VESUVIUS AMERICAS

CASTHOUSE PRESENTATION

Jeff Hilberg
November 6th, 2009
Vizag, India
VESUVIUS AMERICAS
CASTHOUSE FLOOR PRESENTATION

•Trough Design
•Casthouse Floor Materials
•Installation Methods
•Casthouse Maintenance
•New Product Development
VESUVIUS AMERICAS
TROUGH DESIGN CONSIDERATIONS

•Pooling Design

•4- Material Component Trough Lining

•Typical Campaigns to Achieve 90,000- 146,000

MT

•Repair Method- Cast in Place or Shotcrete

 Main Iron Runner Design – Target residence time of >7 minutes
for Optimum Separation
General Principles :

Slag line and freeboard should

be a minimum of 300mm
Slag dam

Iron pool depth set by iron

dam, minimum 250mm to
reduce impact wear in bottom Height between iron Iron
Slope of 2 to 2.5% to dam and slag dam dam
drain runner quickly should be 250mm

Depth of ski slope sufficient to

prevent backwash of liquids
against furnace
VESUVIUS AMERICAS
POOLING TROUGH DESIGN

EXISTING IRON TROUGH- Pool Volume = 2.0 M3

Slope 4%
VESUVIUS AMERICAS
POOLING TROUGH DESIGN

EXISTING IRON TROUGH- Pool Volume = 3.4 M^3

Slope 1%
VESUVIUS AMERICAS
POOLING TROUGH DESIGN
VESUVIUS AMERICAS
MULTI COMPONENT TROUGH LINING

Hydra Max A & B

Hydra Max C
Dry Ram
Insulating Board
 Typical Trough TOTAL Rebuild

8’
CAST
Set Forms

Backfill with Dry-Vibe Steel “Box”

Pre-cast Shapes

2” Dry-Vibe
6’ Insulation
Board
MAIN IRON TROUGH
INSULATING BOARD
MAIN IRON TROUGH
PRECAST BOTTOM BACK-UP SHAPE
MAIN IRON TROUGH
PRECAST BOTTOM BACK-UP SHAPE
MAIN IRON TROUGH DRY RAM
MAIN IRON TROUGH FORM
MAIN IRON TROUGH
FINISHED CASTABLE LINING
VESUVIUS AMERICAS
CASTHOUSE MATERIALS

Our products and systems have been engineered

to provide,

•Optimal Service life

•Reduced Refractory Related Down Time

•Safe Reliable Casthouse Floor System

CASTHOUSE FLOOR
WORKING LINING MATERIAL
Chemical Hydra Max A Hydra Max B
Analysis
Silicon Carbide SiC 26.9 % 16.9 %
Alumina Al2O3 66.1 % 76.0 %
Silica SiO2 3.7 % 3.7 %
Calcium Oxide CaO 0.9 % 0.9 %
Titanium Oxide TiO2 1.6 % 1.8 %
Iron Oxide Fe2O3 0.2 % 0.9 %
Density kg/m3 2819 2979

Water 4.75 % 4.75 %

HMOR@ 1371 4.1 N/mm2 4.1 N/mm2

C
CASTHOUSE FLOOR
BACK UP LINING MATERIALS
Chemical Hydra Max C Dry Ram
Analysis
Silicon Carbide SiC 24.8 % 15.3 %
Alumina Al2O3 63.8% 79.1 %
Silica SiO2 6.0 % 0.9 %
Calcium Oxide CaO 1.3 % 0.1 %
Titanium Oxide TiO2 2.1 % 2.4 %
Iron Oxide Fe2O3 0.9 % 0.3 %
Density kg/m3 2723 2803

Water 5.25- 5.75 % N/A

HMOR@ 1371 2.3 N/mm2 N/A

C
Typical Wear Patterns in a Trough

Impact Zone

Separation Zone
Slag/Air
Interface
Slag/Iron
Interface
VESUVIUS AMERICAS
WEAR MECHANISMS IN A TROUGH

• Flow speeds are too low even in the “impact

zone” (few cm/s maximum) for mechanical
erosion alone to explain wear

• Must be coupled with chemical corrosion to

form a softened layer that can be washed off
VESUVIUS AMERICAS
HIGH WEAR AREAS IN A TROUGH

• Areas where oxidation, contact with slag and

mechanical washing action are present
together:

