Your contractor/partner specialized in furnace ... - HeatTeQ

Your contractor/par tner specialized in furnace inspection, installation and repair services for the iron and steel industry

Welcome to HeatTeQ

It is our goal to provide the industry with the full range of services such as furnace repairs, design, engineering, inspections and all installation services, covering the global market. HeatTeQ wants to fill up the void between contractors and engineering companies and strengthen our position by continuously improving the level of our services and the quality of our products. It is our objective to foster a work environment that encourages new ideas, innovation and growth.

Hot Blast Stoves – Apart from our activities in full

stove construction, over the years we have specialized

ourselves in performing smart repairs in the hot blast

stoves with the objective to have the stoves out of

operation as short as possible. Most of the repair works

on stoves takes place on and around the hot blast outlet

and ceramic burners. We have developed a program

where the downtime of the stove is kept to a minimum,

under cold conditions or, if necessary, under hot con-

ditions, where we have developed and implemented

a system to isolate the lower part of the combustion

chamber and keep the remainder of the stove hot.

Blast Furnaces – The demand for quick and safe

repair solutions becomes more and more important

for the blast furnace operators. Downtime (loss of

production) thus total repair cost is to be kept to the

bare minimum, plus the fact that the furnace in poor

condition has to be dragged to the scheduled repair

period.

The focus has moved to (intermediate) repairs on

those areas where the condition is worst. These are

typically the furnace stack lining, the tap hole areas

and the hearth ring walls & bottom. HeatTeQ is able

to offer you complete repair scenarios for those

repairs. HeatTeQ works with strategic partners for

demolition and cleaning out the furnace and for stack

gunning or shotcreting work. We are experienced

with different furnace designs and refractory materials

and are able to give you an unbiased opinion on repair

options.

Inspection Projects – Inspections are being

performed on all sorts of installations, blast furnaces,

hot blast stoves and coke batteries. When our customer

demands information about the condition of their

installation, in order to determine future life, furnace

availability and repair planning, HeatTeQ is your partner.

We have developed a program where the customer

can choose the moment they want us to be involved.

That obviously depends on the data and information

which is already available. Our inspection services

consits of data review, field inspection and reporting.

Coke Batteries – When coke batteries reach an

age of 10-15 years, repairs are to be done on the

refractory, mainly at the end flues of the walls. We are

in the fortunate situation that, over the last decades,

our specialists have been involved in new-build and

repair project featuring different coke battery designs.

Since investments are high building new batteries,

repairs are necessary.

HeatTeQ is able to perform all sorts of repair services:

such as full battery inspections, ceramic welding,

end flue repairs and through wall repairs. HeatTeQ

has a lot of experience applying non-expanding large

modules made of fused silica in both end flues as well

as through wall repairs.

Refractory Training Course – As a refractory instal-

lation company it is important to employ members who

are aware of the aspects that determine the success of

a refractory lining as intended in it’s application.

Since 2010 we have started the HeatTeQ Refractory

Academy. The academy was set up to train our own

personnel only, since 2012 we have opened the course

for our customers or dedicated partners as well.

The training is set up for (young) engineers and

refractory foremen/supervisors, working in the iron

making Industry. The purpose of the training is to

make the participants aware of the different type of

installations, their behavior and the role refractories

have in these installations.

The participants will be made aware of different

material applications and all sorts of problems we

typically find on repair projects. The focus is mainly

on blast furnaces, hot blast stoves and coke battery

repairs. The attendees are made aware of the base

operations of the installations, explained by our

operating specialists.

• Onsite engineering to establish the right

location for the salamander runner.

• Determine scope of work for the mechanical

and refractory contractor.

• Prepare installation drawings in close

cooperation’s with client engineers.

• Write enquiries for the mechanical and

refractory contractor.

Fa c t s & f i g u r e sProject . . . . . . . . . . . . Blast Furnace – Taphole Repair

Client . . . . . . . . . Arcelor Mittal Newcastle, South Africa

Blastfurnace: . . . . . . . . . . . . . . . . . . . . . . . .N5

Design . . . . . . . . . . . . . . . . . . HeatTeQ/Graftech

Duration . . 8 Weeks including engineering and preparation

Execution year . . . . . . . . . . . . . . . . . . . . . . 2012

Scope . . .Tap-hole repair incl. installation of new jacket cooler

Arcelor Mittal Newcastle – Blast Furnace Taphole Repair

• Technical and commercial evaluation of

the tenders received.

• Set up & control shutdown program.

• Execute and supervise all the on-site

installation works.

• Quality control to all the installation works.

• Monitor actual duration to planning duration.

• Monitor safety during the execution of the project.

In February 2014 SSAB awarded an order to

HeatTeQ for the refractory installation of the new

Hot Blast Stove 46 of Blast Furnace 4 and an

extension of the hot blast main. The stove,

designed by Paul Wurth, was of the internal com-

bustion type provided with a ceramic burner.

Fa c t s & f i g u r e sProject . . . . . SSAB EMEA AB Oxelösund Blast Furnace 4

Duration: . . . . . . . . . . . . . . . . . . . . . . . 8 weeks

Plant: . . . . . . . . . . . . . . . . . . . Hot Blast Stove 46

Design: . . . . . . . . . . . . . . . . . . . . . . Paul Wurth

Tonnage: . . . . . . . . . . . . . . . . Refractories 1800 ton

Execution: . . . . . . . . . . . . . . May – September 2014

Scope: . . . Installation of refractories in new hot blast stove

Partners: . . . . . . . . . . . . . . . . . . . . Lizmontagens

SSAB EMEA AB Oxelösund Hot Blast Stove 46

Scope of Work:

• Design and Supply of all auxiliary equipment

• Gridblasting and Shotpeening of the inside of the

new stove shell

• Applying Stellatar on the inside of the new stove shell

• Installation of auxiliary equipment required for

installation

• Receiving and off-loading free issued refractory

material

• Installation of checker support

• Installation of all stove internals

On February 14, 2014 the order was placed and HeatTeQ

started with the engineering of the auxiliary equipment

and the preparation of enquiries for sub-contracts. By

the beginning of July the preparations were completed,

subcontracts were placed and the work on site was started.

