PBI is active in the majority of departments (Coking, Blast Furnaces, Refining Converters, All types of forming or die castings, Heat Treatment, etc.) with value-added solutions for protection, insulation or sealing which enable the optimization of processes and usage values.
The objective is to maintain the optimal temperature during critical phases of production and processing in order to optimize production resources, limit energy losses and protect operators and their production resources.
Whether you are in the ferrous alloy industry (cast iron, stainless steel, surgical steel, etc.) or non-ferrous alloys (copper, bronze, brass, palladium, platinum, titanium, tin, zinc, etc., but also magnesium or molybdenum used in petrochemicals, pressure vessels, electronics, armaments, aerospace, etc.), it is important for you to maximize energy efficiency, reduce heat loss and improve the safety of your operators.
AT THE HEART OF THE PROCESS
Textile expansion compensators up to 1300°C
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Absorb expansion movements between flanges (great flexibility)
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Airtight, gastight, smoketight...
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Limit heat loss and protect personnel
- Fixing by clamps or screws
- Anti-abrasive, anti-corrosive solutions…
- Stand-alone installation without structural modification
Sealing of butterfly valves, damper
- Lifespan > 4 years in daily use
- Recovery and compensation of misalignments and deformations
- Easy and very quick assembly : 1 frame = 1 complete seal
- Soft & compressible
- Stand-alone installation without structural modification regardless of the model (Stack damper, Butterfly damper, Louver damper, etc.)
- Removable for maintenance
- Excellent abrasion resistance
Insulation Jackets
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Limits heat loss to save energy and improve the efficiency of your installation
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Reduces energy costs and greenhouse gas emissions
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Provides touch protection to prevent burns
Thermal Insulation is commonly used in applications that have a large temperature difference between the process and the ambient air. In this case, the aim is to limit convection and conduction of the hot element.
Each insulation is custom-made with materials adapted to its constraints. It is generally composed of insulation encapsulated in a thermally resistant fabric, "on the hot/warm side", and a waterproof finishing fabric, "on the cold side".
Its scope of application is vast and its variations varied; it can also meet additional requirements, such as mechanical and chemical constraints.
Back-up insulation of ladle/tundish/torpedo/furnace
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Cold face temperature reduction respected throughout the process
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Increased refractory life
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Quick setup
Proven reliability:
Production site 2.5 million T/year, 350 T ladle, 1650°C steel, 1,000 castings/year
- Additional time of 3 minutes/m² for the addition of Nefalit® 11, 12 mm thick as a back-up for 280 mm thick refractories
- 10% reduction in cold side temperature
- Optimization of 13% of refractories
- Up to 1200°C: very efficient in radiant heat & able to withstand high temperatures under high compressive loads
- Density 1,000 Kg/m3: allows to obtain a higher thermal capacity compared to existing products on the market
- Hot compression resistance: <10% (versus >14% existing alternatives)
- Thermal conductivity: 0.16 to 0.21 W/mK for a temperature of 600 to 1000°C
- Bio-persistent refractory insulation
- Easily cut with a cutter and bend to fit the structure of your installations
Example of customer constraint*: maximum authorized temperature limit 260°C cold side
PBI solution: addition of Nefalit® 16, 10 mm thick, as a backup for the 290 mm thick refractories
Validated result: constant temperature <238°C on the cold side
* on production site 3 million T/year, 120 T ladle, 1650°C steel, 1,100 castings/year.
PRIMARY STEEL INDUSTRY
Initially, we worked to achieve perfect sealing for doors subject to high stresses and requiring frequent maintenance. Then, following customer satisfaction and demand, we extended our developments to the most critical points of the process.
We have therefore developed solutions for insulation/sealing/protection with high usage/utility value, enabling us to optimize production resources, limit energy losses and protect operators and the environment.
EAF
Protective, insulating and sealing curtains… up to 1390°C
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Limiting heat losses and partitioning in furnaces: uniform temperatures, regular production cycles, energy savings, etc.