• Slag/Air interface- oxygen from air and

presents of flowing slag
VESUVIUS AMERICAS
HIGH WEAR AREAS IN A TROUGH

• Slag/Iron interface- oxygen from oxides in

slag and metal, flow of iron

• Impact Zone- slag, iron and air bubbles all

mixed together and flow is turbulent
VESUVIUS AMERICAS
REDUCING TROUGH REFRACTORY WEAR

• Key is the matrix

• Lower porosity, smaller pores to reduce

access of slag and oxygen

• More refractory matrix composition to reduce

the softening effect of the reaction with slag
VESUVIUS AMERICAS
INSTALLATION METHODS

• Pump Casting

• Shotcrete

• Gunite
VESUVIUS AMERICAS
INSTALLATION METHOD PUMP- CASTING

• Same ingredients as a vibration castable

product, but in different proportions to
maintain plasticity required for pumping
• Plasticity allows the mix to compress going
through a reducer
• Particle sizing is a compromise between
maximum density and plasticity
VESUVIUS AMERICAS
INSTALLATION METHOD PUMP- CASTING

• Limited by capacity of mixer, not by

capacity of pump
• Mixes designed for 4-minute mix time
– Undermixed material is too stiff, so required
more water to compensate
– Remixer and pump will complete mixing,
so undermixed material is likely to be too
wet at the end of the host; liable to
segregate
VESUVIUS AMERICAS
INSTALLATION METHOD PUMP- CASTING

Swing-tube pump with Allentown MR3300 pump with pan

integral paddle mixer mixer

Allentown MR3300 pump with pan mixer 3000-lb mixer, 16 MT per hour
VESUVIUS AMERICAS
ADVANTAGES OF PUMP CASTING

• Faster installation rates than conventional

vibration casting
• Less equipment required for material transfer
• Easier material handling in areas with difficult
access
• Less intense vibration required because of
more fluid mix
• Less labor intensive than conventional
vibration casting
VESUVIUS AMERICAS
DISADVANTAGE OF PUMP CASTING
• High initial and maintenance costs of mixer and pump

• Requires good control of flow and set time of material

to prevent flash setting in the pump or hose

• Clean up requires large quantity of water, which may

present a disposal problem

• Material remaining in mixer, pump, and hose is lost at

the end of the installation; it cannot be recovered

• Need to keep mixer and pump as close as possible to

the installation site to minimize pumping
complications
VESUVIUS AMERICAS
INSTALLATION METHOD- SHOTCRETING

• Combines the physical properties of low

cement or no-cement castables with the
shotcreting process used in installation of
civil engineering concretes
VESUVIUS AMERICAS
INSTALLATION METHOD- SHOTCRETING

•The first requirement for shotcreting is that the product must

be pumpable

•In general any low cement castable can be pumped can also
be shotcreted with the appropriate accelerator
VESUVIUS AMERICAS
ADVANTAGES TO SHOTCRETING
•Little or no framework required for
installation
•Low rebound (typically <5%)
•No dusting at the installation site, so
other work can be on-going in the
same area
•Easy material handling in areas with
difficult access
•Physical properties approaching
vibration cast
VESUVIUS AMERICAS
ADVANTAGES TO SHOTCRETING

Less prone to laminations than gunning

•Smaller air compressor required than for gunning

•Less experience required of nozzleman than for
gunning
•Ideal for large installations (>20 tons); faster
installation rates than for conventional gunning
•Ideal for irregular surface applications
VESUVIUS AMERICAS
DISADVANTAGES TO SHOTCRETING

• Same disadvantages as for pump casting

• Minimum economical installation probably 15-
20 tons, because of clean-up required and
material losses
• Two pumps are typically required at large job
sites, in case one breaks down
• Limited time available for trimming,
depending on the accelerator used
VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

Maintenance Schedules and Materials for

•Blast Furnaces Producing 2,700 MT/Day

•Blast Furnaces Producing 4,100- 5,900 MT/Day

•Blast Furnaces Producing 9,100 MT/Day

VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

Customer AHMSA
Location Monclova, Mexico
Furnace #4, Single Taphole
Production 2,700 MT/Day
Product Hydra Max A Castable
SurShot A Shotcrete
VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

AHMSA #4 Blast Furnace Repair Schedule

• 4/5-weeks shotcrete repair schedule or 90,000-

100,000 MT campaign.

