Refractor y Systems Direct Reduction Plants

Transcription

1 Refractor y Systems Direct Reduction Plants

2 Right: Various shapes and qualities of STEULER-KCH refractory products STEULER-KCH supplies the full range of refractories and ser vices for the DRI production process. Scope of supply: Refractory Bricks Refractory Mortars Refractory Castables Fire Lightweight Bricks Insulating Bricks Insulating Castables Insulating Fibers Anchoring Systems Accessories Scope of service: Refractory Engineering Heat Transition Calculations Customised R & D Quality Controlled Production Just-in-Time Delivery Installation On site Supervision Commissioning Continuous Technical Support Left: Different methods of fabrication allow Steuler to produce large-sized bricks with complicated geometries. The gas inlet area in a Midrex -Shaft is one application which requires such complex shapes in high-grade Mullite and Zirconia qualities. These gas inlet blocks need to be produced within tight dimensional tolerances. For the direct reduction industry STEULER-KCH supplies individual solutions for several kinds of aggregates. Ranging from Process Gas & Air Heaters, over Reformers and certainly the core of your plant the Reduction Aggregate as well as gas ducts and chimneys. We offer our range of products and services for following DRI manufacturing methods: Shaft kiln process Rotary kiln process Fluidized bed process Rotary hearth process Other individual processes STEULER-KCH is one of the most innovative suppliers in the field of refractory systems for DR-Plants. The demand for improved efficiency of Direct Reduction Plants has made innovative refractory concepts increasingly important. Beside the extreme stresses caused by reducing atmospheres and thermal shocks the refractory lining has to face higher abrasions through working loads over the originally specified capacity maximum. STEULER-KCH is specialised to provide you with refractory solutions for application in such aggressive environments. We deliver the full product range and service from one source. During our nearly 100 years of experience we have ever been a reliable and trustful partner and mastered all challenges in close cooperation with our customers. Our ambition is to improve the refractory performance in your plant, reduce down times and to grant you the most possible operation safety.

3 Unten: FE-Haltesteine für Wandverankerungen mit Aussparungen für Metallanker in verschiedenen Ausführungen und Materialqualitäten. Upper Part & Middle Section In the upper part and the middle section of the shaft furnace the refractory lining is exposed to strong abrasion due to the feed of lump iron ore in that area as well as strong gas circulations caused by the off-take which is placed in the upper part. Due to that demand highly abrasion resistant bricks and castables are needed which on the same hand have to be resistant against CO and H 2 attack. Moreover the materials used have to show very good thermal shock resistance. For that application STEULER-KCH offers a combination of the Super Duty Firebrick Antelco 42 with high-grade castables. Antelco 42 is a low iron fire clay brick that has been fired up to C and fulfils all mentioned demands easily. High-end refractory linings for Midrex reduction shaft furnaces. Gas Inlet Ring The gas inlet ring or is certainly the most stressed and sensitive part of a Midrex Shaft Furnace. The refractory material in this area especially the gas inlet nozzles have to face extreme stresses. The lining has to withstand extensive mechanical abrasion, thermal shocks and of course the enormous chemical attack by the reduction gas. STEULER-KCH has developed special high-grade refractory qualities for this specific application. For the bustle walls the Andalusite- and Corundum-based quality Suprema SA 752 P is used. This phosphate bonded material is highly abrasion resistant, withstands thermal shocks and bears the chemical attack through H 2 and CO. Reformer and Recuperator For the two main aggregates beside the shaft furnace the reformer and the recuperator STEULER-KCH offers a wide range of refractories starting form dense castables and bricks over firelightweight bricks and castables up to insulating fiber materials and bricks as well as state of the art anchoring systems. This range of materials is certainly also used for gas and air heaters, gas ducts, the ejector stack and all connected parts. Due to our long experience in the field of refractories and continuous innovation we can offer you individual solutions to all challenges of these parts of your DR-plant. Above: Detail of the grooved gas inlet For the gas inlet blocks our quality Suprema ME 901 comes into operation. This high-grade fire brick is based on white fused Mullite and has a very low iron content. Its performance is only toped by our newly introduced quality Suprema ZM 25 P which is the current State-ofthe-Art product for this highly demanding application. You will find more details about it on the following pages and the mentioned table. Brand Raw Material Base Chemical analysis Bulk density Open Porosity Cold Crushing Strength Thermal Shock Resistance Al 2 O 3 SiO 2 Fe 2 O 3 ZrO 2 P 2 O 5 H 2 0 RUL-t 05 % g/cm 3 Vol. % N/mm 2 n C Lower Section The lower section, starting just underneath the gas inlet area combines all mentioned thermal, chemical and mechanical demands. Therefore this section is lined with radial bricks in our phosphate bonded quality Suprema SA 752 P that is also used for the lining of the Bustle walls. As front face lining it masters all stresses perfectly Antelco 42 Super Duty Fire Brick ,1 2, Antelco 50 Super Duty Fire Brick ,2 2, Suprema SA 752 P Phosphate Bonded Andalusite ,7 1,3 2, > Suprema KE 85 P Phosphate Bonded Corundum ,3 3, > 30 > 1670 Suprema ME 901 White Fused Mullite ,2 3, > 30 > 1670 Suprema ZM 25 P Corundum Zircon-Mullite ,2 23 1,4 3, > 30 > 1670 and ensures a long life time of the whole refractory lining in this area.

