Seven Refractories Russia has successfully completed a project for a walking beam furnace sidewall repair. A new concept of lining was installed during the repair of WBF n°5 in NLMK. The repair was performed in a tightly run project in only two weeks between October 14th and 25th.
The main aim of the project was to increase the resistance of the sidewall above the burner zone and to avoid occurences detachment that are common with standard lining concepts using insulation bricks and plastic material.
The project was composed of 70 m2 of ceramic boards, one layer of Sevenlite 1300 and one layer of Seven Shot 60 NH CO as a working lining, the equivalent of 52 tons of unshaped refractories. The 11 days of project work included the demolition of the old lining, the complete replacement of the ceramic anchors with metallic parts, and the sealing of the open space between roof and sidewall.
After successful completion, the walking beam furnace returned to full operation: Seven days of drying and heating were enough to fully perform its function again. Temperature values were checked constantly both inside the lining and on the metal shell of the furnace, showing lower values compared to the standard lining currently used.
“The client decided to entitle Seven with the project based on the performance of our products and the project management that we can offer”, explains Roman Cheglov, Seven’s responsible manager for the Russian market. “We are very pleased, both with the technical results and the speed of implementation. The quicker our clients have their furnaces online again, the better for them.”
BF N°9 – Main runner n°2 – SEVEN CAST 2770 UB
Installation and heating up has been done from 29 May to 3 June 2014.
120 tons of Seven Cast 2770 UB has been delivered to the plant to fulfill the standard throughput campaign of 300’000 tons of pig iron.
80 tons of vibrating castable has been used for the first installation and to rebuilt completely the working lining, Seven Refractories technicians followed and controlled all the phases of the job starting from the inspection of the runner before castable application until the beginning of iron casting operations.
Casting of iron started on June 3rd without any problems.
One intermediate repair has been performed after 200.707 tons iron throughput on 26th of August , casting 28 tons of residual 40 tons in warehouse.
Specific consumption has been estimated as low and condition of the runner showed no particular wear in the most critical areas.
On October 20th 294.000 tons of pig iron were casted.
The runner will reach the target guaranteed within October 25th and then will continue to work until the end of November due to good condition of the residual lining.
MMK project represent a key milestone for Seven Russia in one of the biggest steel plant all over the world.
Seven Refractories Ukraine in cooperation with Gunform LCC (UK) has successfully conducted the repair of the blast furnace n°5 (hearth diameter 12,648 м, and working volume 2300 m3) in MMK Ilicha- Metinvest Holding in Mariupol.
The shotcrete job has been started on May 23rd and ended on May 25th 2014.
370 tons of dense refractory castable have been installed with use of robotic shotcrete equipment without any delay; the blast furnace has been consigned to the customer according the schedule agreed.
The repair has been performed with a pod driven from outside the furnace after complete removal of the BF top charging bell with a re-profiling of the upper part of the bosh, the full belly with shotcrete castable based on silicon carbide and fused corundum.
Stack with exclusion of areas of the armored plates has been lined with mullitic shotcrete castable “CO resistant”.
The MMK Ilicha project is the second blast furnace shotcrete repair in Ukraine after the repair held in AMK Alchevsk in October last year. Also in August last year a shotcrete repair in AMK Alchevsk was cionducted with usage of our materials.
Through our technical department we supplied the complete engineering for the refractory lining and through a partnership with an Italian installation company we have installed all the refractory materials.
The new furnace started the production on the 3rd week of May 2014.
At BF-3 NLMK (Lipetsk) Seven Refractories and the installation company Refracon performed gunning repair of hot blast pipe and stoves system.
This project included refurbishment of damaged arcs of brick lining in regions of hot blast valves and valve fittings of 3 staves where brick lining were fallen out; restoration of combustion chambers front walls, local gunning of straight pipe of bustle pipe (inlets from staves) and area around valve “on draught”.
All these jobs were made by one team within 2 day-shifts under strict control of Seven technical engineers. Totally there were installed 21 t of gunning material using anchoring system in the most damaged places like holes in top of arches. This method of repair is very adequate alternative to local repairs of brick lining, especially in cases where the repair of brick lining requires a lot of time and big scale of demolition before construction.
A significant and strategic agreement between Saint Gobain Group and Seven Refractories was achieved in Divača on the 25th of February 2014.
A large Sales Meeting with representatives of Saint Gobain coming from all the major European countries was held in Seven premises in order to consolidate this important partnership: Seven will supply the new high end monolithics range for the SG Waste to Energy – power plant offer.
The innovative plant concept in Divaca, combining efficiency, reliability and flexibility as well as the Seven product development team matches at best the high expectations of the SG global leading group.
The full product range SG Cast, SG Gun, SG Trow, it’s available by now from the experienced SG Sales team and will be formally launched at the Munich fair IFAT in May.
Seven Refractories will support with its best resources the project and its proud of this new development step.