• Trough is re-cast every 26 weeks or 600,000 MT

• *Typical 42 MT castable repair takes 18-hours
• *Typical 25 MT shotcrete repair takes 11-hours

*excludes tear-out time

VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

Customer US Steel ET Works

Location Braddock, PA, USA
Furnace #3, Single Taphole
Production 2,900 TTHM/Day
Product Hydra Max B Castable
SurShot B Shotcrete
VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

USS ET WORKS #3 Blast Furnace Repair Schedule

• 5/6-weeks shotcrete repair schedule or 118,800 MT

campaign.

• Trough is re-cast every 909,000 MT

• *Typical 23 MT shotcrete repair takes 6-hours

*excludes tear-out time

VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

Customer Mittal Inc.

Location Cleveland, OH, USA
Furnace C-5, Two Tapholes
Production 4,100 MT/Day
Product Hydra Max A Castable
VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

Mittal Cleveland C-5 Blast Furnace Repair Schedule

• 5-week castable repair schedule or 145,500 MT

campaign.

• Trough is re-cast every 582,000 MT

• *Typical 65 MT castable repair takes 48-hours

*excludes tear-out time

VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

Customer AK Steel
Location Middletown, OH, USA
Furnace #3, Two Tapholes
Production 5,900 MT/Day
Product Hydra Max B Castable
SurShot B Shotcrete
VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

AK Steel #3 Blast Furnace Repair Schedule

• 6-week shotcrete repair schedule or 123,900 MT

campaign.

• Trough is re-cast every 26-weeks or 537,000 MT

• *Typical 68 MT castable repair takes 18-hours

*excludes tear-out time

VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

Customer Severstal
Location Sparrows Pt, MD, USA
Furnace “L”, Four Tapholes
Production 9,000 MT/Day
Product Hydra Max A Castable
VESUVIUS AMERICAS
CASTHOUSE MAINTENACE

Severstal “L” Blast Furnace Repair Schedule

• 4-week shotcrete repair schedule or 118,000-

127,800 MT campaign.

• *Typical 82 MT castable repair takes 86-hours, with 3

available casthouses, the repair system is not rushed
into service

*excludes tear-out time

VESUVIUS AMERICAS
NEW PRODUCT DEVELOPMENT

Three New Product Technologies for

Casthouse Floor Runner System
Applications.

• DB 19
• FERROBOND T-1
VESUVIUS AMERICAS
NEW PRODUCT DEVELOPMENT

Product Development

Trial Results
VESUVIUS AMERICAS
NEW PRODUCT DEVELOPMENT “DB 19”

DEVELOPMENT SUMMARY

• Casting Water Reduced by Close to 50%

Compared to Conventional trough castable

• Large Increase in Density Achieved (160-320

kg/m3) Depending on Aggregate Composition
VESUVIUS AMERICAS
NEW PRODUCT DEVELOPMENT “DB19”

DEVELOPMENT SUMMARY

• Porosity Reduced by Almost 50% Compared

to Current Trough Castable

• An Induction Furnace Slag Test (AK

Middletown Slag) Showed Much Less
Erosion Than the Low Moisture Castable
Mix Variation A Variation B Variation C Conventional
Hydra Max B

Total % Water to Cast 2.6* 2.6* 2.6* 5.0**

Notes: *Slurry 8.5% Water, 126 flow ** 41 Flow

Properties Dried at 230oF/24 h:

MOR, psi 1885 2162 2524 1641

Kg/cm^2 133 152 177 115

CCS, psi 6175 7985 8917 5128

Kg/cm^2 434 561 627 361

Bulk Density, pcf 207 201 191 181

Kg/m^3 3316 3220 3060 2899

% Apparent Porosity 6.7 6.4 6.9 12.2

Induction Fce Slag Erosion Resistance Test:

% Cut 35 42 76
71

Relative (HM TC-9 =100) 49 59 106

100
VESUVIUS AMERICAS
ULTRA LOW MATRIX DB 19

Variation A

Variation B

Variation C

Conventional
Hydra Max B
DB 19
TRIALS- AK STEEL ASHLAND

• Ashland Skimmer Block was put Into Service

for 90-Days, 220 000 thm
• Block was Removed due to scheduled trough
repair
• Life was at least double that of typical
castable skimmer blocks
• DB 19 skimmer block significantly beat the
service of the very best blocks.
DB 19 TRIALS- AK MIDDLETOWN

