Refractory Systems | Direct Reduction Plants

For the direct reduction industry STEULER-KCH supplies individual

solutions for several kinds of aggregates. Ranging from Process

Gas & Air Heaters, over Reformers and certainly the core of your

plant – the Reduction Aggregate – as well as gas ducts and chim-

neys. We offer our range of products and services for following

DRI manufacturing methods:

Shaft kiln process

Rotary kiln process

Fluidized bed process

Rotary hearth process

Other individual processes

Scope of supply:

Refractory Bricks

Refractory Mortars

Refractory Castables

Fire Lightweight Bricks

Insulating Bricks

Insulating Castables

Insulating Fibers

Anchoring Systems

Accessories

Scope of service:

Refractory Engineering

Heat Transition Calculations

Customised R & D

Quality Controlled Production

Just-in-Time Delivery

Installation

On site Supervision

Commissioning

Continuous Technical Support

STEULER-KCH is one of the most innovative suppliers in the

field of refractory systems for DR-Plants.

The demand for improved efficiency of Direct Reduction Plants

has made innovative refractory concepts increasingly important.

Beside the extreme stresses caused by reducing atmospheres and

thermal shocks the refractory lining has to face higher abrasions

through working loads over the originally specified capacity

maximum.

STEULER-KCH is specialised to provide you with refractory

solutions for application in such aggressive environments. We

deliver the full product range and service from one source.

During our nearly 100 years of experience we have ever been a

reliable and trustful partner and mastered all challenges in close

cooperation with our customers. Our ambition is to improve the

refractory performance in your plant, reduce down times and to

grant you the most possible operation safety.

Right: Various shapes and qualities of

STEULER-KCH refractory products

Left: Different methods of fabrication allow

Steuler to produce large-sized bricks with

complicated geometries. The gas inlet

area in a Midrex®-Shaft is one application

which requires such complex shapes

in high-grade Mullite and Zirconia qualities.

These gas inlet blocks need to be

produced within tight dimensional tolerances.

STEULER-KCH supplies the full range of refractoriesand services for the DRI production process.

Upper Part & Middle Section

In the upper part and the middle section of the shaft furnace the re-

fractory lining is exposed to strong abrasion due to the feed of lump

iron ore in that area as well as strong gas circulations caused by the

off-take which is placed in the upper part.

Due to that demand highly abrasion resistant bricks and castables

are needed which on the same hand have to be resistant against CO

and H2 attack. Moreover the materials used have to show very good

thermal shock resistance.

For that application STEULER-KCH offers a combination of the Super

Duty Firebrick Antelco 42 with high-grade castables. Antelco 42 is a

low iron fire clay brick that has been fired up to 1.450 °C and fulfils

all mentioned demands easily.

Gas Inlet Ring

The gas inlet ring or is certainly the most stressed and sensitive part

of a Midrex® Shaft Furnace. The refractory material in this area espe-

cially the gas inlet nozzles have to face extreme stresses. The lining

has to withstand extensive mechanical abrasion, thermal shocks and

of course the enormous chemical attack by the reduction gas.

STEULER-KCH has developed special high-grade refractory qualities

for this specific application. For the bustle walls the Andalusite- and

Corundum-based quality Suprema SA 752 P is used. This phospha-

te bonded material is highly abrasion resistant, withstands thermal

shocks and bears the chemical attack through H2 and CO.

For the gas inlet blocks our quality Suprema ME 901 comes into

operation. This high-grade fire brick is based on white fused Mullite

and has a very low iron content. Its performance is only toped by

our newly introduced quality Suprema ZM 25 P which is the current

State-ofthe-Art product for this highly demanding application. You will

find more details about it on the following pages and the mentioned

table.

Lower Section

The lower section, starting just underneath the gas inlet area com-

bines all mentioned thermal, chemical and mechanical demands.

Therefore this section is lined with radial bricks in our phosphate

bonded quality Suprema SA 752 P that is also used for the lining of

the Bustle walls. As front face lining it masters all stresses perfectly

and ensures a long life time of the whole refractory lining in this

area.

Reformer and Recuperator

For the two main aggregates beside the shaft furnace – the reformer

and the recuperator STEULER-KCH offers a wide range of refrac-

tories starting form dense castables and bricks over firelightweight

bricks and castables up to insulating fiber materials and bricks as

well as state of the art anchoring systems. This range of materials is

certainly also used for gas and air heaters, gas ducts, the ejector

stack and all connected parts. Due to our long experience in the field

of refractories and continuous innovation we can offer you individual

solutions to all challenges of these parts of your DR-plant.

Unten: FE-Haltesteine für Wandverankerungen mit

Aussparungen für Metallanker in verschiedenen

Ausführungen und Materialqualitäten.

Above: Detail of the grooved gas inlet

High-end refractory linings for Midrex®

reduction shaft furnaces.