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Protection of personnel against radiation and certain projections: protects and improves working conditions
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Flexible fastening systems for easy and independent installation
- From 500 to 1390°C
- Mechanical and chemical reinforcement options
- Full, weighted, fringed, with thread strips...
- Removable, expandable…
Example of thermal protection of the wheels and front apron of the forklift.
Protection up to 1390°C for critical cables/flexibles:
- Protection of cables/hoses against extreme accidents : flashbacks, projection of molten materials, slag, etc. and limits unexpected production shutdowns.
- Effectively and durably protects against daily process-related attacks : heat, abrasion, splashes (oil, metal, etc.)
- Increases the lifespan of cables/flexibles, >20% with a very concrete ROI
- Limits maintenance and increases the lifespan of equipment
- Modularity and adaptability : fits independently onto your cables/hoses
- Withstands up to 1 390°C with excellent resistance to direct flames
- Fire protection of critical cables (emergency stop hoses, fire alarm hoses, fire extinguisher cables, etc.)
- Flexibility and bendability retained
- Possibility of over-braiding at our factory directly on your equipment
- Numerous options such as simple terminations or with connectors:
COKE PLANT
Door sealing
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Increased lifespan (*)
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increased lifespan of refractories
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significant reduction in door deformation
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- Maximum limitation of harmful leaks (SO2, NOx, C6H6, PAH, etc.)
- Save 90% of installation time compared to usual solutions (VS ceramic sheets)
(*Site of 159 cells for a coke production of 950,000 T/year)
The Membrane-Nefex ® sealing KIT for coke oven doors has been specially developed to solve recurring problems in this application such as energy & gas leaks, door deformation, refractories changed regularly, coke quality, too frequent maintenance.
- Membrane Nefatex® 1390 :
- Set up in less than 2 minutes for 6 blocks (VS >20 minutes with tablecloth)
- Delivered pre-drilled according to your template
- No fiber dispersion
- Perfect seal between the door and the refractory blocks
- Prevents door deformation due to its insulation
- Excellent mechanical resistance
- Nefex ® high temperature gaskets used between refractory blocks which, by expansion fill all the space between the refractory blocks:
- Nefex gasket that can expand to 10 times its original size (from 5mm to 50mm), sealing the entire space to be covered
- Set up in less than 5 minutes for 6 blocks ( vs 1 hour with the tablecloth )
- Excellent sealing between the blocks as soon as the temperature rises
- Prevents coke from penetrating between the blocks and damaging them
- Seals increasing the life of the blocks
- TecHeat® gasket used on the oven door or wall to ensure a perfect seal (prevent gas & energy leaks). The gasket is designed for optimal compressibility/recovery.
- Excellent sealing properties
- Resistant to extreme temperatures/radiation, flames, splashes and abrasion
- Supplied in the desired length
- Fiber dispersion limitation
- FCR-free solution
- Quick & easy installation
Each element of the kit is available separately.
End of assembly with joint packing
Sealing of standpipes (risers)
Maintenance reduced by 20% (*)
Maximum reduction of harmful emissions
(*108-cell coke production site)
- Seal resistance at 800°C
- Armed to resist abrasion due to strong expansion movements
- Different diameters to adapt the seal according to the intensity of your axial movements
- Product available in coils or shaped to the diameter of your standpipes
- Fast setup, reduced labor time
Example of a standpipe, with 4 intervention zones
Sealing/Protection of telescopes
>40% annual savings on the “telescope membrane station” (*)
- Lifespan of 180 to 240 days (*)
- Less maintenance required
(*57 cells with 2 loaders/chargers of 4 telescopes for a coke production of 850,000 T/year)
- NEFATEX® base for resistance up to 1390°C
- Ease of implementation
- Excellent resistance to flames, movements and vibrations
- Preserves flexibility and bendability
Protection/Insulation of loader cables/hoses
>20% annual savings on “flexible positions” (*)
- Hose purchases halved
- Total protection in case of fire, flashback
- Reduces downtime and maintenance
(*Site of 585 cells, 13 loaders of 3 Telescopes, for a coke production of 3,600,000 T/year)
The TecHeat® range of protective sheaths has been developed to protect cables/flexibles subject to the most drastic constraints in processes and to avoid certain additional accidents causing production shutdowns.