By that time the erection of the stove shell was completed

and HeatTeQ started with the gridblasting and shotpeening

of the inside of the stove shell after which Stellatar was

applied.

Because the designer of the stove did not allow openings

in the side of the stove shell all material had to be fed over

the top through the dome manhole. For this purpose a

platform and hoisting beam was erected on top of the stove.

Material was hoisted up by a Demag hoist packed on pallets.

To prevent accidental falling of material the pallets were

covered with a safety net.

Installation of refractories in the checker shaft and the

burner shaft was done in parallel, working from scaffolds

in the burner shaft and from the top of the checkers in the

checker shaft.

The work was completed on schedule on September 29 to

the full satisfaction of the customer.

In February 2014 AMSA awarded an order to

HeatTeq for various repairs of the Hot Blast

Stoves of Blast Furnace N5. The stoves, designed

by Krupp Koppers, are of the external combusti-

on chamber type provided with ceramic burners.

Included in the scope was the repair of the

cross-overs connecting the burner shaft with the

checker shaft.

Fa c t s & f i g u r e sSite:. . . . . . . . . . . ArcelorMittal Newcastle South Africa

Duration: . . . . . . . . . . . . . . . . . . . . . . 3 months

Plant: . . . . . . . . . . . Hot Blast Stoves Blast Furnace N5

Design: . . . . . . . . . . . . . . . . . . . . Krupp Koppers

Execution: . . . . . . . . . . . . . . May - September 2014

Scope: . . . . . . . . . . . . . . . . . . Cross-over Repair

Subcontractor Mechanical: . . . . . . . . . . . . . . Elinem

Subcontractor Refractories: . . . . . . . . . . . . . Anmar

ArcelorMittal Newcastle South AfricaBlast Furnace N5, Hot Blast Stoves, Cross-over Repair

Scope of Work:

The external combustion chamber Koppers design stoves

at AMSA’s Newcastle BF5 have suffered from hot spots at

the cross-over section. Because endoscopic inspection

of the inside of the cross-overs showed no damage to

the dense lining it was assumed that the cause of the

problems was failure of the insulation. The Koppers design

external combustion chamber stoves compensates the

difference in the shell expansion between the checker

and combustion chamber and the radial expansion of the

domes due to thermal expansion and pressurizing and

depressurizing by two stainless steel expansion bellows

installed in the cross-over.

Based on the results of internal and external inspections

the following scope of work was agreed upon:

• Replacement of the existing damaged expansion

bellows by new bellows.

• Replacement of the outer shell ring 360°.

• Replacement of the inner shell (both sides) 180°.

• Replacement of the upper 180° of the two layers of

insulation lining.

To allow repair under hot conditions a special repair

scenario was developed.

• Remove the existing compensators complete with the

outer shell between the two existing thrust collars.

• Remove top half of the inner sleeves exposing the

refractories.

• Remove and replace two layers of insulation over

the top half.

• Install new inner sleeves over the newly installed

insulation.

• Install new expansion bellows on both sides of the

cross over. Because the cross over refractories

remained in place the bellows had to be installed as

clam shells in two halves. Welding the two halves

together was done in situ by specialized welders

from the supplier.

• Install the outer shell in two halves and weld in situ

to the bellow stubs.

During the execution of the repairs it appeared that on

stove 1 the condition of the lower half of the cross over

was so bad that complete replacement was required. It

was therefore decided to cool the stove down to ambient.

After cool down the old expansion joints, the outer and

inner sleeves and the refractories in the cross over were

removed. After installation of new inner sleeves new

refractories were installed and the new expansion joints

and outer shell could be erected. The space between

the inner sleeves and the outer shell was filled with an

insulating castable.

The coke batteries of SSAB Oxelosund Sweden

run mainly on lean blast furnace gas. The gas

is pre-heated through the regenerator and then

ignited once entered into the combustion cham-

ber. During shutdown of the blast furnaces, the

coke battery will have to be fired with coke oven

gas. The coke oven gas is injected through the

gas gun unit into the horizontal gas channel. Due

to the age of the batteries, the last few years

several gas gun blocks started to leak. Some

ovens had to be taken out of production due to

insufficient heat in the coke oven walls.

Fa c t s & f i g u r e sProject . . . . . . . . . . . . . . . Gas gun block trial repair

Client . . . . . . . . . . . . . . . SSAB Oxelosund, Sweden

No. of ovens: . . . . . . . . . . . . . . . . .100 (5 Batteries)

Coke battery design: . . . . . . . . . . . Twin Flue, Koppers

Duration . . . . . . . . . . . . . . . . . . . . . . . 5 weeks

Execution year . . . . . . . . . . . . . . . . . . . . . 2013

Battery height: . . . . . . . . . . . . . . . . . . . . 4 meters

Manhours . . . . . . . . . . . . . . . . . . . . . . . . 650

SSAB Oxelosund, Sweden – Gas gun block trial repair

HeatTeQ was consulted to investigate the problem area

and they presented a repair plan for the gas gun blocks

in order to secure oven availability while firing coke oven

gas. After presenting our solution to SSAB Oxelosund,

HeatTeQ was awarded the order to perform a trial repair

on the coke oven batteries.

