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HarbisonWalker International is a predominant supplier of basic oxygen furnace (BOF) refractories in the United States, where the BOF is the primary device used to produce high-quality integrated steel. Domestic BOF steel production capacity has leveled off due to the significant capital investment required to build new integrated steel mills. The inherent advantage of the BOF is its capability to produce large volumes of high-quality steel, primarily for the automotive industry.

The BOF converts molten iron and scrap to steel by injecting gases at supersonic velocities. The introduction of oxygen through the top lance (BOF) or the bottom tuyeres (in a quick-quiet basic oxygen process, or Q-BOP) creates an exothermic reaction that melts the scrap and removes impurities. Oxygen, nitrogen, argon, or propane is injected through the Q-BOP bottom tuyeres. The multiple tuyeres produce a higher agitation of the steel bath. Increased agitation, along with the chemical reactions produced by the gases, results in lower levels of carbon, phosphorus, and sulfur in the steel.

In the 1980s some mills adopted the technique of slag splashing to extend the life of a campaign. Slag splashing provides a refractory coating over the existing lining. After a heat is tapped, the BOF is rocked to coat the stadium and lower barrel. Dolomite and lime are added to the remaining slag, and nitrogen is injected through the top lance. This process blasts the slag mixture over the existing refractory lining.

BOF vessel capacities can range from 70 to 300 tons. BOF refractory life varies significantly. A campaign can last from 4,000 heats to as many as 50,000 heats, depending on individual shop practices.

HarbisonWalker International provides a full range products for every part of the BOF process, including:

  • Safety Lining: NARTAR® 7, SUPER NARTAR® R, BOF TANK, and NARMAG® HRB
  • Working Lining: HWI analyzes individual current and historical shop conditions and offers customized lining solutions.
  • Bottom/Stadium: customized BOF 700 and 800 series, NARTAR® TS, NARTAR® XR, and ISOTAP®
  • Barrel: BOF 700, 800, and 900 series, which have been carefully customized for optimal metal content, carbon levels, and magnesia purity.
  • Cone: BOF 700 series, NAREZ AM5, and SUPER NARTAR® R, with an option for co-molding each product.

BOF Gunning

Gun mixes are used to extend the life of the vessel working lining. On a regular basis, the lining is inspected after the vessel has been tapped. Laser profilers can be used to determine where the lining is becoming thin. A gun mix is applied to the areas needing repair, and after minimal dry-out, the vessel is returned to operation.

Gunning materials are designed to be sticky during application to reduce rebound and have enough green strength to prevent slumping or peeling. Magnesium oxide content, basicity, and binder composition will determine the right material for each application.

HWI has developed several gunning materials for use in the BOF application:

  • Cone: BASIC 187 GM-60
  • General Vessel Maintenance: BASIC 187 GM-90 and BASIC 187 GM-93
  • Taphole Replacement and Maintenance: AMERICLASE 98 S

Products
Basic Oxygen Furnace (BOF)

