ROGESA Partners with SMS Group for Comprehensive Blast Furnace Modernization
ROGESA Roheisengesellschaft Saar GmbH, a leading steel producer based in Dillingen, Germany, has taken a significant step to modernize its Blast Furnace 4 in collaboration with SMS Group. This comprehensive upgrade aims to prolong the service life of the furnace, ensure its operational efficiency, and improve the monitoring of its hearth lining, a crucial component for high-temperature iron ore reduction. The project is set to be completed by the third quarter of 2025, with a short shutdown time of only 55 days, minimizing production disruption.
Modernization Driven by Urgent Wear Analysis
The need for the modernization stems from measurements taken in 2023, which showed that wear on the hearth of Blast Furnace 4 was advancing more quickly than initially anticipated. The analysis revealed that the remaining wall thickness of the hearth was nearing the wear limit, signaling the urgent need for a reliable upgrade to avoid potential operational failures. With the furnace originally built in the late 1970s and having undergone an enlargement and reline by Paul Wurth in 2003, this modern update ensures its continued productivity.
Technological Upgrades: Hearth Lining and Sensor Probes
As part of the contract, SMS Group will supply Paul Wurth hearth lining technology, which includes the use of carbon blocks, ceramic cups, and refractory materials that are known for their durability and reliability under extreme conditions. The new hearth lining is designed to withstand the intense physical and chemical stresses inside the furnace, including:
• Exceptional thermal insulation, which is essential to maintain the high temperatures needed for iron ore reduction.
• Corrosion resistance, preventing damage from chemical reactions with molten iron and slag.
• Structural support, which helps maintain the furnace's shape under significant mechanical stresses.
Additionally, SMS Group will install multi thermocouple sensor probes to continuously track the condition of the hearth lining. These sensors provide precise data on wear and temperature changes, allowing for real-time monitoring and ensuring enhanced operational efficiency. This technology will help ROGESA improve furnace performance and reduce the risk of unplanned shutdowns, ultimately contributing to more sustainable and reliable operations.
Blast Furnace 4: Operational Capacity and Past Maintenance
Blast Furnace 4 has a usable volume of 2,460 cubic meters and a daily production capacity of 6,400 metric tons. The furnace has been a crucial part of ROGESA’s operations since its construction, and the last reline was carried out in 2016. Given its critical role in the production process, maintaining the furnace’s operational integrity is essential to ensure continuous steel production without major interruptions.
The upgrades planned by SMS Group are tailored to improve the furnace's longevity, ensuring it remains a key asset for ROGESA for years to come. The strategic timing of the upgrades also highlights the need for proactive maintenance to prevent unplanned downtimes, which could have costly consequences in a steelmaking environment where uptime is critical.
A Long-Standing Partnership Between ROGESA and SMS Group
This modernization project is an extension of the long-standing relationship between ROGESA and SMS Group. The two companies have collaborated on various projects in the past, including work on hot blast stoves and refractory-related solutions, reinforcing their trust and mutual respect. SMS Group has built a reputation for its flexibility and prompt responsiveness, making it a reliable partner for ROGESA in addressing critical operational needs.
Martina Engelmann, the project manager at SMS Group, expressed her enthusiasm for continuing the partnership with ROGESA, stating, “We are delighted to continue our collaboration on this important project. Our advanced hearth lining technology will enable ROGESA to extend the life of their furnace, operate more safely, and prevent forced shutdowns.”
Dr. Jürgen Hochhaus, the operations manager of the blast furnace department at ROGESA, emphasized the importance of SMS Group’s expertise, saying, “We greatly appreciate SMS Group’s flexibility and prompt responsiveness to our requests. Their expert solutions, particularly in hearth lining and multi thermocouple sensor probes, ensure the durability and safety of our operations.”
Strategic Impact and Future Outlook
The modernization of Blast Furnace 4 underscores the importance of proactive maintenance and technological innovation in the steel industry. By investing in advanced materials and precision monitoring systems, ROGESA is ensuring that its furnaces continue to operate at peak efficiency, even in the face of evolving challenges in the global steel market. The upgrades to the furnace's hearth lining and the integration of the multi thermocouple sensor probes will provide ROGESA with a competitive edge in an industry where cost-efficiency, safety, and sustainability are becoming increasingly vital.
By extending the life of Blast Furnace 4 and improving monitoring capabilities, ROGESA is poised to maintain high production levels while minimizing operational disruptions. The project also reflects the growing importance of collaborations between steel manufacturers and technology providers to drive sustainability, reliability, and operational excellence in the steelmaking process.