During the trial repair, a total of thirty eight (38) gas gun

units have been repaired. A stainless steel tube was

inserted through the gas gun block in the gas channel

and a special mortar was injected to seal up open joints,

cracks and gaps around the gas gun block. The results

are excellent, all gas guns were sealed, after the repair

no leakages through the gas gun block were detected.

After the successful trial repair, HeatTeQ received an

order to repair an additional 200 gas gun blocks to allow

SSAB a problem free operation during coke oven gas

firing this summer.

In October 2012 HeatTeQ was awarded a contract

by Cimprogetti Spa. for the refractory installation

of 2 lime kilns at Danielskuil plant of Idwala

Company located in Danielskuil RSA. Cimprogetti

is the designer and main contractor for a new

calcinating plant designed to produce 1050 tons

of quick lime per day.

Fa c t s & f i g u r e sProject . . . . . . . . . . . . . . . . Danielskuil South Africa

Duration: . . . . . . . . . . . . . . . . . . . . . . 2 months

Plant: . . . . . . . . . . . . . . . Calcinating Plant Lime Kilns

Design: . . . . . . . . . . . . . . . . . . . Cimprogetti Spa.


Execution: . . . . . . . . . . . . . . . . January-April 2013

Scope: . . . . . Installation of refractories in 2 new lime kilns

Partners: . . . . . . . . . . . . . . . . . . . . Lizmontagens

Idwala Company Calcinating PlantDanielskuil South Africa

Scope of Work:

• Design and Supply of all auxiliary equipment

• Installation of auxiliary equipment required for

installation

• Receiving and off-loading free issued refractory

material

• Installation of free issued refractory material

On October 30, 2012 the order was placed and HeatTeQ

started with the engineering of the auxiliary equipment

and the preparation of enquiries for sub-contracts. By

the beginning of January 2013 the preparations were

completed, subcontracts were placed and the work on

site was started. By that time the erection of the steel

shells for the kilns was completed and heatteq started

refractory installation.

The work was completed on schedule on March 29 to the

full satisfaction of the customer.

Because of the bad condition of the existing

underground waste gas flue AMSA decided to

install a new waste gas flue. Repairing of the

existing flue would take approximately

2 months during which period the furnace had

to be shut down. This was unacceptable.

AMSA therefore issued an enquiry for design,

supply and installation of a new above ground

flue to be installed over the existing one with

the furnace in operation.

An order was issued to HeatTeQ in April 2011.

A site visit was made in May 2011 to inspect the

site and to make a survey of the existing system

after which design started. HeatTeQ developed

a concept whereby the new flue was supported

on trestles straddling the existing underground

flue. The trestles were supported on one side

on piles driven in beside the old flue and on the

other side on the stove foundation.

Fa c t s & f i g u r e sSite: . . . . . . . . . . . . . AMSA Newcastle South Africa

Duration: . . . . . . . . . . . . . . . . . . . . . . 5 months

Plant: . . . . . . . . . . . . . . . . . BF N5 Waste Gas Flue

Manhours: . . . . . . . . . . . . . . . . . . . . . . 40.000

Design: . . . . . . . . . . . . . . . . . . . . . . . .HeatTeQ

Tonnage: . . . . . . . . Steel: 150 ton, Refractories: 450 ton

Execution: . . . . . . . . . . . . . . . July-December 2011

Scope: . . . . Design, supply and install new waste gas main

Arcelor Mittal South Africa New Castle Works Design, supply and installation of a new waste gas flue for Blast Furnace N5.

Design was completed by the end of July after which

procurement started. Sub contracts were placed

for supply and installation of civil, mechanical and

refractories. HeatTeQ South Africa performed overall

project management with specialized assistance

from HeatTeQ Netherlands.

Civil work on site started in the middle of August in

parallel with mechanical fabrication. Mechanical

installation started by the end of September.

The contract called for completion of the project by

the end of March 2012. Due to a calamity the furnace

was shut down in the middle of August for a repair

scheduled for a duration of 3 months. AMSA requested

HeatTeQ to shorten the duration of the flue project so

the new flue could be taken in operation together with

the repaired furnace. Thanks to a concerted effort by

HeatTeQ and all sub-contractors this request could be

met.

The new flue had to be tied in with the existing waste

gas chimney above ground. For this purpose an opening

had to be cut in the chimney. This opening had to be

properly reinforced. The design of the reinforcement

was sub-contracted to Ferbeck, a company within the

LizMontagem group specialized in chimney design.

Ferbeck designed the reinforcement with the help of

a finite element program.

Blast furnace D – Hot blast stove 4

ArcelorMittal rebuilt their hot blast stoves at

‘D’ furnace in 2004 (#4 stove), 2005 (#3 stove)

and 2006 (#2 Stove), prior to and during the

furnace rebuilt in 2006. The stoves are a Siemens

VAI design, internal combustion chamber type

with ceramic burners.

Fa c t s & f i g u r e sProject . . . . . . . . . . . . . . . Burner and dome repair

Client . . . . . . . . . . . . ArcelorMittal Vanderbijlpark BFD

Design . . . . . . . . . . . . . . . . . . . . . Siemens VAI

Duration . . . . . . . . . . . . . . . . 18 weeks of site work

Execution year . . . . . . . . . . . . . . . . . . . . . . 2012

Arcelor Mittal Vanderbijlpark BFDStove 4 – Burner and dome repair

During 2009 problems were experienced with #4 stove’s

performance. Preliminary Inspections indicated partial

blockage of the burner crown by debris.

HeatTeQ performed a detailed endoscopic inspection in

June 2010, leading to a scheduled replacement of the

ceramic burner area in February 2012. Late 2011 the

scope of work was extended due to sudden hot spots

occurring at the dome area.