- Resists up to 1 200°C
- Excellent resistance to flames, movements, abrasions and vibrations
- Preserves the flexibility and bendability of your original hoses
- Easy and quick to implement
- Exceptional lifespan
Condition of TecHeat ® protective sheath after 50 months of use.
REFINING
VOD-VD
VD/VOD oven lid sealing
- Very high thermal and mechanical performance seal which guarantees efficient decarburization, pure steel and a perfectly stable process
- Lifespan multiplied by 3 with 4,000 charges over a period of 240 days (*)
(*production site of +/-1,000,000 T/year, 2 furnaces of 200 and 300 T)
As these processes require perfect vacuuming of the treatment area in order to produce special and very high quality steels, PBI has developed a range of TecHeat ® VD/VOD seals that perfectly meet your expectations and the various constraints of the application. These are tailor-made seals with high usage values.
- Excellent sealing
- Resistant to extreme temperatures/radiation, flames, splashes and abrasions
- Supplied to length
- No fiber dispersion
- Quick and easy setup
SECONDARY STEEL INDUSTRY
Ladle lids (preheating, holding, pouring, etc.)
- 85% reduction in energy costs (1 hour of preheating vs. 8 hours)
- Lifespan > 3 years in daily use
- 5 times lighter than a concrete lid
- Stand-alone installation without structural modification
- Self-supporting mattress
- Manufactured to include rod/thermocouple passages
- Custom format: oblong, octagonal, etc.
- Reduction of noise pollution in the factory
- Anti-abrasive, anti-corrosive solutions…
- Easy handling by a single operator ( Handles, weights, etc. )
1h30 after emptying, internal temperature of the ladle still > 500°C and external temperature of the lid < 70°C
Sealing oven doors
- Uniform cooking/processing. Prevents parasitic air from entering
- Better energy performance. Very fast ROI
- Process stability. Optimization of the quality of the final product.
- Autonomy of assembly on custom product and reduction of maintenance costs
- Adapts to all oven configurations
- Production of “frame joints” ( shaped angles ), ready to install
- Integration of fixing lips for equipment without a groove
Mobile floor insulation of bogie furnaces using Nefalit® millboard
- Supports rapid and frequent temperature variations (charging/discharging and cycles)
- Excellent retention of mechanical properties when hot (resistant to weights, rolling, vibrations, etc.)
- Light enough to reduce heat loss, but dense enough to provide mechanical strength (Excellent compromise between light fiber and heavy refractory)
- Reduces energy consumption and maintains uniform heating in the oven
- Low thermal conductivity, limits heat loss from the underside.
- Wide range Bio-persistent, thermal resistance up to 1500°C
- Formats 1000*1000 mm, 1500*1000 mm and 2000*1000 mm, easily cut with a cutter
- Good compatibility with difference in expansion of the upper coating (refractory bricks, cast concrete, etc.)
- Standalone installation
CONTINUOUS CASTING
Protection up to 1390°C for critical cables
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Protection of cables/hoses against extreme accidents : flashback, projection of molten materials, slag, etc. and limits unscheduled production shutdowns.
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Effectively and durably protects against daily process-related attacks : heat, abrasion, splashes (oil, metal, etc.)
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Increases the lifespan of cables/flexibles, >20% with a very concrete ROI
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Limits maintenance and increases the lifespan of equipment
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Modularity and adaptability : slips onto your cables/flexibles independently
- Withstands up to 1,390°C with excellent resistance to direct flames
- Fire protection of critical cables ( emergency stop hoses, fire alarm hoses, fire extinguisher cables, etc. )
- Flexibility and bendability retained
- Possibility of over-braiding at our factory directly on your equipment
- Numerous options such as simple terminations or with connectors:
Thermal protection production line
- Removable construction, quick release in the event of an incident (jamming, overflow, maintenance, etc.)
