakhstan 2 9,75 MonoCoral


2009 Lucchini Piombino Piombino Italy 4 11,65 REFRAX 20SBF

REFERENCES BOSH & STACK111 References Bosh and 82 for Stack since 1982

Order in Customer Location Country BF-N. Hearth (m) Bosh Stack

2018 Primetals / TATA Port-Talbot Port-Talbot Great-Britain 5 10,8 SICANIT AL3

2017 Voest Alpine Stahl Linz Austria A 12 REFRAX 20SBF

2017 USS Gary Gary USA 8 REFRAX 20SBF

2016 ArcelorMittal Bremen Germany 2 12 REFRAX 20SBF

2016 NLMK Lipetsk Russia 7 13,1 SICANIT AL3

2014 JSW Dolvi Dolvi India 1 13,8 SICANIT AL3

2014 Bhushan Steel Ltd Orissa India 2 13 SICANIT AL3

2014 HKM Huckingen Germany B 11 REFRAX 20SBF MS10

2014 SG PAM Pont à Mous-son France 3 5,68 43% Al2O3 43% Al2O3

2013 Tata steel Ltd Kalinganagar India 1 13,9

2013 Voest Alpine Stahl Linz Austria A 12 CORANIT

2013 ArcelorMittal Newcastle S.Africa 5 10,14 REFRAX 20SBF

2013 Dillingen Rogesa Dillingen Germany 4 11,2 48% Al2O3

2012 Berry Metal (USS) Ecorse USA SICANIT AL3

2012 Berry Metal (USS) Kosice Slovakia 2 10,8 SICANIT AL3

2012 Berry Metal (USS) Gary USA 14 12,395 SICANIT AL3

2012 Thyssen Krupp Stahl Schwelgern Germany 2 14,9 CORANIT

2012 Neelachal Kalinganagar India 1 9,6 SICANIT AL3 SICANIT AL3

2011 Bhilai steel Bhilai India 8 13,4 SICANIT AL3

2011 Thyssen Krupp Stahl Schwelgern Germany 2 14,9 CORANIT CORANIT

CONTACTSWorldwide Presence

www.refractories.saint-gobain.com

Saint-Gobain IndustrieKeramik Rödental Gmbh

Concordiaplatz 351143 KölnGermanyPhone: +49(0)2203956275Fax: +49(0)2203956459

Saint-GobainIndustrial Ceramics

Mill Lane, Rainford, St. Helens WA11 8LPUnited KingdomPhone: +44 (0) 1744 88 2941Fax: +44 (0) 1744 884746

Savoie Réfractaires

4, rue de l‘Industrie 69200 Vénissieux FrancePhone: +33 (0) 4 78 78 14 38Fax: +33 (0) 4 78 78 14 65

Saint-Gobain Grindwell Norton ltd

Village: GET MUVALA, Halol, R.S No: 54/1,Paiki, 55/2,57,56 Halol, Dist Panchmahal 389350 IndiaPhone:+91 7228950889Fax: +91 2676-300086/87

Saint-Gobain Grindwell Norton ltd

Devanahalli, Off old Madras roadBangalore - 560 049IndiaPhone: +91-80-28471130Fax: +91-80-2847205

Saint-Gobain Ceramics

1 New Bond StWorcester, Ma 01606USAPhone: +1 (508)-795-5577Fax: +1 (508)-795-2051

Saint-Gobain Do Brazil Productos Industriais e para construção ltda

Avenida Independência, 7031Vinhedo - SP, 13284-400 BrazilPhone: +55 (19) 2127-8680Fax: +55 (19) 2127-8548

September 2018

iron making solutions to extend blast furnace lifetime ... · example where a specific advanced...

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