HeatTeQ was able to prepare and undertake a practical

repair, with specially designed shaped refractory materials

for the dome area. The repair period was scheduled for

60 days, from off blast to on-blast.

Whilst demolishing the dome area, the extent of the

damage was found to be larger than expected. With a

combined effort of HeatTeQ, the customer (Arcelor-

Mittal) and the designer (Siemens VAI), the dome area was

inspected, redesigned and repaired in a record time con-

sidering the limitations of refractory materials available.

The project Scope of Work consisted of:

• ‘Zero Tolerance Safety Performance’ during the

execution of the whole project.

• Removal and replacement of several process valves

to isolate the stove from the live systems and to

make clearance for cool down and heat up auxiliary

equipment.

• Controlled cool down of the refractories in stove 4.

• Demolition and installation refractories lower hot

blast outlet and draught hole.

• Demolition and Installation of the ceramic burner

• Demolition and installation of ± 2.5 meter from the

hot face lining of the top part combustion and

partition wall.

• Additional repair on the checker chamber and partition

wall just beneath the dome ledges (2.5 meter).

• Replacement of process valves prior to heat up stove.

• Controlled heat up of the refractories stove 4.

• Supply of all refractories for the ceramic burner

& dome repairs.

13

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A 20-10-2010REV DATE DESCRIPTION DRAWN CHECK APPRO

Form- and placetolerances acc. to NEN-ISO 2768-2Dimensional tolerances acc. to NEN-ISO 2768-1Rougness acc. to NEN 3632/3634

CHECK...:

DRAWN..:

APPROV.:

AL RIGHTS RESERVED. THISIS A COMMERCIAL DRAWINGAND IS SUPPLIED FOR USEFOR AN AUTHORIZED JOB.THIS DRAWING OR ANYINFORMATION THEREFROMSHALL NOT BE DISCLOSEDUSED OR REPRODUCEDEITHER WHOLLY OR INPART. EXEPT INCOMMUNICATION WITHSUCH USE AND WITH THEPRIOR WRITTEN CONSENTOF THE OWNER. THISDRAWING MAY NOT BEUSED FOR CONSTRUCTIONOR FABRICATION UNTILSIGNED AS CHECKED ANDAPPROVED.© 2010 HeatTeQ

REV.:SCALE.:

DRAWING No.:

MATERIAL:

CLIENT:

PHASE 6

ARCELOR MITTAL

HPaABaABa

A1

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AMSA BFDCooldown stove-4

T-dome T-interface 1 T-Interface 2 Cooldown Curve T-grid Temp. Stack

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AMSA BFDHeat Up Stove-4

T- Dome Actual T-interface 1 T-Interface 2 Heat Up Curve Temp. Stack

16.00 27-5-12 16.00 10‐6‐12

The reline of blast furnace #4 was scheduled for

the summer of 2012. HeatTeQ was awarded the

contract for the wrecking and removal of all bur-

den, refractories and solidified salamaner from

the furnace proper. The work, under supervision

and coordination of HeatTeQ, was performed

by our dedicated sub-contractors DGC Déman-

tèlement and HOLTMANN Fahrzeug- und Ma-

Fa c t s & f i g u r e sSite: . . . . . . . . . . . . . . . . . . TATA Steel Port Talbot

Plant: . . . . . . . . . . . . . . . . . . . . . Blast furnace #4

Design: . . . . . . . . . . . Siemens VAI, Plate cooled stack

Execution: . . . . . . . . . . . . . . . . . . . . . July 2012

Duration: . . . . . . . . . . . . . . . . . . . . . . . 28 days

Manhours: . . . . . . . . . . . . . . . . . . . . . . . 5200h

Furnace size: . . . . . . . . . . . . . . . . . . . . . 11 meter

Scope: . . . Demolition & removal of all burden & refractory in

furnace proper and removal of solidified salamander.

TATA Steel Port Talbot Works Demolition & removal of furnace proper

schinenbau GmbH. DGC is a French based demolition

company, Holtmann GMBH from Germany builds and

operates their own remote controlled stack demolition

deivce, the so-called ‘Slageater’.

Demolition started with the safety blasting shot, the

safety blasting shot is to remove loose skull and brick-

work from the furnace stack to enable a safe entering

of the furnace. After the safety blasting shot the cold

burden and stack refractory lining was removed from the

furnace by the Slageater. Below Tuyere Level the brick-

work and skull was removed with excavators.

After the brick work and skull were removed down to the

furnace entrance the salamander was dug out. Due to a

very successful salamander tap by TATA, no more than

50 ton of salamander was left in the furnace. No lancing

was required as we were able to remove the two pieces

of salamander as a whole.

A second shell opening at the bottom of the base plate

was cut to remove the remaining carbon block and to

clean out the furnace down to the base plate.

Despite certain delays we managed to complete our scope

of work within the project schedule. The demolition

project was completed with ZERO accidents and to total

satisfaction of TATA Steel UK.

SSAB Lulea has a one-furnace operation with four

(4) hot blast stoves. On one of their stoves they

were experiencing performance problems for the

last 4 years. After Inspections it became clear

that the burner crown was severely damaged

and partially collapsed. This created problems

with gas & air mixing during the heating phase

thus affecting the whole heating cycle and stove

efficiency. In order to maintain a continuous

operation, there was a need to do a repair on

the ceramic burner.

Fa c t s & f i g u r e sProject . . . . . . . . . . . . . . . . Ceramic burner repair

Client . . . . . . . . . . . . . SSAB Tunplatt, Lulea, Sweden

Design . . . . . . . . . . . . . . . . . . . . . Siemens VAI

Duration . . . . . . . . . . . . . . . . . . . . . . . 60 days

Execution year . . . . . . . . . . . . . . . . . . . . . . 2012

Partners . . . . Lulea Industriemontagens AB, Lulea, Sweden

. . . . . . . . . . . . . . . . . . . . Lizmontagens SA, Lisbon

SSAB Lulea Ceramic Burner Repair

SSAB placed an order with the design company Siemens

VAI for new ceramic burner refractories in 2009, in order

to have the most critical lead item on site, in case a repair

was required.

