Basic Oxygen Furnace (BOF)

HWI 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.

HWI 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:

 

Refractory Solutions for Iron and Steel

Products
Basic Oxygen Furnace (BOF)

Filters
Product SDS
‘SAIRSET A wet, air-setting, fireclay mortar
60DB® A direct-bonded 60% magnesia, burned brick
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 A 65% magnesia hearth mix designed for stacking at steep angles of repose for use where material is applied by a spreader.
AMERICLASE HD A 65% magnesia hearth mix designed for stacking at steep angles of repose for use where material is applied and compacted by hand.
AMERICLASE HP A 78% magnesia, dry ramming mix
ANKORBOND C® A wet, resin bonded, heat setting high alumina mortar
BASIC 187 DV-88D A 90% magnesia, dry, heat setting vibratable
BASIC 187 GM-60 A 60% magnesia, silicate bonded gunning mix
BASIC 187 GM-75 A 75% magnesia, silicate bonded gunning mix
BASIC 187 GM-88 An 88% magnesia, silicate bonded gunning mix
BASIC 187 GM-88 RH An 88% magnesia gunning mix with a dual binder system
BASIC 187 GM-90 A 90% magnesia, chemically bonded gunning mix
BASIC 187 GM-92 A 92% magnesia, chemically bonded gunning mix
BASIC 187 GM-93 A 93% magnesia, chemically bonded gunning mix
BAYONET MORTAR A high alumina, carbon containing, heat setting mortar
BOF 2812 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 411 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 412 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 711 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 712 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 713 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 722 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 732 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 811 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 812 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 822 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 831 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 832 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 911 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 921 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF 932 A magnesia carbon brick for Basic Oxygen Furnace Linings
BOF TANK A magnesia carbon brick for Basic Oxygen Furnace Linings
CLEANCOAT 6M A magnesia troweling mix
CLIPPER® DP A super duty fireclay brick
COMANCHE® A carbon bonded, alumina magnesia brick
COMANCHE® FA A carbon bonded, alumina magnesia brick
COMANCHE® GOLD A carbon bonded, alumina magnesia brick
COMANCHE® PLATINUM A carbon bonded, alumina magnesia brick for enhanced impact resistance in ladle bottoms.
COMANCHE® SL A carbon bonded, alumina magnesia brick
CORAL® BP A burned, phosphate bonded 80% alumina brick
D-CAST TRC-OR PLUS An ultra-low cement, high Alumina castable with a silicon carbide plus carbon addition
D-CAST® 85 GOLD CASTABLE An 85% alumina, low moisture castable
D-CAST® 85TMCC CASTABLE An ultra-low cement, high alumina castable
D-CAST® XZR-OR An ultra-low cement, high alumina castable with 26% silicon carbide
DAUBPAX An 86% silica, plastic refractory
DESCON® S97 ADTECH A vitreous silica-based castable
DOSSOLITE 1400-72 A 77% magnesia, fine grained mix designed for spraying
DV-38® An 80% alumina, burned, phosphate bonded brick
EAF 211 AS A magnesia-carbon brick for EAF service
EAF 212 AS A magnesia-carbon brick for EAF service
EAF 213 A magnesia-carbon brick for EAF service
EAF 221 A magnesia-carbon brick for EAF service
EAF 222 AS A magnesia-carbon brick for EAF service
EAF 231 A magnesia-carbon brick for EAF service
EAF 231 AS A magnesia-carbon brick for EAF service
EAF 232 A magnesia-carbon brick for EAF service
EAF 232 AS A magnesia-carbon brick for EAF service
EAF 233 AS A magnesia-carbon brick for EAF service
EAF 521 AS A Mag-Carbon brick for general use in EAF's with high FeO slags and high O2 ppm steels.
EAF 621 AS A magnesia-carbon brick for EAF service
EAF 622 AS A magnesia-carbon brick for EAF service
