Steel and foundries

We protect your process

HASLE Refractories offers the Steel- and Foundries industry a wide selection of refractory castables such as insulation, dense, conventional, LCC, gunning and PCF shapes and high-temperature insulating materials.

Our products can increase your energy- and production efficiency, ensure longer life and lower maintenance costs at your plant.

We can provide you with the proper product and design solution for your specific application. Our solutions are successfully installed in reheating furnaces, roller hearth furnaces, rotary furnaces, DRI rotary kilns, pellet plants, coke ovens and blast furnaces.

Find the right castable for your process

Click on the number by the various areas to see what problems typically occur. Find the number in the table below to see our recommended solution.

1

Continue steel hood
Suffers erosion and corrosion from hot gas released from EAF

2

EAF Backup lining

  1. The backup lining is a safety lining. Typically, this area will not directly contract with molten steel. It could be damaged only if steel penetrated from working lining (hot face)
  2. Demolishing process, when lining is replaced. Most plants use heavy machines to remove old wear-lining. This can cause mechanical damage to the back-up/insulating lining.
3

EAF Slag door
Primarily chemical erosion. During operation, slag will be drained every single heat.

4

EAF Delta roof core

  1. Main erosion caused by thermal wear when starting arc electrode in EAF, which will produce enormous heat (1,600°C) around castable hole.
  2. Mechanic wear: The arching flame can cause splash damage to the castable if the fill-level of scrap metal come close to the Delta Roof Core.
  3. Chemical wear: the accumulated slag on EAF Delta Roof core could significantly erode castable layer.
5

Ladle cover lid
Main cause of failure is thermal shock. Hot gas that is released from slag surface in ladle will cause thermal damage directly to the castable. The ladle cover alternates between closed and open position through the casting cycle, thus exposing it to temperature fluctuations.

6

Ladle Backup lining

  1. The backup lining is a safety lining. Normally, this area will not be directly in contract with molten steel. It could be damaged only in case steel penetrates from working lining (Hot face).
  2. Demolishing process, when lining is replaced. Demolishing process, when lining is replaced. Most plants use heavy machines to remove old wear-lining. This can cause mechanical damage to the back-up/insulating lining.
7

Ladle top ring

  1. The ladle top is most often damaged by chemical erosion because the ladle top ring is directly in contract with molten slag. This is sometimes what decides ladle service life.
  2. Thermal issues. If the ladle cools down during service stop, thermal shock can lead to tension build-up and subsequent crack formation.
8

Tundish cover lid

  1. Main cause of failure is thermal shock. Hot gas released from slag surface in tundish will cause thermal damage directly to the castable, such as cracks and surface spalling.
9

Tundish backup lining

  1. The backup lining is a safety lining. Normally, this area will not be in direct contract with molten steel. It could be damaged only in case steel penetrates from working lining (Hot face).
  2. Demolishing process, when lining is replaced. Demolishing process, when lining is replaced. Most plants use heavy machines to remove old wear-lining. This can cause mechanical damage to the back-up/insulating lining.
10

Reheating furnace roof and wall
The problem of castable in reheating furnace is cracking.

1

Continue steel hood
Suffers erosion and corrosion from hot gas released from EAF

2

EAF Backup lining

  1. The backup lining is a safety lining. Typically, this area will not directly contract with molten steel. It could be damaged only if steel penetrated from working lining (hot face)
  2. Demolishing process, when lining is replaced. Most plants use heavy machines to remove old wear-lining. This can cause mechanical damage to the back-up/insulating lining.
3

EAF Slag door
Primarily chemical erosion. During operation, slag will be drained every single heat.

4

EAF Delta roof core

  1. Main erosion caused by thermal wear when starting arc electrode in EAF, which will produce enormous heat (1,600°C) around castable hole.
  2. Mechanic wear: The arching flame can cause splash damage to the castable if the fill-level of scrap metal come close to the Delta Roof Core.
  3. Chemical wear: the accumulated slag on EAF Delta Roof core could significantly erode castable layer.
5

Ladle cover lid
Main cause of failure is thermal shock. Hot gas that is released from slag surface in ladle will cause thermal damage directly to the castable. The ladle cover alternates between closed and open position through the casting cycle, thus exposing it to temperature fluctuations.

6

Ladle Backup lining

  1. The backup lining is a safety lining. Normally, this area will not be directly in contract with molten steel. It could be damaged only in case steel penetrates from working lining (Hot face).
  2. Demolishing process, when lining is replaced. Demolishing process, when lining is replaced. Most plants use heavy machines to remove old wear-lining. This can cause mechanical damage to the back-up/insulating lining.
7

Ladle top ring

  1. The ladle top is most often damaged by chemical erosion because the ladle top ring is directly in contract with molten slag. This is sometimes what decides ladle service life.
  2. Thermal issues. If the ladle cools down during service stop, thermal shock can lead to tension build-up and subsequent crack formation.
8

Tundish cover lid

  1. Main cause of failure is thermal shock. Hot gas released from slag surface in tundish will cause thermal damage directly to the castable, such as cracks and surface spalling.
9

Tundish backup lining

  1. The backup lining is a safety lining. Normally, this area will not be in direct contract with molten steel. It could be damaged only in case steel penetrates from working lining (Hot face).
  2. Demolishing process, when lining is replaced. Demolishing process, when lining is replaced. Most plants use heavy machines to remove old wear-lining. This can cause mechanical damage to the back-up/insulating lining.
10

Reheating furnace roof and wall
The problem of castable in reheating furnace is cracking.

Download the chart to see the details of our recommended solutions for the individual areas of a cement plant.

“We found that HASLE’s high-quality products have a very consistent quality and great flowability. We achieved an excellent lifetime of 3-4 months in the big ladles and 4 months in the small ladles.”

– Jesper Mølgård
Vald. Birn A/S

References and case studies

HASLE Refractories A/S
Kanegaardsvej 1
DK-3700 Roenne, DENMARK
Phone: + 45 56 95 18 00

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