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Dear Valued Customer:
The global economy is beginning to pull out of a recession unprecedented in the post WWII era, as reported by IMF in July 2009.
At GrafTech, we understand that anticipating the market and being prepared for the future is the only way to survive and, in fact, thrive in today's ever-changing marketplace. We are continuously evaluating and improving our product offerings and services to be of an even better value to our clients.
In this issue you will see examples of two leading ferro-alloy producers that are investing in GrafTech refractory linings to be prepared for the upturn: BHP Billiton and Assmang. We will also share why more and more furnace operators have decided to keep spare parts in the form of HotPressed™ bricks for their precious hearths. |
The RefractoryFlex™ Program - great solutions for emergency repairs!
What are the most critical pieces of equipment on your furnace? What makes them critical? What would happen if any one of them broke down? Do you keep spares for each? How would a furnace hearth breakout affect your operation? Do you have a spare lining or a contingency plan?
Stopping and starting furnaces or rough operation related to reduced production can be hard on the hearth wall. GrafTech is now introducing two solutions for emergency repairs: the FlexLine™ and FlexRepair™ systems. The FlexLine™ system is a universal hearth lining and the ultimate solution. It is a complete lining at hand to fit any of your furnaces. It provides you with the ability to make any size repair, including complete hearth wall replacement. Any material not used can be applied to the next repair or reline.
The FlexRepair™ system is an alternative to the FlexLine™ system, offering enough material to make a medium size repair, approximately 4m x 4m, intended for a single or multiple furnaces. All unused material can be applied to the next repair or reline. Let us provide you with a quotation for either or both of these programs. Compare the FlexLine™ and FlexRepair™ systems to the cost of downtime or the cost of purchasing material on the spot market in an emergency situation. Read more about these programs here. 
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BHP Billiton TEMCO now 100% ChillKote™ Lining
As many of you know, at GrafTech we refer to the freeze lining design and materials used for Submerged Arc Furnaces as the ChillKote™ Lining. This is a story of another plant that has converted all of their furnaces to this technology. The BHP Billiton TEMCO Plant in Tasmania has now successfully converted their 4 manganese furnaces to this technology:
- June 2001 furnace #1 (36MVA)
- June 2007 furnace #3 (54MVA)
- March 2009 furnace #2 (33MVA)
- June 2009 furnace #5 (51MVA)
The motivation was to extend the reline life from a historical 10 year to 15+ years. You can read more about the relining of furnace #3 in our May 2008 Newsletter.
Furnace 1 was relined in 2001 and is now into its 8th year of operation with excellent results. This formed the basis for the decision to replicate the design for the remaining 3 furnaces. TEMCO aims to achieve lower overall cost of operation with improved lining safety. TEMCO tells us that, "the combination of quality materials, a design specific to the TEMCO operations and adopting a rigorous lining management philosophy provide the basis for achieving a successful result." |
Another well attended SAF seminar in South Africa
Assmang's HQ in Johannesburg, South Africa was the site of the most recent GrafTech SAF Seminar. In addition to presentations by GrafTech and Assmang, the audience enjoyed discussions with representatives from Hatch, IRCI, Refraline, Calderys and Allied Furnace Consultants. Prior to the May seminar, key personnel from Assmang Machadodorp visited GrafTech's HotPressed™ brick manufacturing plant in Lawrenceburg, Tennessee (USA). They inspected the material to be shipped for their #1 FeCr furnace at Assmang Chrome. As expected, the product inspection went very well, and the material was scheduled for installation during the month of August 2009. The Assmang group operates a total of 10 Ferrochrome and Ferromanganese submerged arc furnaces in South Africa. GrafTech has supplied complete ChillKote™ linings to 6 of these furnaces since the early 2000s, along with various tap hole and refractory lining materials to the remainder of the furnaces.
The Assmang Group is owned by African Rainbow Minerals and Assore Groups. In addition to its smelting activities, the Group also owns the Nchwaning Manganese Mine and the Gloria Iron Ore Mine.
Interested in GrafTech arranging a seminar at your location to discuss these or related subjects for blast furnaces, or submerged arc furnaces? Please visit this link to submit a request form and we will do our best to accommodate and bring our knowledge and expertise to your site! |
The LT1™ MetalCeramic Thermocouple Protection Tubes
The GrafTech™ LT1™ MetalCeramic Thermocouple protection tube is a combination of a chromium metal matrix and a pure alumina ceramic phase. The material is slip cast, sintered and then oxidized. A physical-chemical bond is formed through the sharing of oxygen by the chromium and alumina. By the very nature of its constituents, these tubes exhibit unique properties that are not found in either metal or pure ceramic alone. They are extremely well suited for extraordinarily demanding conditions. Please ask us about applications in your specific process. You can also read more about this product here. |
Some of you may recall crossing paths with Jeff over the years, whether on-site during an installation of a refractory lining, at a technical conference, participating in a  customer product inspection, or maybe receiving some of the many proposal/installation drawings he has prepared over his 20 years of service.
Jeff started his refractory career in 1981 with a ceramic refractory manufacturer in Cleveland, Ohio, and then he came to work for GrafTech in 1989 as a Designer/Estimator. Eventually, he migrated to the position of Applied Technology Engineer, creating technical proposals and providing guidance during reline projects. In 2005, Jeff was re-assigned to our production facility in Lawrenceburg, TN, as a Process Engineer for the manufacture of HotPressed™ bricks.
The last four years of experience have given Jeff a very intimate knowledge of our products which he can now apply as your Customer Technical Service contact. Jeff can be emailed directly at jeff.toth@graftech.com. We are confident that Jeff's refractory knowledge and field experience will greatly benefit our customers. | |
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We would love to hear from you and receive feedback on how we are doing!
If you have suggestions for articles or information that you would like to see, please feel free to contact us! Also, if you know of someone who would value this information, please forward it on to them!
Sincerely,
Your GrafTech Refractory Systems Team
GrafTech, HotPressed, ChillKote, C34, GR37, Grade D, NMA, NMD, SmartRam, UniGraf, RefractoryFlex, FlexLine, and FlexRepair are all trademarks of GrafTech International Holdings Inc. The information contained in or referred to in this newsletter is based on data believed to be reliable but GrafTech makes no warranties, express or implied, as to its accuracy and assumes no liability arising out of its use. GrafTech's liability to purchasers is expressly limited to the terms and conditions of sale. | |
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