Brand Raw Material Base Chemical analysis Bulk density

Open Porosity

Cold Crushing Strength

Thermal Shock Resistance

RUL-t05

Al2O3 SiO2 Fe2O3 ZrO2 P2O5 H20

% g/cm3 Vol. % N/mm2 n °C

Antelco 42 Super Duty Fire Brick 45 51 1,1 2,35 15 60 20 1440

Antelco 50 Super Duty Fire Brick 49 46 1,2 2,38 15 70 20 1460

Suprema SA 752 P Phosphate Bonded Andalusite 73 24 0,7 1,3 2,80 13 100 > 30 1670

Suprema KE 85 P Phosphate Bonded Corundum 88 9 0,3 3,08 14 130 > 30 > 1670

Suprema ME 901 White Fused Mullite 90 9 0,2 3,05 15 100 > 30 > 1670

Suprema ZM 25 P Corundum Zircon-Mullite 63 12 0,2 23 1,4 3,30 15 150 > 30 > 1670

STEULER-KCH provides customised solutions for refractory appli-

cations from one source – ranging from research and develop-

ment to engineering, production in our own workshops and final

assembly.

We develop reliable and durable materials in our own laborato-

ries and test these products according to international standards.

We prepare comprehensive service designs and refractory cons-

tructions based on specific process conditions and requirements.

Our own production workshops and qualified specialists in the

field of mould construction and production ensure utmost flexibi-

lity. We custom-manufacture to your specifications, whether it be

single shaped bricks or complete refractory linings.

Complete refractory engineering and material delivery from

one source

STEULER-KCH also designs the complete refractory layout for

each individual aggregate based on the steel construction dra-

wings and process data provided by the customer. The scope of

our services also includes the assembly drawings as well as heat

transfer calculations and heat-up recommendations. Specially trai-

ned STEULER-KCH erection engineers direct the entire sequence

of works on the site and supervise the assembly. This ensures the

proper realization of our refractory system solutions.

STEULER-KCH is your complete service provider for safe and re-

liable materials as well as efficient project execution from one

source.

STEULER-KCH is a specialised in refractory engineering

STEULER-KCH develops individual engineering solutions for you.

We are only working with state-of-the-art CAD engineering equip-

ment. Our engineering services includes the assembly of detailed

drawings, heat transition calculations, installations drawings and

instructions and are not limited to heating up recommendations

New developed Zirconium-Mullite brick

The gas inlet ring is certainly the most stressed and sensitive part

of a Midrex® Shaft Furnace. Especially for this application we

have developed the new Quality Suprema ZM 25 P which is

a phosphate-bonded Corundum-Mullite based brick with 23%

zircon content. This high-quality material shows all necessary

properties like mechanical strength, chemical and thermal shock

resistance in order to withstand the extreme demands caused by

abrasion, reduction and thermal cycling. It performs even clearly

better than the pure Corundum-Mulite materials.

Special Features of Suprema ZM 25 P:

High Refractoriness

Excellent Hot Abrasion Resistance

Outstanding Thermal Shock Resistance

CO-Resistance Class A

Suprema ZM 25 P is specially developed for the nozzle bricks of

the gas inlet, but of course it can also be used for other applica-

tions with the same high demands.

This quality is available for nearly all shapes either pressed or

hand rammed.

Left: Beschreibung

Innovative material developments,production, engineering and assembly

Above: Moulds produced in our own workshops provide Steuler with utmost

flexibility in the production of special formats.

Above: Steuler also offers erection services thereby ensuring the qualified

implementation of the refractory system design.

Above: Test sample before CO Test.

Above: Test sample after CO-Test. According to ASTM

with Class-A CO resistance.

STEULER-KCH GmbHSurface Protection SystemsPlastics TechnologyPool ConstructionsBerggarten 1 56427 Siershahn | GERMANYPhone: +49 26 23 600-0Fax: +49 26 23 600-513Mail: info@steuler-kch.de

Refractory Systems DivisionGeorg-Steuler-Straße 56203 Höhr-Grenzhausen | GERMANYPhone: +49 26 24 13-246Fax: +49 26 24 13-305Mail: ff.info@steuler-kch.de

www.steuler-kch.de

Together with its international subsidiaries and representations, STEULER-KCH offers its customers a worldwide network which develops and implements comprehensive system solutions.

SURFACE PROTECTION SySTEMSLining and flooring systems Cements, jointing materials, masonry systems, rubber linings

PLASTICS TECHNOLOGyThermoplastic lining systemsEquipment, piping and tanks made of duroplastics and thermoplastics

REFRACTORy SySTEMSHigh temperature refractory linings

POOL CONSTRUCTIONSTEULER-Q7 lining systems

SUBSIDIARIES

Steuler Técnica S.L.Spain

Steuler France S.A.R.L.France

Ditescor S.A. de C.V.Mexico

Steuler Maroc S.A.R.L.Marocco

Alphaplast S.A.Spain

Steuler Nordic ABSweden

Shanghai STEULER-KCH Anticorrosion Engineering Co. Ltd.China

CIMA S.r.l.Italy

KCT Sp. z o.o.Poland

Steuler Industrial Corrosion Protection Pty. Ltd.Australia

Steuler New Caledonia S.A.R.L.New Caledonia

STEULER-KCHBranch Saudi Arabia

STEULER-KCHBranch Austria