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December 2014                                                                                                           Issue 29
LATEST NEWS
Yiwang 30 MVA SAF
Spare Refractory Linings
Time to Grout?

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Dear Newsletter Reader, 

The holidays are quickly approaching and we are looking to begin a new year!

We wish you the very best during this season, and we hope that the new year looks promising for you. GrafTech is excited to see what 2015 has in store for us and we are very excited for business opportunities.

In this issue of our newsletter we would like to tell you about the Yiwang 30 MVA SAF that has been started, spare refractory linings and grouting your lining.

 Yiwang 30 MVA SAF Started

 

On October 6, 2014, Shanxi Jiaocheng Yiwang Ferroalloy Co. (Yiwang) started up its F#401 30 MVA Submerged Arc Furnace using UCAR� ChillKote™ refractory systems. This is the third Submerged Arc Furnace in which Yiwang has used the UCAR ChillKote lining technology. The first 2 furnaces that adopted this technology were operated separately in 2007 and 2012, and all three furnaces produce the FeMn and Rich Mn Slag.

 

We sincerely thank the Yiwang operation team for their relentless quest for quality during the installation of the UCAR lining materials. With over 50 years of experience in HotPressed™ brick production, GrafTech looks forward to helping Yiwang reach stable furnace operation with long refractory lining life.

Spare Refractory Linings

What happens when you are forced to idle your furnace because it requires refractory replacement and you are unable to obtain the refractory required to replace it with? Can you put a monetary figure on the cost of your iron or metal alloy producing furnace being idle for several days, a week, a month, or longer?

 

What is the solution to eliminating your risk should an unforeseen emergency arise and force you to take your furnace out of service because of a refractory replacement issue? Have you considered investing in a spare refractory lining to have on hand as protection against the possibility that something dire could occur to your existing furnace lining?

 

The popular responses to not purchasing refractory lining materials to have on hand for emergency situations are:

  • the monies are not available
  • we have no place to store it
  • too expensive!

Before you consider one of the referenced responses as the reason not to buy a replacement refractory lining - DO The Math! Can you not afford to protect one of your most important assets?

 

Is it time to Grout your Refractory Lining?
  

Are you experiencing elevated thermocouple temperatures in your hearth lining?

Has your furnace been stopped, or started, recently?

Have you detected and/or corrected a water leak that may have found its way to the hearth lining?

Or, maybe you just have a short maintenance outage scheduled in the near future.

With fluctuations in temperatures for any reason, refractory linings undergo a certain amount of movement. How much movement is dependent on the amount of heat and the Coefficient of Thermal Expansion (CTE) of that specific material. It is then that the differential movement of two adjacent materials most likely results in separation of the lining from the essential cooling. Once separated from the cooling element, the hot face temperature may rise above the solidification temperature of the process/slag and thermal attack on the lining commences.

For these reasons GrafTech recommends installing our GR37™ Grout. This is a resin bonded two-component carbonaceous material containing a special graphite flake that expands at temperatures above 200� C. The fine, flour-like, particle sizing of the powder component, when mixed with the furfuryl alcohol-based liquid component and mechanically pumped, either by hand or machine, allows this material to flow into extremely thin gaps of less than 1 mm thickness. The residual heat in the lining is sufficient to cure the mixture and reinstate contact between the refractory lining and the cooling element. Shortly after using GR37 grout, thermocouple readings of the lining temperatures should return to normal.

Before grouting consider the possible condition of the lining - it may not tolerate excessive pressure and could further dislodge. Also keep in mind that this mixture is flammable. Please contact the Refractory Systems Sales Office or Territory Manager with more details of your furnace and condition and we will provide you with Technical Data Sheet, Safety Data Sheet and complete Product Use Instructions.

 

Redefining Limits


GrafTech, HotPressed and ChillKote are all trademarks of GrafTech International Holdings Inc.  UCAR� is a registered trademark used under license by 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 its terms and conditions of sale. �2014 GrafTech International Holdings Inc.