NFM / LINING CONCEPTS Lining Concepts for the Nonferrous Metal Industry © RHI Magnesita There for you, wherever you need us 9 COUNTRIES 3 R&D CENTERS Europe The more closely we work with our North customers, the greater the impact America we can make for them. So a global network of offices, research centers, and production sites is important to us, and to them. We are continuously 6 COUNTRIES Asia extending our global reach to be closer 1 R&D HUB to even more customers. Middle East/ Pacific Being closer to customers doesn’t just Africa mean we can be more responsive to 3 COUNTRIES their needs. It also helps us to listen 1 R&D CENTER better – to understand their concerns, cultures and ways of working. It makes South us alert to new ways of thinking and 17 COUNTRIES ideas that enable us to deliver even America 1 R&D HUB 1 R&D CENTER better advice, services, and solutions. 35 Main production and Our exceptional resources and raw material sites expertise extend far beyond making 2 COUNTRIES and selling products. We provide 70 solutions to customers worldwide for Sales offices cover projects, material specifications, thermal studies, numerical simulations, 180 follow-ups and technical support Countries shipped in application of minerals, and to worldwide maintenance and electromechanical services for refractory equipment. NFM / LINING CONCEPTS We are RHI Magnesita Refractory Competence – Nonferrous Metal Industry Waelz Kiln Ausmelt Technology ISASMELT™ Teniente Converter Anode Furnace Slag Cleaning Furnace – EAF Kaldo – TBRC – Converter Flash Smelting Furnace Six-In-Line Concentrate Smelting Short Rotary Furnace PS Converter Content Aggregates Solutions Technology Content NFM / LINING CONCEPTS We are RHI Magnesita Refractory Competence – Nonferrous Metal Industry RHI Magnesita is the global leader in refractories. We have the largest number of locations RHI Magnesita is not just a reliable supplier of high-grade refractory products but also partner for around the world and the most innovative, reliable products and services. Our exceptional the nonferrous metal industry to work on complete all-inclusive solutions: vertical integration – from mining to full service solutions – ensures our customers the most • Refractory material concept and lining designs robust reliability of supply with the best quality. • Heat flux, heat transfer and stress calculations by CFD and FEA modeling The RHI Magnesita brand comprises a large number of successfully established trademarks • Metallurgical process analyses by FactSage (Radex, Didier, Veitscher, Interstop, Agellis), which combine tradition with innovative technology • Refractory lining installation drawings and highest quality standards. • Instructions for furnace heat-up or shutdowns • Instructions for refractory material storage We are a global partner for the nonferrous metal industry. The complete program of products • Process and flow control solutions such as purging plugs, purging and injection tuyeres and and services ranges from basic and non-basic mixes and bricks to prefabricated products, slide slide gates gate plates, isostatically pressed products, special machines and repair systems, and technical • Installation service (e.g. by the RHI Magnesita-owned company RHI Magnesita Installation equipment used to install refractory products into the various production units of the nonferrous Services) and installation supervision metal industry. • Post-mortem analysis of refractory materials in our own R&D facilities RHI Magnesita stands for optimum refractory solutions for pyrometallurgical vessels in the nonferrous metal industry. This means lining concepts and process solutions for any type of primary furnace, slag cleaning furnaces, electric arc furnaces (AC and DC), PS converters, anode furnaces, ladles and launders used in the base metals industry. The quality and service offered by RHI Magnesita are based on carefully selected raw materials which have provided good service results for many years, state-of-the-art manufacturing plants, continuous and intensive research and development work and competence of all RHI Magnesita employees. The refractory materials and systems applied for base metals production make a significant contribution to the efficiency and safety of the nonferrous metal smelters. A prerequisite for optimum application of the refractory products is extensive knowledge of all steps of the production process and conditions at customer plants. Our metallurgists and process experts are active around the globe and cooperate with renowned research facilities and universities in Austria and other countries. In addition, the partnership and close cooperation with the customers are contributing factors that ensure enhancement of processes in the nonferrous