- Reduces radiation towards operators/equipment to ≤ 1–2 kW/m² (T ext. wall ≤ 80 °C)
- Excellent mechanical resistance
- No snagging/abrasion by the scales, during vibrations and expansions
- Easy, self-contained “triptych” setup, adapts to your easels
- Low bio-persistence and dust-proof and waterproof enclosure on the operator side
Dummy bar insulation with Nefalit® millboard
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Ensures controlled and uniform solidification that promotes a clean, straight and stable start
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Limits heat transmission to the drive system
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Avoids unwanted metallurgical sticking and ensures perfect demolding after each casting
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Extends the life of the Dummy bar (prevents deformation)
- Ready-to-use gasket, self-installation on the bottom and walls
- Drastically reduces the risk of sticking or total destruction of the starting system
- Absorbs thermal expansion
- FCR fiber-free biopersistent seal
- High compressive strength of steel
INGOT CASTING
NEFALIT® millboard casting sealing
- Financial gain +/- 20% (*)
- Guaranteed sealing (no energy loss or steel leakage)
- FCR fibre-free seals
(* production site of 110,000 T/year, 12,000 seals/year based on 4 seals/barrel)
The sealing between the ingot mold and the mold is one of the priorities of this process to avoid negative impacts on the quality of the steel, risk of accident, loss of energy, therefore PBI has developed seals with optimal use value.
- NEFALIT® ready-to-use cut
- Easy and simple setup
- Resistant to high temperatures up to 1200°C
- Mineral or bio-soluble fiber-based gaskets
Ingot mold cover
- Metal channeling: promotes even filling in the center of the mold, reducing turbulence and surface defects
- Transient thermal insulation: maintains heat at the ingot head during the critical first seconds, improving feeding and reducing the risk of shrinkage
- Immediate protection: limits splashes of liquid metal and prevents pollution of the casting environment.
- Guaranteed cleanliness: the millboard is formulated to burn completely before demolding to preserve the integrity of the ingot
- Essential sacrificial consumable to guarantee clean, regular ingots without surface pollution, with a secure and controlled process
- Ensures Anti-oxidation and Anti-inclusion
- Easy cutting and self-installation
CENTRIFUGAL CASTING
With more than 30 years of trusted partnerships with the biggest European and global players in centrifugation, our product range has proven its flawless effectiveness in a sensitive process where team safety is a priority.
Ladle lids (preheating, holding, pouring, etc.)
- 85% reduction in energy costs (1 hour of preheating vs. 8 hours)
- Lifespan > 3 years in daily use
- 5 times lighter than a concrete lid
- Stand-alone installation without structural modification
- Self-supporting mattress
- Manufactured to include rod/thermocouple passages
- Custom format: oblong, octagonal, etc.
- Reduction of noise pollution in the factory
- Anti-abrasive, anti-corrosive solutions…
- Easy handling by a single operator (Handles, weights, etc.)
1h30 after emptying, internal temperature of the bag still > 500°C and external temperature of the lid < 70°C
Mold sealing / centrifugal shell
- Team safety
- Prevents metal from sticking to the ends, reduces lost production time and scrap end plates or castings.
- Consistent performance in casting Nickel, Hastelloy, Monel, Babbitt, Austenitic, Duplex, Cobalt, Titanium Superalloys, etc.
- Dedicated to the production of tubes for extreme conditions (nuclear, petrochemical, oil, ammonia, gas, bluehydrogen, ethylene, etc.)
- Excellent mechanical resistance
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Perfect sealing.
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Delivered in the form of seals or in plates for cutting on site ( die cutter, etc. ).