HeatTeQ received the order for the complete site work,

including the following activities;

• Site management and planning (included client

activities);

• Engineering & manufacturing of all auxiliary

equipment, in order to have safe access in the stove

during the repairs;

• Perform all mechanical works related to the

disconnection of the stove from the life systems

at the blast furnace;

• Controlled cool down of the hot blast stove

• Installation of safety deck;

• Demolition and installation of new ceramic

burner refractories;

• Inspect & cleanout of the area under the grids;

• Perform all mechanical works related to the

disconnection of the stove from the life systems

at the blast furnace;

• Controlled heat up of the hot blast stove

• Zero tolerance safety performance during the

execution of the whole project.

Stove cool down Stove heat up

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SSAB LuleaHeat Up Stove 24

T-Dome Point 1 T-Interface Point 2 T-Interface Point 3 T-Grid Point 4 Heat Up Curve

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SSAB LULEACooldown Stove‐24

T-Dome Point 1 T-Interface Point 2 T-Interface Point 3 T-Grid Point 4 T-Stack Point 5 T-Comb. Point 6 Cooldown Curve #REF!

02-08-2012 10:00 AM 17‐08‐2012 07.00 AM

4°C/hr

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In July 2014 HeatTeQ received an enquiry for the

repair of the stoves no.4 of blast furnaces 2 & 3 of

the Katowice plant of Arcelor Mittal. The scope

of work for this enquiry was based on an inspec-

tion of both stoves after they had been cooled

down to ambient temperature by the customer.

In the enquiry the bidders were requested to

propose methods for repair of both stoves.

Fa c t s & f i g u r e sProject . . . . . . . . . . . . . Repair of 2 Hot Blast Stoves

Duration: . . . . . . . . . . . . . . . . . . . . . . 3 months

Customer: . . . . . . . . . . . . . . . Arcelor Mittal Poland

Partner: . . . . . . . . . . . . . . . . . . Lizmontagens SA

Execution: . . . . . . . . . . . . . . . . . . . . 2014/2015

ArcelorMittal Katowice PolandRepair of two Hot Blast Stoves

Stoves No.4 of Blast Furnaces 2 and 4 are internal com-

bustion chamber stoves of similar size, equipped with ex-

ternal burners. Stove 4 of BF 2 is a so called high alumina

design stove, whilst stove 4 of BF 3 is a so called Silica

design stove. The other difference is that Stove 4 of BF 3

is equipped with a so called protection wall to cope with

the impact of the mechanical burner; this protection wall

is not incorporated in Stove 4 of BF 2.

Arcelor Mittal prepared the Scope of Repair for both

stoves based upon an internal inspection of both stoves

after cool down to ambient temperature. This scope was

subsequently confirmed with certain amendments after

an inspection by HeatTeQ and agreement was reached

on the repair methods proposed by HeatTeQ.

HeatTeQ provided the following services

and supplies:

• Engineering of the required modifications

• Supply of all refractory materials

• Engineering and supply of all auxiliary equipment

required for installation

• Provision of supervision and labour required for

installation

• Provision of equipment and supervision of heat-up

of both stoves

The repairs can be summarized as follows:

• Repair of cracks in the dome area of both stoves

• Removal and replacement of 3 layers of checkers on

the top of the checker column of both stoves

• Complete removal and replacement of hot face

lining in the burner shaft above the hot blast outlet

of stove 2.4

• Repair of cracks above the hot blast outlet in the

combustion chamber lining of stove 3.4

• Removal and replacement of the hot face lining

between the burner inlet and the hot blast outlet of

stoves 3.4 and 2.4

• Complete removal and replacement of the hot blast

outlet refractory lining of both stoves

Section A-AScale 1 : 50

Section B-BScale 1:50

Section C-CScale 1:25

Detail IScale 1:10

See Detail I C

C

2400

Ø1296

2342Ø

6511

411

423

0

Castable

Grade 23

Grade 28

Andulasite Block

10068

230

1515

90

6°

102

67

60°

345

60°R5

Andulasite Block - 60x/360°Scale 1:5

2400

R5500

Ø12

96

R1545

200

40

45°

8357

355

8712

1320

1850

Ø1296

In February 2014 AMSA awarded an order to

HeatTeQ for various repairs of the Hot Blast Stoves

of Blast Furnace N5. The stoves, designed by

Krupp Koppers, are of the external combustion

type provided with ceramic burners. Included in

the scope of repairs was the complete replace-

ment of 2 ceramic burners and 3 hot blast

outlets. As the repairs had to be executed with

the stoves in hot condition HeatTeQ had to

develop special provisions to make this possible.

Fa c t s & f i g u r e sProject . . . . . . . . . ArcelorMittal Newcastle South Africa

Duration: . . . . . . . . . . . . . . . . . . . . . . 3 months

Plant: . . . . . . . . . . . Hot Blast Stoves Blast Furnace N5

Design: . . . . . . . . . . . . . . . . . . . . Krupp Koppers


Execution: . . . . . . . . . . . . . . May – September 2014

Scope: . . . . . . . . . . . . . . . . . HBO & Burner Repair


Subcontractor Refractories: . . . . . . . . . . . . . . Anmar

ArcelorMittal Newcastle South AfricaBlast Furnace N5, Hot Blast Stoves, Replacement of Ceramic Burners.

Scope of Work:

• Develop methodology for hot repair.

