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Plant Tour: Höganäs Bjuf Refractory Plant – part two

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World Cement,

A new range of monolithics

Monolithic products are to be manufactured in Höganäs Bjuf’s new facility in Bjuv. As stated, the factory has a total area of 1000 m2 and a capacity of 30 000 tpy. It is highly automated with the most modern refractory equipment available to the market.

The starting point for producing the monolithic product is the careful selection of the raw material, composed according to a very specific recipe. This material is moved into swap containers that transport the material into batch preparation silos for weighing and dosing. At this stage in the process small amounts of additives, occasionally as small as 20 g per t, are manually added to the blend. The product is then moved into the quick lift mechanism for mixing. The mixing stage is a critical step in the monolithic production process as Höganäs Bjuf desire the mix to be as homogenous as possible. The Eirich intensive mixer, where parameters like pan and tool speed can be specifically set, ensures excellent homogeneity.

The monolithic product is then packed into big bags using a Vebe Technik big bag filler or moved for Autopac filling (25 kg). ABB supplied the electronics for the bagging mechanics. The bagged product is then covered in a stretch hood using a Lachenmeier stretch hood machine, and transported by Lyftab conveyors into the warehouse for shipping.

The new Höganäs monolithic product range consists of four product families. Depending on the customer’s requirements, these products can be installed through vibration, self-flowing gunning, pumping and shotcreting.

The four product families and their respective qualities are outlined below:

– Höganäs Conventional

  • Robust range of products for customers with a wide range of applications.
  • Less sensitive to climatic variations (setting time) and application mistakes (water addition).
  • Multipurpose mixes; castable, pourable, and gunnable.

– Höganäs Ultra Low Cement

  • Based on the latest surfactant and bonding matrix technology.
  • Even distribution of binder even at low level.
  • Superior high-temperature properties including higher hot strengths due to less CaO in the matrix.
  • Less reactive with a variety of melts and slags at elevated temperatures.

– Höganäs Low Cement

  • Well-designed, homogenous mixes with improved mechanical and thermo-mechanical properties.
  • Very short wetting and mixing time, less risk of adding excessive water during applications.
  • Multipurpose mix technology for casting, self-flowing, rodding, pumping and shotcreting.

–Höganäs No Cement

  • Designed with nano-bond technology.
  • Fast setting and rapid heat-up due to strong permeability, leading to shorter drying time.
  • Strong mechanical and thermo-mechanical properties.

The end of the guided tour marked the beginning of production for Höganäs Bjuf at the new facility. The monolithic line was officially put into production on 1 September, christened by the breaking of a sacrificial bottle of champagne on the main mixing tower by Ann Calven, a employee of the company for over 40 years.

This is part two of a three-part article written for World Cement’s December issue and abridged for the website. Subscribers can read the full December issue by signing in, and can also catch up on-the-go via our new app for Apple and Android. Non-subscribers can access a preview of the December 2016 issue here.

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