4 Left: Beschreibung Innovative material developments, production, engineering and assembly STEULER-KCH provides customised solutions for refractory appli- New developed Zirconium-Mullite brick cations from one source ranging from research and develop- The gas inlet ring is certainly the most stressed and sensitive part ment to engineering, production in our own workshops and final of a Midrex Shaft Furnace. Especially for this application we assembly. have developed the new Quality Suprema ZM 25 P which is We develop reliable and durable materials in our own laborato- a phosphate-bonded Corundum-Mullite based brick with 23% ries and test these products according to international standards. zircon content. This high-quality material shows all necessary We prepare comprehensive service designs and refractory cons- properties like mechanical strength, chemical and thermal shock resistance in order to withstand the extreme demands caused by Above: Test sample before CO Test. tructions based on specific process conditions and requirements. Our own production workshops and qualified specialists in the abrasion, reduction and thermal cycling. It performs even clearly field of mould construction and production ensure utmost flexibi- better than the pure Corundum-Mulite materials. Special Features of Suprema ZM 25 P: lity. We custom-manufacture to your specifications, whether it be single shaped bricks or complete refractory linings. Above: Moulds produced in our own workshops provide Steuler with utmost flexibility in the production of special formats. High Refractoriness Complete refractory engineering and material delivery from Excellent Hot Abrasion Resistance one source Outstanding Thermal Shock Resistance CO-Resistance Class A Above: Test sample after CO-Test. According to ASTM with Class-A CO resistance. STEULER-KCH also designs the complete refractory layout for each individual aggregate based on the steel construction drawings and process data provided by the customer. The scope of Suprema ZM 25 P is specially developed for the nozzle bricks of our services also includes the assembly drawings as well as heat the gas inlet, but of course it can also be used for other applica- transfer calculations and heat-up recommendations. Specially trai- tions with the same high demands. This quality is available for nearly all shapes either pressed or hand rammed. STEULER-KCH is a specialised in refractory engineering STEULER-KCH develops individual engineering solutions for you. We are only working with state-of-the-art CAD engineering equipment. Our engineering services includes the assembly of detailed drawings, heat transition calculations, installations drawings and instructions and are not limited to heating up recommendations ned STEULER-KCH erection engineers direct the entire sequence of works on the site and supervise the assembly. This ensures the proper realization of our refractory system solutions. STEULER-KCH is your complete service provider for safe and reliable materials as well as efficient project execution from one source. Above: Steuler also offers erection services thereby ensuring the qualified implementation of the refractory system design.

5 SUBSIDIARIES Steuler Técnica S.L. Spain Steuler France S.A.R.L. France Ditescor S.A. de C.V. Mexico Steuler Maroc S.A.R.L. Marocco Alphaplast S.A. Spain Steuler Nordic AB Sweden Shanghai STEULER-KCH Anticorrosion Engineering Co. Ltd. China CIMA S.r.l. Italy KCT Sp. z o.o. Poland Steuler Industrial Corrosion Protection Pty. Ltd. Australia Steuler New Caledonia S.A.R.L. New Caledonia STEULER-KCH Branch Saudi Arabia STEULER-KCH Branch Austria Together with its international subsidiaries and representations, STEULER-KCH offers its customers a worldwide network which develops and implements comprehensive system solutions. Surface Protection Systems Lining and flooring systems Cements, jointing materials, masonry systems, rubber linings Plastics Technology Thermoplastic lining systems Equipment, piping and tanks made of duroplastics and thermoplastics Refractory Systems High temperature refractory linings Pool Construction STEULER-Q 7 lining systems STEULER-KCH GmbH Surface Protection Systems Plastics Technology Pool Constructions Berggarten Siershahn GERMANY Phone: Fax: Mail: info@steuler-kch.de Refractory Systems Division Georg-Steuler-Straße Höhr-Grenzhausen GERMANY Phone: Fax: Mail: ff.info@steuler-kch.de