Indonesia National Seminar Iron & Steel IV Bandung

BLAST FURNACES RUNNERS

Stephane LAMONTRE
Technical Manager I&S SEA, Pacific
Calderys Indoporlen

CALDERYS ABOUT US

We are a world leader in providing refractory

projects

Providing end-to-end refractory product
portfolio across diverse industries

Delivering exceptional project management
services - from planning and installation, to
turnkey delivery and commissioning

Annual revenue over 500 million EUR

More than 100 years of experience. Created by the

merger in 2005 of Lafarge Refractories & Plibrico
International

Fully owned subsidiary of Imerys

Our business delivery model

Leveraging the benefits of a global scale and an integrated system

Constant benchmarking of technical solutions,

Globally coordinated R&D effort

A global purchasing power

Delivering local sales of tailor made solutions

Products adapted to industry specificities and local practices

Based on local raw materials

Delivering via country organization with local sales and technical service teams
R&D

Raw Material

Manufacturing

Engineering
& Design

Project
Management

Logistics
& Delivery

Dry-out
& Commissioning

Installation
& Supervision

Prsentation Groupe Dcembre 2014

Technical
Support

Our global network





Over 2,600 employees in 31 countries

Delivering through our dedicated country organisations to small and medium sized companies

3 R&D Centers and 11 Design & Engineering centers

18 plants in 16 countries totalling 600,000 tons of capacity

worldwide while delivering global projects for major Engineering, OEM, and EPC companies
with our international teams
4

Geographic expansion: a key vector of our growth

Selected acquisitions that re-inforce out

Ace Refractories (India) in 2007, leader for monolithics on

the fast growing Indian market, which allowed us to improve

our understanding of end user needs in emerging countries

Indoporlen (Indonesia) in June 2013, with strong

positions in fast growing Cement, steel and metal

processing sectors in Indonesia

Tokai Ceramics (Japan) in July 2013, well-known producer

of monolithics, to enlarge our customer base in Japan

QA Refractories (South Africa) in 2005 and Svenska
Silikawerken (Sweden) in 2008

Acquisition of refractory installer Arefcon b.v. (Netherlands)
to reinforce our ability to deliver turn-key projects to the
Petrochem sector

Acquisition of refractory services specialist Termorak
Group (Finland, Sweden, Thailand) to offer a wider range
of refractory management project management solutions to
all our customers.

Recent set up of sales offices in Dubai, Vietnam, Algeria,
USA and Singapore for closer customer relations

Business principles that guide us

End-to-end product portfolio serving diverse markets

Our products deliver consistent performance:

Improved productivity

Cost optimization

Ensuring safety

Enhancing profitability

Our portfolio includes globally established brands including CALDE, ALKON and SILICA MIX,
as well as renowned local brands like WHYTHEAT in India, and TAICAST in Taiwan and
Southeast Asia.

PERFORMANCE OF OUR PRODUCTS ARE BENCHMARKS IN THE DIVERSE MARKETS WE

SERVE

We have strong references in all markets we serve

Our focus on Innovation and R&D

Innovation plays a key role in our status as world leader

We are pioneers in product development and installation

techniques

Our R&D teams have access to state-of-the-art laboratories and
to secure supply of raw materials

We stay at the forefront of technical trends and are prepared to
respond to changing customer requirements

Incremental improvement for continuous improvement

Top priorities of Calderys R&D:

Reduce equipment downtime: e.g. Quick-Dry (QD) materials

Improve health & safety: e.g. dust-free materials

Increase lining life: e.g. alkali resistant versions

Facilitate installation - (speed, ease and reliability):

e.g. Low Porosity Dense Gunning materials & precast solutions

Increase energy savings: e.g. precast solutions in diamond
shape for Reheat Furnace roofs

IMPROVE TOTAL VALUE PROPOSITION FOR OUR

CUSTOMERS

The refractory lining resists to high temperatures. and to

stresses caused by thermal, corrosive and abrasive
conditions.

Our project management capabilities

 We provide complete project management services to
efficiently deliver end-to-end refractory solutions.

Our services include consultation, planning, delivery

scheduling, supervision, site management, and direct training

for customer personnel.

+150 major projects implemented every year

Global market team structure to leverage best-practices and
drive efficiencies

 We have a global network of specialized industry

experts and project management professionals
ensuring local presence

over 100 project managers and supervisors

over 70 technical experts and engineers

ON-TIME and ON-BUDGET COMPLETION be it

part-service projects or turnkey delivery and
commissioning

Our installation and commissioning services

Were a solutions provider

We carry out technical dialogue with customers to

select the most appropriate solution

We provide complete solutions including
merchandise products and installation services

Our strengths as a service provider are:

detailed planning of the installation

surface preparation

adhering to stringent safety norms

superior standards of workmanship,

detailed delivery scheduling,

flawless supervision and efficient site management,

WE ARE A RELIABLE INSTALLATION AND

COMMISSIONING PARTNER TO OUR CUSTOMERS

Our maintenance services

 Calderys maintenance services include






monitoring the refractory performance of

your equipment
permanent on-site refractory service
regular and predictive maintenance and
repair,
trouble shooting and round-the-clock rapid
response to emergencies.
on-site and off-site training programs to
enhance your teams knowledge of the
application, function and maintenance of
the refractory solutions in use.