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Wide range, mostly ceramic-free
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For horizontal or vertical centrifugation
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Also suitable for producers of Grinding Rollers for the food industry
LOW-PRESSURE CASTING
Low pressure casting sealing
- Ensures perfect sealing
- Maintains constant pressure (>1 bar)
- Prevents any entry of parasitic air (sources of oxidation and porosity)
- Real “process assurance”, drastic reduction in unplanned shutdowns, maintenance on “tank/mold interfaces”, fewer rejected parts
- Ensures the regularity and consistency of production rates, essential for safety parts such as a railway wheel
- Reduced scrap through better control of metal flow
- Prevents any leakage of liquid metal
- Filling without internal defects, metal missing parts, porosities, shrinkage or inclusions
- Increases operator safety
- Excellent chemical and thermal resistance
PRECISION CASTING
Protective, insulating and sealing curtains… up to 1 300°C
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Protection of personnel from radiation and certain projections: protects and improves working conditions
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Water-repellent and splash-resistant construction
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Limiting heat losses and partitioning in furnaces: uniform temperatures, regular production cycles, energy savings, etc.
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Flexible attachment systems for easy and independent installation
- From 500 to 1 390°C
- Mechanical and chemical reinforcement options
- Full, weighted, fringed, with thread strips...
- Removable, expandable…
Example of thermal protection of the wheels and front apron of the forklift.
Thermal regulation/control heat-insulating hood
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Maintaining the temperature of the liquid metal: ensures optimal fluidity and complete filling of the clusters
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Controlled solidification: promotes progressive and homogeneous cooling, reducing internal tensions, cracks and porosities
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Reduction of scrap and rework : better structural homogeneity of parts
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Multi-alloy compatibility: effective with the most demanding aeronautical alloys (nickel-based superalloys, cobalt, titanium, etc.)
- Improved casting success rate: fewer defects related to shrinkage or lack of filling
- Ensures temperature maintenance, efficient filling and controlled cooling during metal solidification
- Optimization of hidden costs: savings in metal, energy and cycle time thanks to better efficiency
- Low biopersistence; Developed to replace ceramic as a mold shell
- Resistant and stable materials: retain their properties despite repeated thermal cycles
- Self-contained, quick and easy installation; easily adapts to clusters
Rollover shock absorber mattress (clusters, crucibles, flanges, etc.)
- Allows for firm and even controlled pressure to be applied during turning to ensure molds remain securely in place in contact with our gasket, reducing the risk of cracking or warping during handling
- Combining Sensitivity and Delicacy, our solution protects the (fragile) ceramic shell while ensuring safe handling, avoiding production losses or defects in the castings.
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Absorbs mechanical stress
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Persistent Bio Solution
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Supplied in custom pieces or in rolls for greater versatility of use
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Possibility of custom-made mattresses
Sealing of castings
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Optimal sealing between the different elements (molds, clusters, crucibles, flanges, etc.), limiting any leakage of liquid metal.
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Resistance to high temperatures and extreme casting conditions ( superalloys, stainless steel, titanium, etc. ) guaranteeing better surface quality of parts ( Aeronautics & Space, Energy & Turbines, Medical & Biomedical, Defense & Armament, Nuclear & Oil, etc. )
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Absorption of expansions and micro-movements; follows thermal deformations without losing its sealing properties
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Easy to install and remove
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Easy and very quick assembly: 1 ring = 1 complete seal
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Sustainability: allows for multiple cycles of use depending on the process, reducing replacements and production shutdowns
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Also available in cut-out insulating millboard gaskets
Cooling control / protection mattress
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Controls the cooling of your parts to avoid thermal shocks
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Reduction of residual stress to optimize the performance of your parts
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Possibility of integrating it into an existing structure
- Maintains uniform temperature (avoids residual stresses, deformations, cracks & rectification of parts)
- Persistent Bio solutions made to limit fiber transfer
- Limits projections of scales or burning oxides
- Contributes to cleaner and more eco-responsible production; less reheating required = CO₂ & energy reduction
MATRIXING
Mattress die lubricant
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Supports the deformation and creep of your plots
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Prevents thermal shocks and limits hot cracking ( cracks )
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For a cleaner working environment and room
- Improves metallurgical quality
- Extends the life of dies and tools
- Increases your productivity
- Strengthens operator safety
- Customized solutions that take into account all your constraints, including installation, transport, storage, etc.
- From prototype part to series part
FINISHES
THERMAL TREATMENT
Always attentive to your needs, PBI has developed value-added solutions that precisely meet your expectations for various treatment furnace processes.