metal industry. Content Aggregates Solutions Technology NFM / LINING CONCEPTS Product Classification Methods Wedge splitting test (WST) Rotary kiln test (RKT) The WST is a tension test carried out in a hydraulic press to quantify the thermal shock resistance The RKT is a more labor-intensive, expensive and time-consuming slag testing method, or the flexibility of refractory materials. Thereby a wedge is pressed into a sample of the refractory which is conducted with bricks in the final stage of development. Different sizes of kilns material, which is prepared in a special shape with notches to guide the crack propagation in a are available, whereby 3 rings with 20 bricks each can be applied for testing in the biggest defined direction. The evaluation of the fracture mechanical characteristics allows calculation one. Chemical corrosion by molten metal and its slag, thermal fatigue (stress) as well as of the characteristic length (L) as an index for thermal shock resistance or flexibility based on the mechanical abrasion can be simulated close to practical conditions. The kiln rotates 2-10 following equation: times per minute while a gas burner heats the kiln up to 1700 °C. After the test, the wear is evaluated as wear area on the sections of the test bricks and compared to each other. E Young’s Modulus GF E L = GF Fracture work 2 L Characteristic length σ σ Tensile strength The higher the value for L, the higher the flexibility of the material and therefore also the thermal shock resistance. The wedge-splitting experiment can be conducted under controlled atmosphere from ambient temperature to 1500 °C. Scanning electron microscopy (SEM) Hot modulus of rupture (HMOR) Examinations based on SEM can be done on polished sections as used for light microscopy, but The HMOR (N/mm2 or MPa) can be applied to a cuboid-shaped sample performed with the also on powders or fractured surfaces. A finely focused electron beam, emitted from a glowing three point bending technique. According to international standards, the sample size is tungsten filament, scanned across the surface of the sample, generates secondary electrons, 25 x 25 x 160 mm. The determination of the limiting forces at high temperatures is one of the backscattered electrons and characteristic X-rays. These signals are collected by different most important thermo-physical methods for quality control and development of refractory detectors to form images on a screen or to generate a spectrum for chemical analysis. Materials materials. The HMOR is also an indicator of adhesive forces between the grains and the are usually viewed with magnifications from 10 to 10,000 times but a close look at even up to surrounding matrix. It can be used to characterize the hot abrasion resistance of a material at 300,000 times is possible. Features seen in the SEM image may then be simultaneously analyzed specified temperatures up to 1600 °C, either in oxidizing or reducing atmosphere. for composition using an EDS (Energy Dispersive System) or a WDS (Wavelength Dispersive System). These kinds of examinations are of great importance for studying reactions taking place in the refractory material during operation, for instance interaction between the refractory material and the slag. Content Aggregates Solutions Technology NFM / LINING CONCEPTS Waelz Kiln The Waelz kiln is a rotary kiln used for Zn recycling. Zn-bearing residues (filter cakes Standard lining concept and lining from Zn smelters, steel mill dust, steel EAF dust) are treated in refractory-lined rotary recommendation for WAELZ kiln kilns. The efficiency of the Waelz process and also the performance of the refractory lining strongly depend on the raw material preparation. The air oxidizes the volatized The lining recommendation is an engineered lining concept according metals and CO from the reduction reactions inside the feed. to customer process parameters. There are two different operation modes known: • Acidic operation mode C/S = 0.2 • Basic operation mode C/S = 2–3 Due to the effect of waste gas containing Zn that condensates inside the lining, a high corrosion effect will occur. To avoid Zn infiltrations from the waste gas, IS impregnation is highly recommended: • Increase of thermal shock resistance • Increase of acidic resistance • More dense structure and gas permeability of 0% • Increased resistance to Zn vapor • Increased resistance to alkalis (Na, Ka, Cl) • Low Fe2O3 and TiO2 content to lock reaction potential with hydrochloric acid Inlet Zone (formation of Fe- and Ti- chlorides) Cooling zone Reaction Zone Outlet Content Aggregates Solutions Technology Aggregates NFM / LINING CONCEPTS Ausmelt Technology The Top Submerged Lance – TSL technology was invented in the early 1970s and permanently developed by Ausmelt