The first GrafTech hearth lining has now been shipped to Russia! JSC Tulachermet, located in Tula, Russia, produced its first pig iron in 1935. Today the company owns and operates three blast furnaces. Under the "program for enterprise's further development," a scheme is being carried out which will permit increasing the output of pig iron and sinter burden of improved quality. Tulachermet decided to install a GrafTech HotPressed™ Refractory system in it's blast furnace #1. The material was shipped from Tennessee at the end of June, and, as part of the quality control system, Tulachermet inspected the HotPressed™ bricks in Lawrenceburg, Tennessee, prior to shipment. Both parties were satisfied with the result.

Furnace data Tulachermet #1:

• Hearth Diameter: 9m
• Working Volume: 1,520m3
• Production: 3,200 MT/day
• Tapholes: 2

The Tulachermet managers that inspected the material were: Mr. Andrey Drabik - Chief Specialist of Technical Development Department; Mr. Artem Lazarenko - Foreman of Refractory Works; Mr. Victor Salnikov - Deputy Chief of Technical Development Department; and, Mr. Aleksander Sankin - Chief of the BF Shop.

Ukrainian Metinvest Holdings Yenakievsky Steel Works (EMZ) has begun rebuilding its #3 blast furnace at a cost exceeding USD 260M. The modernization will nearly double the furnace's output from 760,000 tons per year of pig iron to 1.2 million tons per year. Commissioning is planned for 2010. In 2007, EMZ produced a total of 2.4 million tons of iron, up by 11% from 2006, while annual steel production grew 9% to 2.8 million tons. The plants' products include beams, channels and angels.

With an ambition to continue to grow and modernize its operations, EMZ/Metinvest has now placed an order for a turn key blast furnace hearth refractory lining for its BF #3, including installation and supervision, with the leading Dutch contractor Pirson Refractories. The order for the hearth refractories was awarded to GrafTech. This is the first GrafTech hearth lining in Ukraine. We are confident that EMZ will conclude that the GrafTech HotPressed™ Refractory system has a superior value in performance, and we look forward to a long and prosperous relationship.

The EMZ#3 furnace has a hearth diameter of 9.1 m and two tap holes.

Above photo shows EMZ managers discussing their new #3 lining design at the GrafTech plant in Tennessee (USA).

Newcastle Works GM Jaco Stapelberg: "We have shown leadership by pooling global skills and resources to complete the project ahead of schedule, raised the quality of the furnace so that we can produce more efficiently and secured jobs by ensuring the plants sustainability." The partial hearth reline of Blast Furnace #5 in the Newcastle Works was completed in 44 days; 50 days were initially allocated, i.e. ahead of schedule as well as within budget. The production with the existing conventional type large micro pore carbon blocks was 4,660MT/day. One of the limiting factors was "hot spots in the refractory hearth wall." New target production with the GrafTech HotPressed™ brick wall is 5,132MT/day. With today's prices, we would estimate the gain to exceed well over $30 million per annum with the new lining installed, allowing for full production. With additional productivity enhancing improvements like new oxygen enrichment capacity, the productivity is estimated by ArcelorMittal to reach 5.440MT/day at year-end. Other furnace data:

• Hearth Diameter: 10.1m
• Working Volume: 2,017m3
• Number of tapholes: 3

The GrafTech™ refractory material included:

• NMA™ HotPressed™ Carbon Bricks
• NMD™ Hot Pressed™ Semigraphite Bricks
• SmartRam® RP20 Ramming Paste
• C34™ Cement

GrafTech is pleased to introduce the Hearth Calculator to our customers. When planning a reline or new furnace project, the Hearth Calculator will enable you to obtain a cost indication immediately. Speeding up the planning process and potentially reducing project cost, this web-based tool, now available on www.graftech.com, allows the project engineer, the furnace operator or the lining purchaser to enter the actual data for the blast furnace hearth in question (dimensions, number of tap holes, etc.) This results in an instant budgetary cost illustration for the GrafTech lining! The Hearth Calculator will present up-to-date prices for deliveries in 2009, as well as 2010. In addition, the Hearth Calculator user can easily depict how changing other parameters might impact the indicated cost. Try it here: Hearth Calculator

In addition to the Hearth Calculator, current list prices per metric ton for our most popular HotPressed™ bricks and related refractory materials are now available on our web page by clicking here: Price List

As we all know, there is more to the cost of your lining than the initial price paid. In the section above about ArcelorMittal South Africa, you can read about the potential value offered by a shorter installation time and not slowing down production to save a failing refractory block lining. For more insights into the long- term value of your lining investment, please consult our Hearth Investment Financial Model paper!

In the last 2 years alone, at least 4 break-outs per year through "micropore" carbon "big block" hearth walls were recorded around the world. Break-outs through HotPressed™ brick linings? Zero (contact us for further details). These emergencies call for fast and highly qualified repair services! Needless to say, in today's marketplace, lost production will have a major impact on the bottom line for any iron and steel producer!

Pirson Refractories, the European installation experts, and Graftech can provide all furnace operators a unique offer in case of lining disasters:

• 1st assessment by Pirson within 24 hours after being contacted.
• Solution planning starting within 24 hours.
• Pirson repair scenario utilizing GrafTech carbon and graphite material fully available within 48 hours!

For further information and details about these services, call or email Pirson 24 hours a day, 365 days a year:

Phone: +31 (0) 251 27 24 12 Email: smartrepair@pirsonholland.nl

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