Our range of Door Stoppers, PIT Mattress, TecHeat ® Bell Oven, etc. ensure perfect sealing, significant energy savings and enable the optimization of processes and usage values.
Oven door sealing/insulation
- Lifespan multiplied by 4 compared to traditional refractories (*)
- Easy to handle solution: 4 times lighter than concrete plugs (approximately 8 kg vs 32 kg)
- Perfect sealing thanks to custom production
(* Pass-through furnace, temperature 1200°C, 24 inspection hatches)
PBI has developed a range of custom-made door stopper seals as an alternative to existing solutions (concrete/bricks, etc.). Easy to handle (light weight), they ensure perfect sealing and improved durability.
- Excellent sealing
- Easy handling and installation
- Solutions up to 1390°C
- Excellent radiation resistance
- No fiber emissions
PIT oven sealing
- Reduction in energy costs (+/- 15% depending on the site)
- Exceptional durability (works up to 20 times longer than "classic" braids)
- Significant reduction of deformations on the knives
PBI has developed a range of sealing mattresses with optimal usage value to limit as much as possible:
- Gas consumption in furnaces
- The presence of calamine on the ingots (cause: entry of parasitic air)
- Deformation of the cover (knives)
- Excellent sealing
- Prevents deformation of lid knives
- Resistant to very high temperatures (1390°C), splashes and abrasion
- Supplied as a ready-to-install kit
- No fiber dispersion
- Quick and easy setup
Sealing of bell furnace
- Lifespan multiplied by 25 compared to usual fibrous materials (*)
- Energy saving >20%
- Prevents the dispersion of dust (fibers, sand, etc.)
(*production site of +/-1,000,000 T/year, 30 furnaces)
PBI has developed a range of TecHeat ® bell furnaces (process under controlled atmosphere) in order to obtain absolute sealing between the table and the bell for optimal and homogeneous treatment of the coils, to limit the deformation of the bell, energy consumption and increase the life of the seal.
- Excellent sealing
- Reduced maintenance
- Resistance to high temperatures ( 1000 to 1200°C )
- Resistance to mechanical and chemical stresses
- No FCR
- Supplied ready to use
- Quick and easy setup ( <30 minutes )
Range HAPL
With more than 50 years of experience, PBI has developed a range of millboards entirely dedicated to the HAPL (Hot Annealing Pickling Lines) process for the coating of single, up-and-down rolls as well as for revolvers, up to 1500°C.
The world's largest steelmakers (Outokumpu, Thyssenkrup, Aperam, etc.) call on us to deliver the seals that meet their expectations.
Our main references for HAPL:
NEFACIER CF (Céramic) : Max 1 200°C
NEFACIER 1500 (Céramic) : Max 1 500°C
NEFINOX HTG (Mineral Fibers) : Max 1 350°C
Sealing oven rollers
- Expanding sleeve filling the usual misalignments of the rollers
- Ensured sealing of the rocket passages of roller heat treatment furnaces
- Lifespan >3 years (*)
- Significant economic gains ( maintenance, energy, refractories, etc. )
(* 36 and 48 roll ovens)
PBI has developed an expanded solution ensuring perfect sealing of the roller spindle passages to protect the integrity of the rollers' external drive system (motors, gears, etc.).
- Excellent sealing
- Reduction of the risk of burns to personnel
- Quick and easy installation (kit + assembly instructions)
- Resistant to high temperatures (up to 1390°C) and abrasions
- Without FCR and without fiber dispersion
- Reduced maintenance
Examples
Our achievements
Our partners
STEEL
Zoom
APPLICATIONS
TEXTILE EXPANSION COMPENSATORS
TEXTILE EXPANSION COMPENSATORS 100°C TO 1300°C
BACK-UP INSULATIONS
BACK-UP LADLE/CRUCIBLE/ FURNACE INSULATIONS
INSULATION AND PROTECTION LAGGING
INSULATION AND PROTECTION LAGGING 100°C TO 1390°C
PROTECTION OF CRITICAL CABLES
PROTECTION OF CRITICAL CABLES UP TO 1390°C