EAF 623 AS A magnesia-carbon brick for EAF service
EAF 631 AS A magnesia-carbon brick for EAF service
EAF 632 AS A magnesia-carbon brick for EAF service
EAF 822 AMS A magnesia-carbon brick for EAF service
EAF 832 AMS A magnesia-carbon brick for EAF service
EAF 833 AMS A magnesia-carbon brick for EAF service
EAF 8632 AS A magnesia-carbon brick for EAF service
EAF 8831 AS A magnesia-carbon brick for EAF service
EAF 8832 AMS A magnesia-carbon brick for EAF service
EAF 8832 AS A magnesia-carbon brick for EAF service
EAF 8833 AS A magnesia-carbon brick for EAF service
EAF BB1 A magnesia-carbon brick for EAF service
EXPRESS®-27 PLUS A 50% alumina, cement bonded, self flowing castable
FASKAST® 75 PLUS An ultra-low cement, high alumina castable
FASKAST® 80 An ultra-low cement, high alumina castable
FUSECRETE® C An high alumina course aggregate castable
FUSIL® CASTABLE 820 I A fused, silica-based castable
GR-FG CASTABLE A chemically bonded magnesia castable
GR-FG RAMMING MIX A magnesia ramming mix
GREENAL®-80 An 80% alumina, dry pressed brick
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
GREENGUN®-85 P PLUS An 85% alumina, phosphate bonded gunning plastic
GREENLITE®-45-L GR ON-LINE® A 2500°F rated lightweight gunning mix
GREENSET®-80 BH An 80% alumina, air setting mortar
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
GREFCON® 98 SP A 3300°F, spinel-containing castable
GREFCON® 98 SPL A 3300°F, spinel-containing castable
H-W 3-75 A high alumina, burned, phosphate bonded brick
HARWACO BOND (DRY) A 50% alumina, air setting, dry mortar
HARWACO BOND (WET) A 50% alumina, air setting, wet mortar
HOT BANK 19 A dolomite based dry ramming mix
HOT BANK 53 A dry ramming mix composed of sintered dolomite and magnesia
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
HP-CAST ® ULTRA VC A high-purity alumina, spinel-forming, ultra-low cement castable
HP-CAST 93S High-Purity Alumina, Spinel-Containing, Ultra-Low Cement Castable
HPV®-ESX CASTABLE A fused silica castable designed for thermal shock resistance
HW-BF 55
HW-BF 60
HW-CO SHD A high-density 95% silica brick for coke ovens.
HW-CO SRD A regular-density 95% silica brick for coke ovens and hot blast stoves.
HW-CO SRDAH A 95%, air-rammed silica brick for coke ovens.
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 A 2300°F rated, alumina silica ceramic fiber blanket
INSWOOL®-HTZ BLANKET A 2600°F rated, alumina silica zirconia ceramic fiber blanket
IRONMASTER® An 81% alumina brick 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
ISO-STAR® MC An Iso-Pressed magnesia and graphite ladle weel block and pocket block
ISOTAP F An Iso-Pressed magneisa and graphite taphole
ISOTAP LC An Iso-Pressed magneisa and graphite taphole
ISOTAP MC1 An ISOPRESS mix for tapholes
ISOTAP® An Iso-Pressed magneisa and graphite taphole
KALA® A 50% alumina brick
KALA® HPC CHECKERS A 50% alumina brick
KALA® SR A 50% alumina brick designed for thermal shock resistance
KAST-O-LITE 23 LI PLUS A 2300°F rated lightweight gunning mix
KAST-O-LITE® 19 L PLUS A 1900°F rated lightweight castable
KAST-O-LITE® 50-25 PLUS A 2500°F low-density insulating castable
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
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
LADLE SL TANK A magnesia carbon brick
LO-ABRADE® GR PLUS A 2600°F dense, abrasion-resistant, gunning castable
LOTHERM® RK High Strength Insulating Brick - 101 pcf
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
NARCOGUN® 50 BG A 50% alumina gunning mix
NARCOGUN® 70 BG A 70% alumina gunning mix
NARCOGUN® BSC-DS A trough gunning mix
NARCON® 65 CASTABLE A 65% alumina, low-cement castable
NARCON® 70 CASTABLE A 70% alumina, low moisture castable
NARCOTUN® 72 A 72% magnesia, dry, heat setting vibratable
NARCOTUN® 83 A 86% magnesia, dry, heat setting vibratable
NARCOTUN® 83XH A 87% magnesia, dry, heat setting vibratable with an extra hard bond
NARCOTUN® 87 A 87% magnesia, dry, heat setting vibratable
NAREZ AM5 A magnesia carbon brick for Basic Oxygen Furnace Linings
NARMAG EAF RAM Magnesia-Chrome-Alumina based, Heat-Setting, Ramming Mix
