Innovation

is at the heart of everything we do.

The right solution for each furnace

Making the most of scarce resources, preserving the environment, and using energy in an efficient way are the megatrends of our times.

Controlled incineration processes under technically optimized circumstances provide one part of the answer.

Well-constructed boilers and modern power plants contribute valuable energy and give their share in an integrated approach to waste management.

Our Innovation approach is the best practice

The approach

We entrust our dedication to constantly find new and better solutions to existing problems of our Research and Development department and our Technical department.

Refractories are a crucial interface for many core industries, such as the production of iron, steel, cement, aluminum and other essential materials.

Our products are used in the most exposed areas of production. They are subject to a wide range of highly adverse conditions: extreme temperatures and sudden temperature changes, chemical attacks, abrasions, infiltrations and build-ups by potentially detrimental materials.

All our formulations, research and developing procedures are extremely precise, dedicate and challenging. The process starts with the QC control of all raw materials, it has to pass all our internal testing procedures. Has to be supported by internal and customer specific request, while during the application and installation step, we can identify a better solution for each kind of operation.

When we innovate, we consider a wide range of factors: economic, environmental, ergonomic, and others.

Taphole Clay – What is it?

is used to plug furnaces during tapping operation.
represents specific refractories made of inorganic raw materials (MINERALS) and organic compounds (BINDERS)
MINERALS are the “refractory part“, BINDERS provide proper plasticity and injectabilty during operation.
Most BINDERS were composed of Coal Tar Pitch (CTP) derived from carbon coke production as by product of coal distillation.

Coal Tar Pitch – Why has it been used?

Simplicity of usage
Availability as a byproduct of coke distillation
Relatively low cost compared to other chemical substances
Elevated thermomechanical properties of Coal Tar Pitch in metallurgical process
“Graphite” structure after its decomposition in operation

Coal Tar Pitch – Why will be banned?

CTP contains large quantities of potentially harmful substances that are released both during production and application.
These substances are commonly referred to as Polycyclic Aromatic Hydrocarbons (PAHs).
According to the harmonised classification and labelling approved by the European Union, CTP may cause genetic defects, may cause cancer, decrease fertility and damage the unborn child.
The EU REACH regulation (Registration, Evalution, Authorisation, and Restriction of Chemicals) defines the standards of chemicals and their potential impacts on both human health and the environment.

In addition, our unique taphole clay palette packaging is designed so that the operators on the casthouse can take each individually wrapped piece of product in an ergonomic way instead of having to bend down into a box.

MODULAR HEARTH SHIELD

The Modular Hearth Shield (MHS) by Alumina Monolithic Solutions & Ironmaking offers products to create a protective long lasting layer for the carbon lining in the blast furnace hearth.

With this concept we offer an ideal geometrical solution based on optimal material quality, instead of liningfollowing a “just enough” approach.

Targets

Carbon lining protection, i.e. contrast the erosion mechanisms given by:

Oxidation
Corrosion by alkali
Disintegration by CO
Hot metal and slag penetration
Thermal stress
Dissolution due to hot metal and slag flow

Architecture of the wall of the Modular Hearth Shield:

2 different product qualities for the blocks
1 ceramic bonded carbon-SiC containing ramming
1 chemically bonded mortar
14 different shapes
NO CEMENT FREE CASTABLES

Advantages

Material quality and geometrical solution overcome the concept “preshaped” lining.

Products thermal characteristics enhance the heat transfer to the cooling elements contributing to the forming of a dense hot metal layer at the refractory surface contact added
Several years life expectancy is the result of the lining architecture, the dedicated material developed and the accurate manufacture of the blocks.
The concept of Alumina Monolithic Solutions & Ironmaking is an economically attractive and increases the safety and life of the hearth with a limited investment.

Smooth Solutions for Steel Ladle

For the different steel ladle zones and wear mechanisms, Seven Refractories offers a variety of castable materials for vibrating, self-flowing and shotcrete applications.

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