• Tilting runner was put into service for 100 000 thm
• Minimal wear was recorded
• Impact wall- 1 mm per 979 MT
• Opposite wall- 1mm per 1,425 MT
• Bottom impact- 1mm per 392 MT
• Endspout- 1mm per 330 MT
DB 19 AK MIDDLETOWN TILTING RUNNER
Impact Zone to Endspout
DB 19
AK MIDDLETOWN TILTING RUNNER

Opposite Impact Wall

DB19
AK MIDDLETOWN TILTING RUNNER

Impact Wall
DB 19
AK MIDDLETOWN TILTING RUNNER

View Through Tilting Runner

DB 19 AK MIDDLETOWN TILTING RUNNER

Impact Wall Wear

101.6 mm

Impact Pad Wear 254 mm

DB 19
AK MIDDLETOWN TILTING RUNNER

Endspout Wear
152 mm

Opposite Wall
Wear 70 mm
DB 19 SUMMARY

• We have been able to alter traditional

castables and casting techniques to achieve
properties with refractories, which were
previously unattainable
• Must be pre casted off site in a well controlled
facility
VESUVIUS AMERICAS
NEW PRODUCT DEVELOPMENT
FERROBOND T-1

DEVELOPMENT SUMMARY
• One component mix, no cement

• Setting mechanism related to a gel formation

when mixed with water.

• Partly an “air-set”- as water evaporates gel

hardens
VESUVIUS AMERICAS
PROPERTIES OF FERROBOND T-1

•High refractoriness (hot strength)

•Good slag resistance

•Porosity stays low over wide range

of firing temperatures
 VESUVIUS AMERICAS
PROPERTIES OF FERROBOND T-1
P orosity vs Firing Tem perature
FB T-1 (C ast) TC -8 (C ast)
FB T-1 (S hotcreted) T-5 (S hotcreted)
30

25
% Apparent Porosity

20

15

10

260 C 538 C 816 C 1093 C 1371 C 1646 C

5

0
0 500 1000 1500 2000 2500 3000
Tem p, F
VESUVIUS AMERICAS
PROPERTIES OF FERROBOND T-1
1482 C
o
Hot MOR at 2700 F
With Metals No Metals

800
Kg/cm^2
52.7
700

600

35.1
500
MOR, psi

400 26.3

300
17.6
14.4
200

100

0
Ferrobond T-1 Bond Colloidal Silica Bond Ultra Low Cement
VESUVIUS AMERICAS
PROPERTIES OF FERROBOND T-1
R o tary S lag T ests - E ro sio n R elative to F erro b o n d T -1

300

M M H P -4
250
Relative Erosion (FB T-1 =100)

S u rS h o t T -5 M M H P -5
200

Gel bonded Products

150

F erro b o n d T -1
100

50

0
M ix T ested
FERROBOND T-1
TRAILS- AK ASHLAND &
MIDDDLETOWN

• Outstanding slag runner performance at AK

Ashland and Middletown

• Slag runner wear after 6-weeks comparable

to 2 weeks wear with ULC
AK ASHLAND SLAG RUNNER
38-DAYS IN SERVICE
FERROBOND T-1
TRAIL AT ESSAR ALGOMA STEEL

• Tilting runner- achieves 93,636 MT

campaign- exhibits less wear than similar
Hydra Max B tilting runner

• Iron runner endspout- achieves 130,491 MT

with only 51mm of wear. Competitors material
exhibits 152 mm of wear at a similar
campaign tonnage
FERROBOND T-1
IRON RUNNER ENDSPOUT WEAR

Competitors material FERROBOND T-1

152 mm of wear at 51 mm of wear at
130,468 MT 130,491 MT
FERROBOND T-1
SLAG RUNNER TRAIL AT USS LAKE ERIE

152- 203 mm of wear after

119,137 MT
FERROBOND T-1
USS LAKE SLAG RUNNER REPAIR
FERROBOND T-1
USS LAKE ERIE SLAG RUNNER

• Based on the superior performance of

FERROBOND T-1, USS Lake Erie plans to
install precast shapes in the slag runners
VESUVIUS AMERICAS CASTHOUSE FLOOR
PRESENTATION SUMMARY

•In Conclusion, our objective as valued supplier is to provide

the most cost effective refractory sytems via,

Design
Casthouse Materials
Installation Techniques
New Product Development
VESUVIUS AMERICAS
CASTHOUSE FLOOR PRESENTATION

Thank you for

your kind attention.