Product SDS
‘SAIRSET A wet, air-setting, fireclay mortar
60DB® A 60% magnesia, burned brick English
ALADIN® 80 An 80% alumina brick
AMERICLASE 94 A 65% magnesia gunning mix
AMERICLASE 98 S A 97% magnesia, chemically bonded gunning mix
AMERICLASE H A 74% magnesia, dry ramming mix
AMERICLASE HC English
AMERICLASE HD English
ANKORBOND C® A wet, resin bonded, heat setting high alumina mortar
BASIC 187 DV-88 A 90% magnesia, dry, heat setting vibratable. English
BASIC 187 DV-88D A 90% magnesia, dry, heat setting vibratable English
BASIC 187 GM-60 A 60% magnesia, silicate bonded gunning mix English
BASIC 187 GM-88 An 88% magnesia, silicate bonded gunning mix English
BASIC 187 GM-88 RH An 88% magnesia gunning mix with a dual binder system English
BASIC 187 GM-93 A 93% magnesia, chemically bonded gunning mix English
BAYONET MORTAR A high alumina, carbon containing, heat setting mortar English
BOF 411 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 412 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 711 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 712 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 722 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 732 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 811 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 812 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 821 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 822 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 832 A magnesia carbon brick for Basic Oxygen Furnace Linings English
BOF 911 A magnesia carbon brick for Basic Oxygen Furnace Linings English
CLEANCOAT 6M A magnesia troweling mix English
CLIPPER® DP A super duty fireclay brick
COMANCHE® A carbon bonded, alumina magnesia brick English
COMANCHE® FA A carbon bonded, alumina magnesia brick English
COMANCHE® GOLD A carbon bonded, alumina magnesia brick English
COMANCHE® PLATINUM A carbon bonded, alumina magnesia brick
COMANCHE® SL A carbon bonded, alumina magnesia brick English
CORAL® BP A burned, phosphate bonded 80% alumina brick
D-CAST® 85 GOLD CASTABLE An 85% alumina, low moisture castable English
D-CAST® 85TMCC CASTABLE An ultra-low cement, high alumina castable English
D-CAST® XZR-OR An ultra-low cement, high alumina castable with 26% silicon carbide
DAUBPAX An 86% silica, plastic refractory English
DESCON® S97 ADTECH A vitreous silica-based castable English
DOSSOLITE 1400–75 A 78% magnesia, fine grained mix designed for spraying English
DOSSOLITE 1400–83 An 88% magnesia, fine grained mix designed for spraying English
DOSSOLITE 1400-72 A 77% magnesia, fine grained mix designed for spraying English
DOSSOLITE 1400-917 An 80% magnesia, fine grained mix designed for spraying English
DV-38® An 80% alumina, burned, phosphate bonded brick English
EAF 231 AS A magnesia-carbon brick for EAF service English
EAF 232 AS A magnesia-carbon brick for EAF service English
EAF 233 AS A magnesia-carbon brick for EAF service English
EAF 621 AS A magnesia-carbon brick for EAF service English
EAF 622 AS A magnesia-carbon brick for EAF service English
EAF 631 AS A magnesia-carbon brick for EAF service English
EAF 632 AS A magnesia-carbon brick for EAF service English
EAF 822 AMS A magnesia-carbon brick for EAF service English
EAF 832 AMS A magnesia-carbon brick for EAF service English
EAF 833 AMS A magnesia-carbon brick for EAF service English
EAF BB1 A magnesia-carbon brick for EAF service English
EMPIRE® C A high duty firebrick English
EMPIRE® S A high duty, dry pressed fireclay brick English
EXPRESS®-27 PLUS A 50% alumina, cement bonded, self flowing castable English
FASKAST® 75 PLUS An ultra-low cement, high alumina castable English
FASKAST® 80 An ultra-low cement, high alumina castable
FUSECRETE® C An high alumina course aggregate castable English
FUSIL® CASTABLE 820 I A fused, silica-based castable
GREENAL®-80 An 80% alumina, dry pressed brick
GREENAL®-80 P 80% Alumina, Burned Brick Containing Phosphate English
GREENAL®-85 HP 85% Alumina, Dry Press Brick designed for superior steel ladle performance versus standard 80% alumina brick.
GREENGUN®-70 P PLUS A 70% alumina, phosphate bonded gunning plastic English
GREENGUN®-85 P PLUS An 85% alumina, phosphate bonded gunning plastic English