• Design, supply and installation of specialized

equipment to facilitate hot repair.

• Demolition and removal as required.

• Supply and installation of refractories for new burners

and hot blast outlets.

• Supply of all required labor.

• Supervision during erection for both the mechanical

and refractory scope of work.

• The stove was kept hot by others, in close cooperation

with HeatTeQ.

• Underpinning of hot blast outlet refractories.

• Installation of a Heat Shield to create a safe working

environment in the lower part of the burner shaft.

• Complete wrecking and re-installation of a new hot

blast stub and compensator (Stove N1 & N3 only).

• Complete wrecking and reinstallation of hot blast

outlet refractories (all 3 Stoves).

• Complete wrecking and reinstallation of the ceramic

burner (Stove N1 & N3 only).

The new burners and hot blast outlets had to be installed

and repaired with the stoves in hot condition. The stoves

were kept hot with auxiliary burners inserted through a

bulkhead installed in the top half of the hot blast out-

let. To allow working underneath the heat-up burners a

safety deck was installed. The high temperatures in the

stoves and the limited access a required a special design.

Support for the deck was provided by water cooled pipes

brought in from the outside through holes drilled through

the stove shell and the refractories. These pipes were

installed at the elevation of the centerline of the hot

blast outlet. The safety deck was designed as a foldable

construction to allow installation through the opening

between the flanges of the removed hot blast valve.

After bringing the deck in position inside the stove it was

unfolded and secured against the wall of the burner shaft.

The gaps between the deck and the wall of the burner

shaft were closed with ceramic wool. Cool down of the

old burner underneath the safety-deck took about three

days after which demolition and installation could start.

After completion of the burner installation a protection

floor was placed on top of the burner. On this floor a

supporting structure was erected taking over the load of

the deck from the water cooled pipe so the pipes could

be removed. The deck was then jacked up to an elevation

above the hot blast outlet permitting replacement of the

hot blast outlet stub and installation of new refractories.

The stove heat-up burners were inserted through an

opening above the deck so the temperatures in the stove

could be maintained during the repair.

In October 2013 HeatTeQ SA received an enquiry

from Milltech SA for the installation of refractories

in a lime kiln in the Kayes district in the republic

of Mali. The bid was submitted November 20,

2013 and the order was placed December 5,

2014. Work on site started on January 7, 2015.

Fa c t s & f i g u r e sSite:. . . . . . . . . . . . . . . . . . . . . . . . Kayes, Mali

Duration: . . . . . . . . . . . . . . . . . . . . . . 2 months

Plant: . . . . . . . . . . . . . . . . . . Single shaft Lime Kiln

Design: . . . . . . . . . . . . . . . . . . . . . . . Magnesita

Tonnage: . . . . . . . . . . . . . . . . . . . . . . . 305 ton

Execution: . . . . . . . . . . . . . January – February 2015

Scope: . . . . . . . . . . . . . . . . . . Cross-over Repair


Subcontractor Refractories: . . . . . . . . . . . . . Anmar

Lime Kiln, Kayes District, Mali

The project was straight forward and well within the

capabilities of HeatTeQ. What made it special was the

location and the short time between the date of order

and the start of work on site. Within the 5 weeks

between date of order and start work on site staff had

to mobilized, the necessary permits and visa had to

be obtained and equipment shipped to site. All this

was efficiently and skillfully handled by the South

African branch office of HeatTeQ within the short time

available.

The work was executed by South African bricklayers

and supervision. Site preparation started on January 7,

2015 and bricklaying started one week later. The work

was completed successfully within the scheduled

34 days and handed over to the customer on February 14,

2015.

HeatTeQ Refractories Services BV was given the

order to perform a battery inspection on Ruukki

Steel’s coke batteries at the Rautaruukki plant.

Ruukki Steel’s objective is to secure trouble free

coke production for the next twenty five years,

with the highest availability of coke ovens to

the most practical achievable levels. Over the

years, HeatTeQ and its employees have built up

Fa c t s & f i g u r e sProject . . Coke battery Inspection, mechanical & refractories

Client . . . . . . . . . . . . . Ruukki Metals, Raahe, Finland

No. of ovens . . . . . . . . 70 (2 batteries of 35 ovens each)

Duration . . . . . . . . . . . . . . . . . . . . . . . 6 weeks

Execution year . . . . . . . . . . . . . . . . . . . . . . 2013

Manhours . . . . . . . . . . . . . . . . . . . . . . . 1.048

Battery height. . . . . . . . . . . . . . . . . . . . . 7 meters

Partners . . . . . . . . . Fully executed with own personnel

Coke battery design . . . . . . . . . . . Twin Flue, Gyprokos

Rautaruukki Oyi, coke battery inspection, mechanical & refractories

a vast experience in coke battery assessments, following

repair recommendations and implementations.

There are three key aspects affecting availability of

production capacity;

• Operational procedures;

• Regular refractory maintenance program;

• Refractory repair program and material applications.

During the inspection a geodetic survey was performed.

If the geodetic survey is repeated with regular intervals,

the wear and growth of the battery can be monitored.

An inspection project basically consists of 4 phases:

preparation, inspection, analyses and reporting. The final

report will be a tool for Ruukki Metals OY to assess the

condition of their batteries and to determine the scope

and time frame of their repair program.

The next steps for a battery repair program are:

• determine detail scope of work. This will also entail

a detail inspection on the regenerator and regenera-

tor wall. The engineering package for wall refractory

replacement will be based on the findings during the

regenerator inspection.

• Determine areas for design improvements to

State-of -the-art.

• Prepare enquiry documents for any design

improvements required for the repair program.

• Determine the right choice of material.

