Industrial Edition RHI Bulletin >2>2014 The Journal of Refractory Innovations Container Glass Furnace High-Temperature Extended Facilities at RHI’s Vibrocast DIDURITAL RK55 Mechanical Fracture Training Center Cement Feeder Channel Characterization RHI Bulletin >2>2014 The Journal of Refractory Innovations RHI Bulletin 2/2014 Industrial Edition Published by: RHI AG, Vienna, Austria Chief Editor: Christian Majcenovic Executive Editors: Markus Dietrich, Roland Krischanitz, Alfred Spanring Raw Materials Expert: Gerald Gelbmann Technical Writer: Clare McFarlane Proofreader: Clare McFarlane Project Manager: Ulla Kuttner Photography, Graphics and Production: Markus Kohlbacher, Christoph Brandner Design and Typesetting: Universal Druckerei GmbH, Leoben, Austria Printers: Universal Druckerei GmbH, Leoben, Austria Contact: Ulla Kuttner RHI AG, Technology Center Magnesitstrasse 2 8700 Leoben, Austria E-mail: [email protected] Tel: +43 50213-5323 Fax: +43 50213-5237 www.rhi-ag.com The products, processes, technologies, or tradenames in the RHI Bulletin may be the subject of intellectual property rights held by RHI AG or other companies. 2 < RHI worldwide Austrian Industrial Successful Commissioning of the New RHI/ Ceramics Apprenticeship INTERSTOP Converter Gas Purging Programme Established Technology at ArcelorMittal Poland by RHI Poland >> On September 28, 2014, the first INTERSTOP converter gas control unit was successfully commissioned at ArcelorMittal Austria >> In September 2014, the first Poland in Krakow. Gas purging and its availability have a signifi- Austrian industrial ceramics apprentic- cant influence on efficient converter process management. An effi- es successfully completed their 3-year cient system is characterized by short control times, individual flow training programme, which had princi- control units, and a broad flow rate spectrum. pally taken place at RHI’s Trieben and The gas flow control unit was developed in a close collaboration Leoben sites in combination with a between RHI and INTERSTOP. It is a central component of the RHI vocational college in Graz. converter gas purging technology, which is marketed under the The training to become an industrial name Converter Inert Purging (CIP). The new gas flow control unit ceramics technician at RHI comprises distinguishes itself significantly from systems existing in the mar- the selection, evaluation, and prepara- ket through its high flexibility, extremely short regulation times, tion of raw materials as well as the large control ranges, and fine-tuning of the purging programs. In subsequent production of refractories order to ensure maintenance friendliness and process safety of the using processes such as pressing and system, a modular design, which allows maintaining the system casting. The comprehensive knowledge rapidly and independent of processes, was chosen. of an industrial ceramics technician A signal test and cold test were performed on site prior to com- also includes heat treatment processes missioning the system. The system was switched on during hot (e.g., tempering and firing), the opera- operation and worked excellently. The compact design and simple tion of relevant production equipment operation were additional benefits appreciated by the customer. (e.g., mixers and presses), and the sub- sequent characterization of refractory products. During their training the apprentices 10th Anniversary of RHI’s Isostatic Pressing also had the opportunity to participate in exchange programmes and work at Plant in Saybrook other RHI sites. Due to the success of USA >> On October 1, 2014, a celebratory event took place at the this programme, three additional Saybrook plant in Ohio (USA) to mark the site’s 10th anniversary. apprentices are currently training at About 65 employees, local business partners, together with RHI’s RHI. Chief Operations Officer, Mr Franz Buxbaum, took part. The Saybrook plant produces isostatically pressed products for the steel continuous casting process. It is RHI’s most modern ISO plant and has the capability to provide the highest quality products RHI India Receives the 2014 for the most demanding applications. A high level of specialist Best Supplier Award From knowledge exists in Saybrook and the site has a proven capability to develop tailored, value-adding solutions for customers located Tata Steel principally in North America. The event was opened by Mr Franz Buxbaum and the plant man- India >> Recently, RHI India received ager, who described a favourable business situation both currently Tata Steel’s 2014 Best Supplier Relation- and for the future. The teamwork, determination, and passion of the ship Management Implementation employees were highlighted as critical reasons it has been possible Award. It was