STEEL MILL

From the Coking Plant to Billets

PBI is active in the majority of departments (Coking Plant, Blast Furnaces, Refining Converters, Heat Treatment, etc.) with value-added solutions for protection, insulation or sealing which allow the optimisation of processes and usage values.

The objective is to maintain the optimum temperature during the critical production and processing phases in order to optimise production means, limit energy losses and protect operators and their means of production.

COKING
PLANT

CONTINUOUS FLOW

INGOT
FLOW

HEAT TREATMENT

Upstream

COKING PLANT

Originally, we worked for the perfect sealing of doors subject to strong constraints and requiring too-frequent maintenance interventions. Then, following the satisfaction of our customers and their requests, we extended our developments to the various most critical points of the process.

We have therefore developed solutions for insulation/sealing/protection with a high use value allowing us to optimise the means of production, limit energy losses and protect operators and the environment.

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Sealing of doors

  • Door lifespan multiplied by up to 20 times (*)
    • refractory life multiplied
    • sharp reduction in door deformation
  • Maximum limitation of harmful leaks (SO2, NOx, C6H6, HAP, etc.)

(*Site of 159 cells for a coke production of 950,000 T/year)

The Membrane-Nefex®-Seal sealing KIT for coking plant doors has been specially developed to solve recurring problems in this application such as energy & gas leaks, door deformation, refractories changed regularly, coke quality, overly frequent maintenance.

  • Nefatex® 1390 membrane:
    • Set up in less than 7 minutes for 6 blocks
    • Delivered pre-drilled according to your template
    • No fibre dispersion
    • Perfect seal between the door and the refractory blocks
    • Prevents deformation of doors thanks to its insulation
    • Excellent mechanical strength
  • High-temperature Nefex® seals used between the refractory blocks which, by expansion, fill the entire space between the refractory blocks:
    • Set up in less than 10 minutes for 6 blocks
    • Excellent sealing between the blocks as soon as the temperature rises
    • Prevents coke from penetrating between 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 (avoid gas & energy leaks). The seal is designed for optimum compressibility/recovery.
    • Excellent sealing
    • Resistant to extreme temperatures/radiation, flames, projection and abrasion
    • Supplied to length
    • Fibre dispersion limitation
    • Ceramic-free Solution
    • Quick & easy to set up

Each element of the KIT is available separately.


End of assembly with gasket packing

Mise-en-place-de-TecHeat-Tubing

Cable/hose protection/insulation

>20% annual savings on the “flexible item” (*)

  • Hose purchases divided by 2
  • Total protection in case of fire
  • Reduces downtime and the number of maintenances

(*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/hoses undergoing the most drastic constraints in the processes and to avoid certain accidents causing production shutdown.

  • Holds up to 1200°C
  • Excellent resistance to flames, movements, abrasions and vibrations
  • Preserves the flexibility and bendability of your original hoses
  • Ease and speed of implementation
  • Exceptional lifespan

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TecHeat® tubing condition after 50 months of use.

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MEMBRANE-FOR-TELESCOPE

Sealing/Protection of telescopes

>40% annual savings on the "telescope membrane station" (*)

  • Lifespan of 180 to 240 days
  • Less maintenance needed

(*57 cells with 2 loaders 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

Other coking plant applications

At the heart of the process

CONTINUOUS CASTING INGOTS

The VD/VOD & Ingot making processes require perfect evacuation of the treatment ladle and absolute tightness which absolutely meets the various constraints in the application; this is why PBI has developed a wide range of TecHeat® Seal VD/VOD Solutions and NEFALIT® Seals with optimal use values.

VD-VOD-Sealing-Packing-in-Appliccation

VD/VOD furnace cover sealing

  • Financial gain >20%
  • Service life 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 next step of treatment in order to produce special and very high-quality steels, PBI has developed a range of TecHeat® Seal VD/VODs ensuring a seal which perfectly meets your expectations and the various constraints of the application. These are made-to-measure seals with high wear values.

  • Excellent sealing
  • Resistant to extreme temperatures/radiation, flames, projection and abrasion
  • Supplied to length
  • No fibre dispersion
  • Quick and easy to set up
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NEFALIT® millboard casting sealing

  • Financial gain +/- 20% (*)
  • Guaranteed tightness (no loss of energy or steel leakage)
  • Ceramic-free Gaskets

(*production site of 110,000 T/year, 12,000 seals/year based on 4 seals/barrel)

As the sealing between the ingotmaking and the mould is one of the priorities of this process to avoid negative impacts on the quality of the steel, risk of accident, loss of energy, PBI has developed seals with optimal use value.