As part of the report, a detail evaluation was made

between traditional wall repairs and the alternative

repair technique HeatTeQ is offering to the market, in co-

operation with Vanocur Llc from Buffalo, USA. The fused

silica modular shape system is a great alternative for the

conventional silica repair systems. The biggest advan-

tage is the huge time savings during the repair period.

Due to the non – expanding characteristics of fused silica

and the large modular shapes, the repair period can be

reduced from 30-60%, depending on battery design and

total scope of work. However, the higher cost of fused

silica materials must be leveled out with the advantages of the

shorter repair period, which are production savings of Coke.

Typical example of wall inspection sheet.

Typical example of buckstay deformation (cause & effect). Note: The pictures in this inspection are typical examples of how wall damage could look and how insepctions are being performed. In no way HeatTeQ will give the impression that these pictures reflect the actual condition of Ruukki’s Batteries.

• Site Management and Planning (included

client activities)

• Coordinate all mechanical works on behalf

of ArcelorMittal

• Demolish side walls and removal of burden

• Install new taphole refractories

• Repair to dome refractories

• Gunite Shaft

• Execute and supervise all the on-site

installation works

• Quality control to all the installation works

• Monitor actual durations to planning

durations

• Monitor safety during the execution of

the project

• Quality control to all the installation works

• Monitor safety during the execution of

the project

Fa c t s & f i g u r e sProject . . . . . . . . . . . . . . . . . . . . Taphole Repair

Client . . . . . . ArcelorMittal Saldanha – Corex, South Africa

Duration . . . . . . . . . . . . . . . . . . . . . . . 36 days

Execution year . . . . . . . . . . . . . . . . . . . . . . 2011

Manhours . . . . . . . . . . . . . . . . . . . . . . . 5.500

Partners . . . . . . . . . . . . . ANMAR-BRS.Lizmontagens

ArcelorMittal Saldanha – Corex Taphole RepairBurden Removal and Taphole Repair (2 Sides).

Assist the client with the following:

For over a 100 years the name Steetley has

been synonymous with high quality Dolomitic

lime and dead burnt Dolomite products for

the steel industry. Steetley Dolomite Limited

is now an independent company owned by its

management. Steetley Dolomite specializes in

Dolomitic products for the steel industry and

is one of the leading producers in the world.

Fa c t s & f i g u r e sProject . Steetley Dolomite Limited preheater, kiln and cooler

Client . . . . . . . . . . . . . . . . Steetley Dolomite Limited

Design . . . . . . . . . . . . . . Preheater - METSO design

Kiln – Magnesita and Duferco design

Cooler – IKN design

Duration . . . . . . . . . . . . . . . . . . . . . . . 50 days

Execution year . . . . . . . . . . . . . . . . . . . . . 2013

Manhours . . . . . . . . . . . . . . . . . . . . . . 13.000

Steetley Dolomite Ltd. preheater, kiln and cooler

Steetley Dolomite invested £10 million for upgrading

W2 Kiln with a new preheater to give:

• Improved efficiency

• Reduced environmental impact

• Additional output

In parallel with the above also the Kiln and Cooler

refractory lining was replaced by HeatTeQ Refractories.

The complete project was executed within the time

frame given by the client.

Preheater 143 Mton material Installation period 23 days

Kiln 510 Mton material Installation period 11 days

Cooler 142 Mton material Installation period 10 days

In December 2010 HeatTeQ received an enquiry

from SSAB for the reline of blast furnace

4 in Oxelösund. The reline was scheduled for

the summer stop of 2011, from the end of week

27 to the end of week 37. The scope of the

enquiry covered the following activities:

1. All preparatory work;

2. Demolition services for mechanical and

refractory portion;

3. All necessary demolition equipment;

4. Installation services for mechanical and

refractory portion;

5. All necessary installation equipment.

We prepared our proposal with a combination

of companies who all have extensive experience

with working for HeatTeQ and SSAB Oxelösund

and at Blast Furnace #4 in particular.

HeatTeQ as main contractor was responsible

for project management and overall coordina-

tion, Berglagens Eldfasta for demolition and

Empower AB for all Mechanical work.

Installation of refractories was handled jointly

between HeatTeQ and Berglagens using

bricklayers from Lizmontagens.

Fa c t s & f i g u r e sSite:. . . . . . . . . . . SSAB EMEA AB Oxelösund Sweden

Duration: . . . . . . . . . . . . . . . . . . . . . . . 70 days

Plant: . . . . . . . . . . . . . . . . . . . . . Blast Furnace 4

Manhours: . . . . . . . . . . . . . . . . . . . . . . 30.000

Design: . . . . . . . . . . . . . . . . . . . . . . Paul Wurth

Tonnage: . . . . . . . . . . . . . . . . Refractory: 1.200 ton

Execution: . . . . . . . . . . . . . . . July-September 2011

Scope: . . . . . . . . . . . Demolition of old and installation

of new furnace lining

Partners: . . . . . . . . . Bergslagens Eldfasta, Empower AB

SSAB EMEA AB Oxelösund Blast Furnace 4 Demolition of the old and installation of a new furnace lining.

On February 14, 2011 HeatTeQ was awarded the order

and preparations started with the design and fabrication

of auxiliary equipment. On July 7 the furnace blow

down started. After salamander tapping and quenching

demolition started and was completed on July 31 and

brick installation could start.

Installation was executed in parallel, working on 3 levels:

Level 1: Hearth, bosh and lower stack using

scaffolding erected on the furnace bottom.

Level 2: Middle and upper stack using a swinging

deck suspended from a fixed top platform.

Level 3: Throat armour and top cone from a fixed

top platform.

On September 25 refractory installation was completed

and handed over to SSAB. Mainly due to a salamander

which was considerably bigger than anticipated this was

about 10 days later than the scheduled completion date.