OUR MAINTENANCE SERVICES ENSURE OPTIMAL

PERFORMANCE IN A COST-EFFECTIVE MANNER

Our strong focus on safety

Safety is a top priority for Calderys

our safety policy is clearly communicated and

implemented at every level of our business, from

design and production of our materials to
installation at the customers site.

our teams are trained and managed to meet bestin-class safety standards, with regular audits and
strict risk assessment procedures.

All our manufacturing plants have an

Environmental Management System (EMS) in
place.

We put strong focus on managing EHS at our

customer sites

WE GIVE TOP PRORITY TO SAFETY AND ARE

COMMITTED TO CONTINUOUS IMPROVEMENT OF
OUR SAFETY PRACTICES

Iron & Steel: production flowchart

IRON MAKING

OTHERS

STEEL MAKING

Our presence on blast furnaces main runners, worldwide

Blast furnaces & corresponding cast-houses floors

Casthouse floors: Key factors for success

Understand & anticipate the evolution of the customer needs & requirements

Promote a clear, efficient & performant offer

Adapt & master the refractory formulation & production technologies to local condition (costs / performance)

Master the product quality

Master the lead time

Anticipate the evolution of the raw materials supply (costs / sources)

Provide the optimal installation services (technologie, team & equipments)

Strong follow-up of performances of the refractory during service

Contribute to the productivity increase and to the costs saving of the customers installations

Different blast furnaces capacities leading to different cast-houses floors designs

 and to different management of the runners inducing different product requirements

BF 4000m3

BF 2500m3

BF 1750m3

BF 350m3

Example of runners of small vs. large capacity BFs

Runners performance linked to many factors

Runner
Geometry
 Casthouse & former
geometry
 Length
 Width
 Slope
 Pool at impact
 Layers thicknesses
 Covers
 Differences of dams
 Cooling effect
 Thermal transfer

Products
used













Wear product
Safety product
Monoproduct
Zoning products
Formulation
Characteristics
SiC Content
Carbons
Other RM
Manufacturing
Ageing

Installation
Maintenance








Precast
In situ
Wrecking
Casting/vibrating
Drying/heating up
Application equipment
Type of maintenance
 Gunning
 Cast repair
 DVM

LEVEL OF PERFORMANCE IS A SHARED RESPONSABILITY

SOLID CO-OPERATION IS KEY OF SUCCESS

Operation
Conditions
 Operation
 Successive
 Alternative
 Flow rates
 Liquid volumes
 Chemistries
 Hot metal
 Slag
 Temperatures
 THC qualities
 Drainages

Parameters having a key impact on runner performance

 Wrong product choice for given application
 Poor product installation (a good product badly installed gives worse results than a
medium product well installed) : water amount / batch layering / vibration / compaction /
wrecking / dry and heat up
 No respect of monolithic basics : missing expansion joints / extensive water cooling on
runners / risky forced air cooling / heterogeneous lining / stress risers
 Poor runner maintenance plan
 Poor runner lining design: thermal calculation and T limits
 Lack of follow up of: the runner performance in time, the BF process evolution
 No constructive exchange between supplier & customer

Runners performance linked to refractory layers design

Various Lining Zones & Installation Types

Runners performance linked to refractory products

Multiplicity of Product Types

Runners performance linked to the design (section & cooling)

 Different runners at same scale

 Runner cooling

 Diversity of profiles & cooling system makes the performance comparison difficult !

Runners performance linked to the design (section & cooling)

Cooled or normally insulated

45 000 thm

Working lining = 340 mm

Uncooled or too insulated

30 000 thm

Working lining = 216 mm

Safety lining =
114 mm
Insulation =
10 mm

Wear speed = 3,0 mm / kthm

Wear speed = 7,4 mm / kthm

Wear thermal gradient = 6,6 C/mm

Wear thermal gradient = 2,6 C/mm

Runners performance linked to the design (layout)

Example of main runner pushing casthouse floor

EXPANSION JOINT between main & secondary runners

Cracks &
deformation&
movement

Runners performance linked to BF operation parameters

Wear vs HM temperature

Slag basicity

HM tonnage variation

etc

Runners performance linked to refractory demolition & installation

Wreck-out and installation : optimized and adapted equipment

Runners performance linked to refractory demolition & installation

 Installation best practice : installation guidelines

 Installation reports and performance follow-up

 Consumption & wear measurements

 Maintenance adapted to each situation:

