By Dr. Saumen Sinha, Mr. Manir Uz Zaman, Mr. Shantanu Deshpande and Mr. Gaurav Jain

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Copyright: Imerys

Continuous casting is the process where liquid steel is converted into solid cast products. Flux Feeders are used to apply a mold flux, which may be a powder or granular material, onto the top of a slab during continuous casting of molten metal, such as steel. The flux turns into slag when sufficiently heated by the molten metal. Fluxes are engineered synthetic slags formed by compounds containing oxides, minerals, and carbonaceous materials that are selected to provide desired characteristics. The flux may include silica, bauxite, calcium silicate/wollastonite, feldspar, soda ash, fluorspar, lithium carbonate, etc.
At the zone of contact with the liquid metal, the flux prevents re-oxidation and avoid heat loss to prevent premature solidification of the liquid metal. The flux also absorbs non-metallic inclusions at the liquid slag-metal interface, thereby producing a cleaner metal. Furthermore, the flux provides lubrication between the solidified metal shell and the mold at the zone of contact with the solidified metal.
The flux feeder plays an important role in controlling and feeding the casting flux throughout the mold as per casting conditions. These functions have a direct impact on the quality and operational stability of the cast steel. For example, inadequate lubrication of the flux can cause loss of containment of the liquid steel due to high friction and shell tearing. Insufficient heat removal will result in a thin shell that cannot withstand the ferrostatic pressure and lose steel containment. On the other hand, excessive heat removal can cause cracks to form on the steel surface, etc. …


By Dr. Saumen Sinha, Manir Uz Zaman, Aditya Soni and Santosh Upadhyay.

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Copyright: Calderys

The running campaign of a Blast Furnace (or BF) is mainly governed by the lifespan of its hearth. The refractories used specifically for the hearth are made up of the materials capable of withstanding extreme temperatures while resisting the interaction with corrosive liquids under high Ferro static load. Nowadays, the Spraycast (or Shotcrete) technology is becoming popular in process industries to repair the refractory linings thanks to its benefits compared to conventional installation methods. Spraycast has been extensively used to repair the lining of Blast Furnace stack areas using robots and platforms. …


By R. Chokkar, S. Thangadurai, Santosh Upadhyay and Amol Kinkar

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Copyrights: Calderys

Iron & Steel, Cement, Boilers & Incinerators, Foundry, Petrochemicals & Refineries. Many of these industrial segments use refractories to help their equipment withstand extreme temperatures and working conditions. Power plants are also major consumers of refractories for the maintenance of their boilers. The challenges they face when repairing or revamping their equipment is unlike any other segment. The dismantling of refractories takes place on the water wall tubes, a delicate part of the equipment. Developing a new technique for the dismantling of refractories can eliminate the damages of dent formation or even prevent them. …


by Thomas Höjer, Boiler & Incinerator Marketing Manager at Calderys.

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In the world of refractories, a faster installation to minimize the downtime while enhancing product performance is a requirement. We’ve been working on developing this ideal solution since 1998. Today, Spraycasting (or Wet Shotcreting) is one of the fastest growing technologies for working and back-up linings. Spraycasting is the process of pneumatically projecting refractory pumpables, at high velocity, on all types of surfaces. Spraycast products combine the technical qualities of a cast material with the speed of a gunning installation method (e.g. CALDE® SPRAYCAST line). The application of moulds is avoided, giving spraycast (a.k.a. wet shotcrete or wet gunning) installation the advantages of cost, time and labor savings. …


by Igor Nesterenko, Deputy Director Iron Segment and Giuseppe Guasto, Expert Consultant Iron Segment.

In Eastern Ukraine, a leading steel producer planned to modernise their blast furnace (BF) against all odds. Our team faced many challenges in obtaining critical machinery, so we decided to get creative. The work was accomplished with a Blastcrete shotcrete pump, borrowed from a local Calderys client, and REED mixers and pumps rented by an installation company. We also saved part of the original upper lining with silico-alumina bricks.

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View of BF & platform assembly prior to the repair

Let’s get into details. For this BF, we installed the refractory lining by manual shotcreting from the lower stack up to the armor plates and later the grouting behind the replaced staves. Together with the engineering company on this project, we installed two platforms inside the furnace. Led by the Calderys Ukraine team, the customer’s team and key suppliers provided support as needed. Initially the installation was in total 358t. …


Spraycast and injection of newly constructed blast furnace, by Dmitriy Povalyaev, Sales Manager in Urals Eastern region, Calderys

Russia’s NTMK Nizshnly Tagil, part of the global Evraz Group, scheduled Greenfield construction for a new blast furnace during a harsh winter in the Ural Federal District. The goal was to have it running by the end of winter. This is how we tackled this challenge.

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Compact arrangement of mixing and pumping equipment in temporary organised covered space.

In late January of 2018 NTMK Nizshnly Tagil and our team brainstormed options to create normal working conditions in hostile weather. This resulted in a novel breakthrough. The BF shell would be insulated from the outside in, enhanced by heating fans in tuyeres. The result was a leap from -25ºC to +25ºC inside the furnace shell.


By David Moore, Commercial Director (Thermal) at Calderys.

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Copyrights: Calderys

In today’s world, minimizing operational downtime is key to profits. The more a plant runs and produces, the more it is able to create profits to re-invest back to their facilities and more importantly their employees. Since 2015, aluminum pricing has been on a steady incline as auto producers and aerospace focus on reducing weights for fuel economy. This steady increase in aluminum prices has caused aluminum producers to have to define new ways to increase their run time.


By Prakash Bharati, Deputy General Manager, Marketing & Sales (Iron & Steel) at Calderys.

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In the 18th century, the introduction of water and steam powered mechanical manufacturing triggered the First Industrial Revolution. The Second Industrial Revolution was mainly driven by ideas and division of labour, whereas the Third Revolution was driven by the introduction of programmable logic controllers (PLC) designed for automation in the manufacturing industry.

The world is rapidly moving toward Industry 4.0, or the Fourth Industrial Revolution. …


A Focus on the Safety Opportunities For Improvement (SOFI) Initiative

In the light of the World Day for Safety & Health at Work, we want to highlight what safety means for Calderys. We evolve in the refractory industry. That means that we deal with materials that retain strength and form at very high temperatures. It may seem a little complicated, but without those materials and their transformation, our world would look very different! At Calderys, we specialise in providing products, installation services and engineering solutions to those working in the following industries: iron, steel, foundry, aluminium, cement, lime, oil refineries, chemical plants, boilers, and incinerators.

Our 19 plants are located in 16 countries, each with its own safety standards. We have more than 2 300 colleagues working both in our plants and on customers’ sites. All of this combined represents more than a hundred countries. The very nature of our business presents many challenges for safety, which is why we have been improving our safety standards continuously over the years. …

About

Calderys

We are a global player in the refractories industry and we even write about it! Find stories about our thoughts on the business. 🌍 http://www.calderys.com

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