The project was completed with zero accidents and to

the total satisfaction of SSAB.

The project consisted of replacement of 6 Oven

Walls, a block of 3 walls on battery 4 and 3 walls

on battery 2. The walls were mechanically

demolished and build with Fused Silica modular

blocks. The mechanical demolition system

was developed in cooperation with Schot

Vertical Transport, based in Alkmaar and Wesco

Machine Manufacturing, based in IJmuiden.

The mechanical demolition consisted of the

following elements:

Fa c t s & f i g u r e sProject . . . . . . . TATA Steel IJmuiden through wall repairs

Client . . . . . . . . . . TATA Steel IJmuiden, Coke Plant #2

No. of Batteries . . . . . . . . . . . . . . . . . . . . . . 4

Design . . . . . . . . . . . . . . . . . . . . . . . Carl Still

Duration . . 6 Months incl. preparation and Christmas break

Execution year . . . . . . . . . . . . . . . . . . . 2011/2012

Manhours . . . . . . . . . . . . . . . . . . . . . . 35.000

Oven Height . . . . . . . . . . . . . . . . . . . 6,5 metres

Partners . . Ovenbouw Holland and Schot Verticaal Transport

Scope 2 x 3 throughwalls, from oven sole through the oven deck

TATA Steel IJmuiden through wall repairs

• A self-propelled demolition platform (Jaap #1) which is

placed on the charge car rail. Jaap #1 is equipped with

a generator, used for the platform lighting and propul-

sion as well as a dust water spraying system.

• A Komatsu demolition excavator, modified with an

pressurized cabin to meet Plant Health and Safety

requirements and special adapted tools to increase the

reach of the excavator down to the regenerator deck.

• 400T mobile crane to place and remove demolition

containers, water and fuel. The 400t crane is also

required to remove Jaap #1 and the Komatsu excavator

in case of an emergency.

The mechanical demolition of 6 coke oven walls was a

big success and is the new standard of demolition for

through-wall repairs.

The temparature of the adjacent walls is maintained by

the installation of 2 insulation curtains, immediately af-

ter the ovens are taken out of production. The adjacent

walls are set to 950 - 1.000˚C, the adjacent ovens are in

operation at a double coking time.

The mechanical installation of modular Fused Silica

blocks is a fast installation system which requires less

manpower thus reduces the exposure of people to the

hot and dusty work environment.

By using big blocks instead of small silica brick we

reduce the number of joints by over 90%. Joints are

typically the place where the problems in a coke oven

wall starts. Spalling of brick, Coke Oven Gas leakage,

etc. is less problematic if the number of joints is redu-

ced. Using Fused Silica also reduces the project duration

by its ‘zero’ expansion abilities. No temperature curve

needs to be followed during the heat up of the walls.

To bring Fused Silica up to operating temperature

requires no more than 24 hrs, whereby traditional silica

requires a heat-up period of 14-21 days.

The mechanical installation of modular Fused Silica

blocks is a fast system which requires less manpower

thus reduces the exposure of people to the hot and dusty

work environment.

Scope of work:

• Installation bottom refractories

• Installation hearth refractories

• Installation lower bosh refractories

• Installation taphole nozzles (frames 4x)

• Engineering, manufacturing, installation

& removal of the hoisting carousel and

material landing deck

• Order for design and supply of ‘black’

material by SGL Poland, ceramic path

and tuyere belt by ‘Vesuvius Poland’.

Fa c t s & f i g u r e sProject . . . AMP Dabrowa Gornicza BF#3 Hearth Installation

Client . . . . . . . . . . . . AMP Dabrowa Gornicza, Poland

Duration . . . . . . . . . . . . . . . . . . . . . . . 34 days

Execution year . . . . . . . . . . . . . . . . . . . . . . 2013

Manhours . . . . . . . . . . . . . . . . . . . . . . 12.322

Heart Diameter . . . . . . . . . . . . . . . . . . 14.6 metres

Sub-Contractors . . . . . . . . . . . . . . . . HPR Centrex

. . . . . . . . . . . . . . . . . MOSTOSTAL Kedzierzyn S.A.

. . . . . . . . . . . . . . . . . . . . . . . . . . . IZOLACJA

. . . . . . . .Lizmontagens Portugal & Lizmontagens Poland

AMP Dabrowa Gornicza Blast Furnace #3: bottom, hearth and lower bosh refractory installation

HeatTeQ was awarded with the refractory installation

contract in September 2013. Preparation work started

immediately after, like engineering of the hoisting

carousel and landing deck, preparation health and

safety plan, quality control plan, selection of

mechanical contractor(s), etc.

The blow-down of the furnace was scheduled for

September 13 after which the demolition of the existing

refractories took place, followed by replacement of

bosh, belly and stack stave coolers.

Site preparation started on November 9, 2013 with a

small crew to unload/install equipment and transporting

the first layers of refractory material from the main store

to the daily store furthermore, the hoisting carousel and

landing deck have been installed.

On November 15, 2013, the furnace was handed over

to HeatTeQ for the refractory installation of the bottom

layers. Total weight of installed refractories 1.450 Mton

After completion of BL1 there was a planned standing

time of 5 days due to machining of top surface BL1

(done by SGL). After completion of the machining activities

and approval of the final survey results the hearth was

given back to HeatTeQ. All hearth ring layers, tuyere

belt & lower bosh materials were installed by using a

scaffold progressively erected during the installation.

On December 18 refractory installation and removal of

the hoisting carousel was completed and the hearth

handed over to AMP. The installation time was 4 days

shorter than the scheduled completion date. The project

was completed with zero accidents and to the total

satisfaction of AMP.

Your contractor/partner specialized in furnace ... - HeatTeQ

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