- Major & big casting repairs
- Intermediate partial casting repairs
- Small repairs Gunning repairs / DVM repairs / Ramming repairs

Some of our references: Blast furnace 3600m3, 9200thm/d - Europe

Blast furnace:
 3600m3 / 9200 thm/d
 4 runners

Perimeter:
 100% Casthouse floor management (TRM)
 Maintenance main & secondary runners including tilters covers

Reliability:





No breakthrough at any of runners

No slag in iron runner / no iron in slag runner (INBA process)
100% of achieved contracted campaign lengths
Continuous improvements goals (campaign length)

Safety:
 No accidents

Some of our references: Blast furnace 3600m3, 9200thm/d - Europe

Installation time:
 7 days to rebuild and prepare the runner between 2 campaigns

Local team & equipment:






Continuous improvement:






3 CALDERYS permanent people: 1 Contract manager + 2 supervisors (availability 7/7 days)

1 installation partner under Calderys management
2x 800kg mixer-transporters / 11 people shift
Gunning machines

Continuous performance & safety improvement actions

Campaign length increased from 180 kthm to 230 kthm
Consequent decreasing of number of runner repairs per year
Safety lining reached 8 years / 6 million thm
Laser measurement of main runner wear evolution

Campaign length:





Main Runner:
Secondary Iron runner:
Secondary Slag runner:
Iron tilter (removable):

230 kthm
230 kthm
230 kthm
150 kthm

Some of our references: BF 4000m3, 9500thm/d - Europe

Blast furnace
 4000m3 / 9500 thm/d
 4 runners

Perimeter:
 100% Casthouse floor management (TRM)
 Relining of full safety lining of 1 main trough / year (includes often also the global steel shell)
 Maintenance of Main & secondary runners + covers

Installation time:
 10 days to rebuild and prepare the runners between 2 campaigns
 Take immediately into account the repairs when local incidents occur
 All works performed by Calderys, including wrecking operation

Local team & equipment:






2 CALDERYS permanent people: 1 Contract manager + 1 supervisor (availability 7/7 days)

1 tonne high intensity mixer, 2x tonn mixer
Gunning machine
Shotcrete pump & mixer

Some of our references: BF 3200m3, 8000thm/d - China

Blast furnace
BF 3200m3 (8000thm/d, 4 runners)

BF operation parameters
Number of casts/day
Tapping practice
Iron temperature
Slag volume

10 - 12
Alternative on the 2 holes
1490 1520 C
< 300 kg/ton

BF trough repair practice

- BF trough repair within 7days

Typical trough performance

- Performance: 120 000 thm
- Continuous improvement : +20% campaign length, -30% consumption achieved
over a year

Some of our references: BFs 2000m3 to 2550m3 - Europe

BFs:
 BF1: 2000m3 / 4500thm/d / 2 runners
 BF2: 2550m3 / 5600thm/d / 2 runners
 BF3: 2000m3 / 4500thm/d / 2 runners

Main Trough practices:

Small gunning repairs: after 90 kthm troughput, systematically done every 20 to 30 kthm
Gunning (Minor) repair is carried out in less than 10 hours
Final Main Trough throughput is 275 320kthm
Casting (Major) repair made in less than 65 - 70 hours

General repairs plan covering 1 year

Schedule of Major repairs of BF Main Iron Runners in 2009
January

February

March

MIR 1

Blast Furnace 1 stopped

MIR 2

Blast Furnace 1 stopped

April

May

June

July

August September October November December

MR

BF 1
MR

MR

MR

MR

MIR 1
BF 2
MR

MR

MR

MIR2
MR

MR

MIR 1
BF 3
MR
MIR 2

MR

Some of our references: BFs 2000m3 to 2550m3 - Europe

Former installation

Casting equipment
 2 mixers-transportes are used in casting repair
 Overhead crane to load the mixers
 Casting speed is 10-12 t / hour

Some of our references: BFs 2000m3 to 2550m3 - Europe

 Former removal / curing

 Dry-out

Some of our references: BF 1780m3, 4000 thm/d - China

Blast furnace:
 1780m3 / 4000 thm/d
 2 runners

Perimeter:
 Management of 1 cast-house side (main & secondary runners)
 Full service (TRM) Main & Secondary runners

Equipment:




Reliability:





13 tons excavator
1 ton planetary mixer
1 batch gun 1 ton

Main runner repairs (24-30 tons) managed within 24 hours (usually <18 hours): hot casting
Main runner casting operation managed within 1:30 hours
No breakthrough at any of runners
Yearly improvements campaign length duration (+15%)

Safety:
 No accidents

Perfomance:
 Campaign length
MT: 95 000 thm
IR: >100 000 thm
SR: 95 000 thm

Thank you for your attention

www.calderys.com
www.calderys-indoporlen.com