  • Ready-to-use NEFALIT® cutout
  • Easy and simple to set up
  • Resistant to high temperatures up to 1200°C
  • Gaskets based on mineral or bio-soluble fibres

Other Continuous Casting / Ingot Casting Applications

  • Sealing of tundish

  • Sealing of dummy bars

  • Argon sealing of ingot moulds

  • Thermocouple protection

  • Protection curtains

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HEAT TREATMENT

Always at your service, PBI has been able to develop solutions with added value and precisely meet your expectations for the various treatment furnace processes.

Our range of Door stoppers, PIT mats, TecHeat® bell furnace ensure a perfect seal, a significant energy saving and allow us to optimize the processes and the values of use.

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Sealing/insulation of furnace door

  • Service life multiplied by 4 compared to traditional refractories (*)
  • Easy-to-handle solution: 4 times lighter than concrete plugs (around 8 kg vs 32 kg)
  • Perfect sealing thanks to custom production

(*Passage furnace, temperature 1200°C, 24 inspection hatches)

PBI has developed a range of tailor-made Door Stopper sealings as an alternative to existing solutions (concrete/bricks, etc.). Easy to handle (reduced weight), they ensure a perfect seal and improved durability.

  • Excellent sealing
  • Easy Handling and Installation
  • Solutions up to 1390°C
  • Excellent resistance to radiation
  • No fibre emission
ACIERIE-FOUR-PIT-2

PIT furnace sealing

  • Energy savings >15% per year (*)
  • Improved sealing
  • Service life multiplied by 20
  • Less knife deformation

(* 12 ovens of 80 T)

PBI has developed a Range of Sealing Mattresses with optimal use value to limit the following as much as possible:

·         Gas consumption in furnaces

·         The presence of calamine on the ingots (cause: parasitic air inlet)

·         Deformation of the cover (knives)

o    Excellent sealing

o    Prevents deformation of the cover knives

o    Resistant to very high temperatures (1390°C), to projections and to abrasion

o    Supplied as a ready-to-install kit

o    No fibre dispersion

o    Quick and easy to set up

CUSTOMIZED-SEAL-FOR-BELL-FURNACE

Bell furnace sealing

  • Service life multiplied by 25 compared to usual fibrous (*)
  • Energy gain >20%
  • Avoids the dispersion of dust (fibres, sand, etc.)

(*production site of +/- 1,000,000 T/year, 30 furnaces)

PBI has developed a range of TecHeat® bell furnaces (bell furnace process under controlled atmosphere) in order to obtain an absolute seal between the table and the bell for an optimal and homogeneous treatment of the coils, to limit the deformation of the bell, the energy consumption and increase the life of the seal.

  • Excellent sealing
  • Reduced maintenance
  • High temperature resistance (1000 to 1200°C)
  • Resistance to mechanical & chemical stress
  • Ceramic-free
  • Supplied ready to use
  • Quick and easy setup (<30 minutes)
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Sealing furnace rollers

  • Expanding sleeve to take the usual offsets of the rollers
  • Sealing of rocket passages in roller heat treatment furnaces
  • Lifespan >3 years (*)
  • Significant economic gains (maintenance, energy, refractories, etc.)

(*36 and 48 roll furnaces)

PBI has developed an expanded solution ensuring the perfect sealing of the rocket passages of the rollers to protect the integrity of the external drive system of the rollers (motors, gears, etc.).

  • Reduced risk of burns to personnel
  • Quick and easy installation (kit + assembly instructions)
  • Resistant to high temperatures (up to 1390°C) and abrasions
  • Ceramic-free and no fibre dispersion
  • Reduced maintenance

Other heat treatment applications

  • PIT oven transport clamp protection

  • Bell furnace insulating spacer

  • Cooling mattresses

  • Protection curtains

  • ...

Other solutions for

STEELWORKS

  • Wagon wheel injection mould sealing
  • Sealing of centrifuge moulds
  • Die-stamping press insulation
  • Furnace control valve
  • Welding mats
  • Relaxation mats
  • Lubricating die-forging mats
  • Wire drawing wiper braid
  • ...

Our partners

STEEL

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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