NARMAG® 60 DB A direct-bonded, 65% magnesia, 18% chromia burned brick
NARMAG® 95 CASTABLE A 95% magnesia castable
NARMAG® FG A 19% chromia, rebonded fused-grain magnesia-chrome burned brick
NARMAG® HRB A 97% magnesia, burned brick
NARMAG® L MORTAR A magnesia dipping mortar
NARMAG® MORTAR HEAT SET A basic mortar
NARPHOS® 90R RAM MIX A high-alumina ramming mix
NARSPRAY® M-77 A 77% magnesia, ultra-lightweight spray mix
NARTAR® 7 A magnesia, pitch impregnated burned brick
NARTAR® XR A magnesia, pitch-impregnated burned brick
NISIC 20 A nitride bonded, silicon carbide brick
NO. 36 REFRACTORY CEMENT A wet, air setting, high alumina mortar
NOZZLE SET 90P High Purity Alumina chemical bond wet mortar
ON-LINE® 70G A 70% alumina, rapid turn-around, low-cement castable
PHANTUM® XL127 A magnesia carbon brick for steel ladle applications
PHANTUM® XL148 SUPER A magnesia carbon brick for steel ladle applications
PLASTECH® 50P STD A 50% alumina, phosphate bonded refractory plastic
PLASTECH® 70P STD A 70% alumina, phosphate bonded plastic refractory
PLASTECH® 85P STD An 85% alumina, phosphate bonded plastic refractory
PLASTECH® 90P FINE A fine grained, 90% alumina, phosphate bonded refractory plastic
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
PRISM® DC High Alumina (96%), Cast Fired Shapes
RENEGADE® BL8H A magnesia carbon brick for steel ladle applications
RENEGADE® XL10F A magnesia carbon brick for steel ladle applications
RUBY® RAMMING MIX A phosphate-bonded, alumina-chromium ram mix
RUBY®190 KSV MORTAR An alumin-chrome mortar
S142® A semi-rebonded 64% magnesia, 17% chrome burned brick
S145® A semi-rebonded 60% magnesia, 20% chrome burned brick
SCHIEBERSAND® BO-2 A dry, granular low-carbon material used for well fill for slide gates.
SENTINEL® RC PLUS A portland cement bonded, high strength, general purpose castable
SFG® A 21% chromia-containing, rebonded magnesia-chrome brick
SFG®-US A magnesia-chrome brick
SHAC ADTECH® An extra-high-alumina castable
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
SHOTKAST® HMC A high-alumina shotcast castable
SHOTKAST® TRW A shotcast trough castable
SILSET An air-set silica mortar for coke oven brick
SLID® An 18% chromia, magnesia-chrome burned brick
SUPER HYBOND® 60 PLUS A 60% alumina, mullite, air-setting, plastic refractory
SUPER HYBOND® PLUS A high-strength, air-setting, super-duty, plastic refractory
SUPER NARTAR® R A magnesia carbon brick for Basic Oxygen Furnace Linings
T-WELL 80 A high alumina, fine graind tamping mix
TAP-312 AS A Mag-Carbon mix for hydraulically-pressed taphole segments.
TAP-322 AS A Mag-Carbon mix for hydraulically-pressed taphole segments.
TAP-332 AS A Mag-Carbon mix for hydraulically-pressed taphole segments.
TAP-332 F A Mag-Carbon mix for hydraulically-pressed taphole segments.
TAP-431 AS A Mag-Carbon mix for hydraulically-pressed taphole segments.
TAP-432 AS A Mag-Carbon mix for hydraulically-pressed taphole segments.
UFALA® A 60% alumina brick shape
UFALA® A 60% alumina brick shape
UFALA® MCR A 60% Alumina - Andalusite Brick Shape
UFALA® XCR A 60% Alumina - Andalusite Brick Shape
UFALA® XCR A 60% Alumina - Andalusite Brick Shape
UFALA® XCR A 60% Alumina - Andalusite Brick Shape
ULTRA-EXPRESS® 70 A 70% alumina, free flowing, ultra-low cement castable
ULTRA-GREEN® 57A A 57% alumina, andalusite base, ultra-low cement castable
ULTRA-GREEN® 60 PLUS A 60% alumina, low cement castable
UNACAST® 1005X An 80% alumina, thermal shock resistant, pre-cast shape
VARNON® AH Air Ram (53% Alumina) Fireclay Brick
VERSAFLOW® 45 C PLUS A coarse, fireclay-based, low-cement castable for high-abrasion environments
VERSAFLOW® 45 PLUS A fireclay based, low-cement castable
VERSAFLOW® 55/AR C PLUS A 55% alumina, coarse aggregate, low-cement castable
VERSAFLOW® 57A PLUS An andalusite containing, low-cement castable
VERSAFLOW® 60 PLUS A 60% alumina, low cement castable
VERSAFLOW® 70 C PLUS A 70% alumina, coarse aggregate, 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

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