Blast Furnace and Coke Oven

Sheffield Hi-Tech Refractories has an experienced Team including Design Engineers, Materials Technologists and Installation specialists.

The basic materials technology utilized in the vast majority of Blast Furnace Runner Castables is now more than 30 years old. It could be argued that a series of economy drives during this period have resulted in more effort being expended in reducing material costs than in actually improving product performance. It is also true that the installation practices used today are less carefully controlled and monitored than in the early years after the initial introduction of Runner castables. Sheffield Refractories is committed to drive Casthouse Materials Technology forward with a joint focus on Material Technology and Installation Technology.

Sheffield Refractories has developed a Casthouse Design Software package where different Runner Designs / Modifications can be reviewed and assessed in minutes. For example, if a Blast Furnace Plant would like to consider switching to a Side Skimmer this option can be reviewed and the various implications in terms of multiple performance factors can be readily assessed. The package will also produce instant 3D Drawings and Dimensioned Technical Drawings along with detailed Thermal Profiles. We believe that this package can significantly assist in revolutionizing the potential development of both current Casthouse Designs and the Casthouse Design for new furnaces. The company is continuing to develop this software.

Sheffield Refractories has developed a FULL range of specialist materials to cover the various Casthouse applications. Where possible the materialshave been developed so that they can be installed as Vibrocast Materials, as Pumping Grade products or even applied as Shotcrete. We have developed Pumping systems that can ‘Speed Up’ Runner Installations, improve the technical quality of the Installation and secure a safer working environment.

Sheffield Refractories has also committed significant resources towards finding workable Shotcrete repair techniques for Main Iron Runners. This includes the innovative use of Depth Image Cameras and Robotics so that material can be applied in hot conditions without operatives having to work in a difficult or uncomfortable environment. 

A further addition to the scope of services Sheffield Refractories Ltd can provide for Blast Furnace customers was realized in November 2015 when the company manually installed 1,000 tonnes of Stack Shotcrete material during the refractory lining rebuild of a Blast Furnace in the Ukraine. The 1,000 tonnes of material was installed on a 24 hour / day basis with the full installation being completed within 6 days. The material, equipment and the full installation crew for this project were supplied from Sheffield Refractories limited in the UK.

Sheffield Refractories is committed to the continued development of Materials and Installation Techniques for Blast Furnace Monolithic applications.

Sheffield Refractories have been supplying refractory repair materials to the coke industry for over 40 years.

The range of products includes wet spray, purge and gunning refractories for coke oven jamb and inner wall repairs, oven sole repair cements, castable refractories for coke oven door and ascension pipe linings, charge hole lid sealing materials, fused cast blocks for the hot cokes ram and 250x250x30 mm plates for the coke transportation ram.

Customers for Sheffield Refractories coke oven products include all the UK coke plants and a number of overseas coke plans including Sollac Dunkerque France and Sidmar Gent Belgium.

Coke Oven Repair Methods

1. Wet spray patching with Jonsett WS chemically bonded refractory cement is used as a routine method for repair of open joints, cracks and slight spall damage.
2. Dry Gunning with Jongun 1600 GM hydraulic bonded gunning refractory is a highly effective method of repairing badly spalled-eroded wall areas.
3. Purging with Jonsett IFT Fine or Coarse is an alternative method to 1&2 for the repair of jamb brickwork.
4. Sole Flooding by the bucket method with Jonsett SOL heat setting cement is the conventional way of repairing worn uneven oven soles. Jonsett SOL contains coarse aggregates which give good wear resistant properties.
5. Riser pipe grouting with Joncast WS chemically bonded refractory cement, applied by pressure vessel, is used for sealing leakages between the gas risers and the regenerators. The fine grading of the Jonsett WS enables it to flow into very narrow joints-cracks giving an excellent seal.
6. Hydraulic bonded cartable refractories are used for a number of coke oven applications. Joncast LC1400 for casting door plugs and Joncast MS for lining ascension pipes.
7. Airborne sealing or oven dusting – Jonsett 4D fine powder is used for sealing fine cracks between the oven camber and flues. This method is only effective if all major leaks have been sealed prior to air bone sealing.

Charge Hole Lid sealing is important in controlling emissions. Jonseal SF Dry is the ideal material for this being an effective sealant with good release properties.