Indo In done nesi siaa Nat atio iona nall Se Semi mina narr Ir Iron on & Ste Steel el IV – Ban andu dung ng BLAST FURNACES RUNNERS
Stephan Ste phanee LAM LAMONTR ONTRE E Technical Manager I&S SEA, Pacific Calderys Cald erys Indo Indoporl porlen en
CALDER CAL DERYS YS – ABOU ABOUT T US 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 planni planning ng and installatio installation, n, 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 purchasin purchasingg power 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
Présentation Groupe Décembre 2014
Technical Support
Our global network Over 2,600 employees in 31 countries 3 R&D Centers and 11 Design & Engineering centers 18 plants in 16 countries totalling 600,000 tons of capacity
Delivering through our dedicated country organisations to small and medium sized companies 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
We’re 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 team’s 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 customer’s 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 customer’s 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)
No accidents
Safety:
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:
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 improvement:
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
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:
4000m3 / 9500 thm/d 4 runners
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 ½ 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:
Perimeter:
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%)
No accidents
13 tons excavator 1 ton planetary mixer 1 batch gun 1 ton
Reliability:
Management of 1 cast-house side (main & secondary runners) Full service (TRM) Main & Secondary runners
Equipment:
1780m3 / 4000 thm/d 2 runners
Safety: Perfomance:
Campaign length MT: 95 000 thm IR: >100 000 thm SR: 95 000 thm