presented in recognition to establish a new ISO facility under demanding market conditions. of the numerous developments and suc- cessful work performed not only by the local RHI Indian organization (Sales and Marketing) but also for the technical RHI Participates at Aluminium China support from Europe. The Head of RHI’s Indian Sales Offices China >> Aluminium China is Asia’s leading aluminium industry together with the Tata Group Sales platform, held annually in Shanghai (China). From July 9–11, 2014, Manager received the award from Mr over 460 international exhibitors from 30 countries represented T.V. Narendran, Managing Director of the entire aluminium value chain. There were more than 16000 Tata Steel. This award is a very presti- attendees this year, an increase of 8% compared to 2013. RHI was gious achievement since it encompassed represented with a 60 m² booth that was visited by numerous all Tata suppliers, not just refractory renowned customers. The next Aluminium China will take place from companies. July 8–10, 2015. > 3 RHI worldwide First Ferrochrome Produced RHI’s Niederdollendorf Plant is Fit for the at Kazchrome JSC’s Aktobe Future Plant Germany >> The Niederdollendorf plant produces nonbasic, ceramic- bonded special products for glass applications. Market developments in Kazakhstan >> On August 23, 2014, recent years indicate that there has been a continuous rise in the the first tapping was performed with demand for high-quality products. In light of this, RHI has made major Kazchrome’s DC electric arc furnace investments in the plant, totalling €8 million since 2011, in order to No. 1 after a 3-week heat-up schedule increase its production capacities and further improve production relia- that had been concluded and super- bility while also ensuring the use of environmentally friendly and vised by RHI service technicians. Fol- resource-efficient technologies. lowing an installation period of more One aspect of the project was the expansion of the mixing plant, than a year with four RHI supervisors at which has enabled separate allocation of the mixers depending on the ENRC’s Aktobe site in Kazakhstan, this raw material base. As a result of purchasing a new 2000-tonne LAEIS event marked the start of the company’s press, large-format products such as bottom pavers and cover tiles (up huge expansion project, comprising to 700 mm x 500 mm) can be pressed. An additional shuttle kiln with a four new 72 MW DC SMS Siemag elec- 75 m³ furnace chamber led to a capacity increase for special silica and tric arc furnaces, which will provide an chrome corundum bricks as well as for tank blocks and large-format annual production capacity of more fired vibrocast products. Over the course of the project existing presses than 400000 tonnes of high-carbon were refurbished, new drying capacities were created, and firing units ferrochrome. were relined. Optimizations in the grinding workshop area have also RHI delivered four complete refractory resulted in a significant productivity increase in the final process step. lining sets for this important project, The investment in a fluorine filter system ensures that the plant will including all the materials as well as the meet the required emission limit values in the coming years, and mod- design, engineering, and simulation ernization efforts in the grinding water cleaning system also provide work. process security for water treatment. Furthermore, a modern heat recovery system in the firing units provides sustainable energy man- agement. RHI Presents at the The continuous optimization of production facilities with regard to safety, quality standards, and the use of resources is an important prior- European Continuous ity for RHI. All of these measures ensure that the Niederdollendorf plant Casting Conference will continue to supply high-quality products in the future and enable RHI to successfully continue its role as a full-range provider for the Austria >> From June 23–26, 2014, glass industry. the 8th European Continuous Casting Conference was held in Graz (Austria). The ECCC is one of the most important conferences in the field of continuous 10-Year Anniversary of Production and Product casting and serves as a forum to dis- Development at the Technology Center ISO cuss present and future developments in the continuous casting processes. Austria >> On September 20, 2014, the isostatically pressed product The programme included lectures competence centre in Trieben (Austria) celebrated its 10-year anniversa- on the newest developments in ry. Following the startup phase in 2004, production processes were ini- control and automation, advanced con- tially established for the commercial supply of ladle shrouds and proto- tinuous casting technologies, and the type