GREENLITE®-45-L GR ON-LINE® A 2500°F rated lightweight gunning mix
GREENSET®-80 BH An 80% alumina, air setting mortar English
GREENSET®-85 P An 80% alumina, phosphate bonded mortar
GREENTHERM 23 LI A 2300°F rated insulating firebrick
GREENTHERM 26 LI A 2600°F rated insulating firebrick
GREENTHERM 28 LI A 2800°F rated insulating firebrick
GREENTHERM 30 LI A 3000°F rated insulated firebrick
GREFCON® 98 SP A 3300°F, spinel-containing castable English
GREFCON® 98 SPL A 3300°F, spinel-containing castable English
H-W 3-75 A high alumina, burned, phosphate bonded brick English
HARWACO BOND (DRY) A 50% alumina, air setting, dry mortar English
HARWACO BOND (WET) A 50% alumina, air setting, wet mortar
HOT BANK 53 A dry ramming mix composed of sintered dolomite and magnesia English
HP-CAST ® 94MA-C A high-purity alumina, spinel-containing, ultra-low cement, coarse castable
HP-CAST ® ULTRA A high purity alumina, spinel forming, ultra-low cement castable English
HP-CAST ® ULTRA VC A high-purity alumina, spinel-forming, ultra-low cement castable English
HPV®-ESX CASTABLE A fused silica castable designed for thermal shock resistance
INSBLOK®-19 A 1900 F rated mineral wool block
INSBOARD 2300 LD A 2300°F Low Density Vacuum-Formed Ceramic Fiber Board
INSWOOL® PUMPABLE 2300°F Ceramic Fiber Pumpable Material - formulated for pumping with special equipment.
INSWOOL®-HP BLANKET 8# A 2300°F rated, alumina silica ceramic fiber blanket
INSWOOL®-HTZ BLANKET 8# A 2600°F rated, alumina silica zirconia ceramic fiber blanket
IRONMASTER® An 81% alumina trough castable with a silicon carbide and carbon addition
ISO-STAR MX2 An AMC material that may be Iso-Pressed for use as ladle well blocks and pocket blocks English
ISO-STAR MX2 An AMC material that may be Iso-Pressed for use as ladle well blocks and pocket blocks English
ISO-STAR® MC An Iso-Pressed magnesia and graphite ladle weel block and pocket block English
ISO-STAR® MX An Iso-Pressed magnesia and graphite ladle weel block and pocket block English
ISOTAP® An Iso-Pressed magneisa and graphite taphole English
KALA® A 50% alumina brick
KALA® SR A 50% alumina brick designed for thermal shock resistance English
KAST-O-LITE® 19 L PLUS A 1900°F rated lightweight castable English
KAST-O-LITE® 20 PLUS A 2000°F rated lightweight castable English
KAST-O-LITE® 23 LI PLUS A 2300°F rated lightweight gunning mix
KAST-O-LITE® 50-25 PLUS A 2500°F low-density insulating castable English
KORUNDAL XD® A 90% alumina, mullite bonded brick with low porosity
KORUNDAL® MORTAR A 90% alumina, heat-setting mortar
KRUZITE®-70 A 70% alumina brick English
KS-4V GR PLUS A fireclay based, conventional cement gunning mix
KS-4V PLUS A fireclay based, conventional cement castable
KX-99® A high fired, super duty fireclay brick
KX-99®-BF A high fired, super duty fireclay brick English
LADLE SL TANK A magnesia carbon brick English
LO-ABRADE® GR PLUS A 2600°F dense, abrasion-resistant, gunning castable English
LOTHERM® RK High Strength Insulating Brick - 101 pcf English
MAGNUM XL10F Magnesia-Carbon brick for Steel Ladle service
MEXI-KOMO® A dry, heat-setting, super duty mortar
MIZZOU® CASTABLE PLUS A 3000°F rated high alumina castable
NARCARB® BSC A carbon bonded, alumina-silicon carbide brick
NARCARB® ZP PLASTIC A 65% alumina, slag resistant refractory plastic English
NARCOGUN® 50 BG A 50% alumina gunning mix English
NARCOGUN® 70 BG A 70% alumina gunning mix
NARCOGUN® BSC-DS A trough gunning mix English
NARCON® 65 CASTABLE A 65% alumina, low-cement castable English
NARCON® 70 CASTABLE A 70% alumina, low moisture castable
NARCOTUN® 72 A 72% magnesia, dry, heat setting vibratable English
NARCOTUN® 72XH A 72% magnesia, dry, heat setting vibratable with an extra hard bond English
NARCOTUN® 83 A 86% magnesia, dry, heat setting vibratable English
NARCOTUN® 83XH A 87% magnesia, dry, heat setting vibratable with an extra hard bond English
NARCOTUN® 87 A 87% magnesia, dry, heat setting vibratable English
NARCOTUN® M-97 A 96% magnesia, dry, heat setting vibratable English
NAREZ AM5 A magnesia carbon brick for Basic Oxygen Furnace Linings English
NARMAG® 60 DB A magnesia chrome burned brick English
NARMAG® 95 CASTABLE A 95% magnesia castable English
NARMAG® FG A magnesia chrome burned brick English
NARMAG® HRB A 97% magnesia, burned brick English
