High-temperature refractory solution helps Southeast Asian steelmaker improve furnace efficiency and life
Customer Background
A large integrated steel mill in Southeast Asia produces 5 million tons of specialty and carbon steel annually. Its high-temperature smelting equipment faced short refractory life and rising costs due to frequent maintenance downtime, and urgently needed an upgraded refractory solution to cope with the demands of high-intensity production.
Core Challenges
1. The electric arc furnace lining is subjected to high temperature metal liquid at 1700°C, resulting in serious local erosion.
2. The ladle slag line is subjected to chemical corrosion by the alkaline slag, which needs to be replaced every 80 furnaces on average.
3. The refractory layer is spalling off due to the frequent thermal shocks at the exit of the converter.
4. The working lining of the middle ladle of the continuous casting is not sufficiently permeable, which affects the purity of the molten steel.
Customized Solutions
After a site inspection by our technical team, we offer a full process refractory system:
| | Equipment parts | Selected materials | Core technical advantages |
| ----------------|--------------------------|-----------------------------|
| Arc furnace melting pot | MgO-C bricks (magnesium-carbon bricks) | Addition of ultra-fine metal powder improves thermal shock resistance by 40% |
| Ladle slag line | Al₂O₃-MgO-C bricks (Aluminum-Magnesium-Carbon bricks) | Microporous structural design, resistance to slag erosion ↑35% |
| Converter outlet | Sailon bonded corundum composite | Thermal conductivity optimization, resistance to spalling ↑ 50% |
| Continuous casting intermediate ladle | Calcium feldspar-based prefabricated parts | Low permeability (<0.5%), reduction of inclusions |
Complementary services: thermodynamic simulation and analysis + fast response local storage + On-site construction guidance
Implementation results (12-month data tracking)
✅ Electric arc furnace age increased from 220 to 320 furnaces
✅ Ladle slag line service life extended to 115 furnaces, reducing refractory cost per ton of steel by $1.2
✅ Converter spout replacement frequency reduced by 60%, saving more than 400 hours of downtime annually
✅ Continuous casting billet inclusions defect rate reduced to 0.03% (from 0.08%)
Customer testimonials
Zhengzhou The refractory system at Chaoyu Refractories has improved the overall energy efficiency of our equipment by 18% and saved us $880,000 on our annual maintenance budget. the modular prefabricated parts have dramatically shortened the overhaul time, which is a perfect match for our 24/7 continuous production needs.
--Mr. Rahman, Chief Plant Engineer
Why choose us?
Material Innovation: In-house developed nano-sized ceramic bond technology
Certification System: ASTM C27 Refractory Classification Certification
Data Enablement: Provide intelligent kiln monitoring system to provide real-time early warning of liner loss.
Previous Page: