refractory systems | direct reduction plants...for the bustle walls the andalusite- and...
TRANSCRIPT
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 chim-
neys. 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
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
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.
Right: Various shapes and qualities of
STEULER-KCH refractory products
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.
STEULER-KCH supplies the full range of refractoriesand services for the DRI production process.
Upper Part & Middle Section
In the upper part and the middle section of the shaft furnace the re-
fractory 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 H2 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 1.450 °C and fulfils
all mentioned demands easily.
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 espe-
cially 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 phospha-
te bonded material is highly abrasion resistant, withstands thermal
shocks and bears the chemical attack through H2 and CO.
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.
Lower Section
The lower section, starting just underneath the gas inlet area com-
bines 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
and ensures a long life time of the whole refractory lining in this
area.
Reformer and Recuperator
For the two main aggregates beside the shaft furnace – the reformer
and the recuperator STEULER-KCH offers a wide range of refrac-
tories 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.
Unten: FE-Haltesteine für Wandverankerungen mit
Aussparungen für Metallanker in verschiedenen
Ausführungen und Materialqualitäten.
Above: Detail of the grooved gas inlet
High-end refractory linings for Midrex®
reduction shaft furnaces.
Brand Raw Material Base Chemical analysis Bulk density
Open Porosity
Cold Crushing Strength
Thermal Shock Resistance
RUL-t05
Al2O3 SiO2 Fe2O3 ZrO2 P2O5 H20
% g/cm3 Vol. % N/mm2 n °C
Antelco 42 Super Duty Fire Brick 45 51 1,1 2,35 15 60 20 1440
Antelco 50 Super Duty Fire Brick 49 46 1,2 2,38 15 70 20 1460
Suprema SA 752 P Phosphate Bonded Andalusite 73 24 0,7 1,3 2,80 13 100 > 30 1670
Suprema KE 85 P Phosphate Bonded Corundum 88 9 0,3 3,08 14 130 > 30 > 1670
Suprema ME 901 White Fused Mullite 90 9 0,2 3,05 15 100 > 30 > 1670
Suprema ZM 25 P Corundum Zircon-Mullite 63 12 0,2 23 1,4 3,30 15 150 > 30 > 1670
STEULER-KCH provides customised solutions for refractory appli-
cations from one source – ranging from research and develop-
ment to engineering, production in our own workshops and final
assembly.
We develop reliable and durable materials in our own laborato-
ries and test these products according to international standards.
We prepare comprehensive service designs and refractory cons-
tructions based on specific process conditions and requirements.
Our own production workshops and qualified specialists in the
field of mould construction and production ensure utmost flexibi-
lity. We custom-manufacture to your specifications, whether it be
single shaped bricks or complete refractory linings.
Complete refractory engineering and material delivery from
one source
STEULER-KCH also designs the complete refractory layout for
each individual aggregate based on the steel construction dra-
wings and process data provided by the customer. The scope of
our services also includes the assembly drawings as well as heat
transfer calculations and heat-up recommendations. Specially trai-
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 re-
liable materials as well as efficient project execution from one
source.
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 equip-
ment. Our engineering services includes the assembly of detailed
drawings, heat transition calculations, installations drawings and
instructions and are not limited to heating up recommendations
New developed Zirconium-Mullite brick
The gas inlet ring is certainly the most stressed and sensitive part
of a Midrex® Shaft Furnace. Especially for this application we
have developed the new Quality Suprema ZM 25 P which is
a phosphate-bonded Corundum-Mullite based brick with 23%
zircon content. This high-quality material shows all necessary
properties like mechanical strength, chemical and thermal shock
resistance in order to withstand the extreme demands caused by
abrasion, reduction and thermal cycling. It performs even clearly
better than the pure Corundum-Mulite materials.
Special Features of Suprema ZM 25 P:
High Refractoriness
Excellent Hot Abrasion Resistance
Outstanding Thermal Shock Resistance
CO-Resistance Class A
Suprema ZM 25 P is specially developed for the nozzle bricks of
the gas inlet, but of course it can also be used for other applica-
tions with the same high demands.
This quality is available for nearly all shapes either pressed or
hand rammed.
Left: Beschreibung
Innovative material developments,production, engineering and assembly
Above: Moulds produced in our own workshops provide Steuler with utmost
flexibility in the production of special formats.
Above: Steuler also offers erection services thereby ensuring the qualified
implementation of the refractory system design.
Above: Test sample before CO Test.
Above: Test sample after CO-Test. According to ASTM
with Class-A CO resistance.
STEULER-KCH GmbHSurface Protection SystemsPlastics TechnologyPool ConstructionsBerggarten 1 56427 Siershahn | GERMANYPhone: +49 26 23 600-0Fax: +49 26 23 600-513Mail: [email protected]
Refractory Systems DivisionGeorg-Steuler-Straße 56203 Höhr-Grenzhausen | GERMANYPhone: +49 26 24 13-246Fax: +49 26 24 13-305Mail: [email protected]
www.steuler-kch.de
Together with its international subsidiaries and representations, STEULER-KCH offers its customers a worldwide network which develops and implements comprehensive system solutions.
SURFACE PROTECTION SySTEMSLining and flooring systems Cements, jointing materials, masonry systems, rubber linings
PLASTICS TECHNOLOGyThermoplastic lining systemsEquipment, piping and tanks made of duroplastics and thermoplastics
REFRACTORy SySTEMSHigh temperature refractory linings
POOL CONSTRUCTIONSTEULER-Q7 lining systems
SUBSIDIARIES
Steuler Técnica S.L.Spain
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Ditescor S.A. de C.V.Mexico
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Shanghai STEULER-KCH Anticorrosion Engineering Co. Ltd.China
CIMA S.r.l.Italy
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