NARMAG® L MORTAR A magnesia dipping mortar English
NARMAG® MORTAR HEAT SET A basic mortar English
NARPHOS® 90 MORTAR A 90% alumina, phosphate bonded mortar English
NARPHOS® 90R RAM MIX A high-alumina ramming mix English
NARSPRAY® M-77 A 77% magnesia, ultra-lightweight spray mix English
NARTAR® 7 A magnesia, pitch impregnated burned brick English
NARTAR® TS A magnesia, pitch impregnated burned brick English
NARTAR® XR A magnesia, burned brick English
NISIC 20 A nitride bonded, silicon carbide brick English
NO. 36 REFRACTORY CEMENT A wet, air setting, high alumina mortar
NOZZLE SET 90P English
ON-LINE® 60 A 60% alumina, low-cement castable designed for rapid curing English
PHANTUM® XL127 A magnesia carbon brick for steel ladle applications
PHANTUM® XL147 A magnesia carbon brick for steel ladle applications English
PHANTUM® XL148 SUPER A magnesia carbon brick for steel ladle applications English
PLASTECH® 50P STD A 50% alumina, phosphate bonded refractory plastic
PLASTECH® 70P STD A 70% alumina, phosphate bonded plastic refractory English
PLASTECH® 85P STD An 85% alumina, phosphate bonded plastic refractory
PLASTECH® 90P FINE A fine grained, 90% alumina, phosphate bonded refractory plastic English
PLASTECH® 90P STD A 90% alumina, phosphate bonded refractory plastic
PLASTECH® RUBY® An alumina-chromium, phosphate bonded refractory plastic
PNEULITE® SPRAY 22 A 2200°F, insulating shotcrete mix English
PRISM® DC High Alumina (96%), Cast Fired Shapes
RENEGADE® BL8H A magnesia carbon brick for steel ladle applications English
RENEGADE® XL10F A magnesia carbon brick for steel ladle applications English
RUBY® RAMMING MIX A phosphate-bonded, alumina-chromium ram mix English
RUBY®190 KSV MORTAR An alumin-chrome mortar English
S142® A 62% magnesia, 17% chrome burned brick English
S145® A magnesia chrome brick English
SCHIEBERSAND® BO-2 A dry, granular low-carbon material used for well fill for slide gates. English
SENTINEL® RC PLUS A portland cement bonded, high strength, general purpose castable English
SFG® A magnesia-chrome brick English
SFG®-US A magnesia-chrome brick English
SHAC ADTECH® An extra-high-alumina castable English
SHOT-TECH® 45 LI A fireclay based, low-cement shotcrete mix
SHOT-TECH® 60 A 60% alumina, low-cement shotcrete mix
SHOT-TECH® 80 An 80% alumina, low-cement shotcrete
SHOTKAST® 65 A high-alumina shotcast castable English
SHOTKAST® HMC A high-alumina shotcast castable
SHOTKAST® TRW A shotcast trough castable English
SILSET An air-set silica mortar for coke oven brick English
SLID® An 87.5% magnesia, burned brick English
SUPER HYBOND® 60 PLUS A 60% alumina, mullite, air-setting, plastic refractory English
SUPER HYBOND® PLUS A high-strength, super-duty, plastic refractory
SUPER NARTAR® R A magnesia carbon brick for Basic Oxygen Furnace Linings English
T-WELL 80 A high alumina, fine graind tamping mix English
TAP-332 AS A magnesia-graphite taphole mix English
TAP-431 AS A magnesia-graphite taphole mix English
TAP-431 AS A magnesia-graphite taphole mix English
TAP-432 AS A magnesia-graphite taphole mix English
UFALA® A 60% alumina brick shape English
UFALA® MCR A 60% Alumina - Andulsite Brick Shape English
UFALA® XCR A 60% Alumina - Andulsite Brick Shape English
ULTRA-EXPRESS® 70 A 70% alumina, free flowing, ultra-low cement castable English
ULTRA-GREEN® 57A A 57% alumina, andalusite base, ultra-low cement castable
ULTRA-GREEN® 60 PLUS A 60% alumina, low cement castable English
UNACAST® 1005X An 80% alumina, thermal shock resistant, pre-cast shape English
VARNON® AH Air Ram (53% Alumina) Fireclay Brick English
VERSAFLOW® 45 C PLUS A coarse, fireclay-based, low-cement castable for high-abrasion environments
VERSAFLOW® 45 PLUS A fireclay based, low-cement castable English
VERSAFLOW® 60 PLUS A 60% alumina, low cement castable
VERSAFLOW® 70 PLUS A 70% alumina, low-cement castable
VERSAFLOW® 80 C PLUS An 80% alumina, coarse aggregate, low-cement castable
VIBE-TITE A 70% alumina, dry vibratable English

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Spotlight

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    On June 15th, 2017 HWI hosted its Third Annual Junior Acheivement Bowl-A-Thon. We would like to thank all of our sponsors who helped make this such a successful event. >