Mini Mill Solutions

Facilities and expertise to provide your mini mill services

RENO Refractories, Inc. is uniquely positioned to provide value to the Mini Mill steel industry.  Our refractory experts have diverse backgrounds in refractory applications and mini mill steel operations, and as a team, we can evaluate all aspects of your operation and recommend the safest, most cost-effective refractory systems available.  Our product offering spans conventional bonding systems up to and including RENO Refractories, Inc. Nano-Bond systems (both sol gel and our novel Electrolyte-bond technology). Our newest developments provide for the highest performing refractory systems available.   We specialize in unique offerings such as, cement-free sol gel bonded gunite, and cement-free precast technology.  Let our experts work with you to develop a world class refractory program.

RENO Electro Coatings and Maintenance Products

TUNDISH INTERIORS can be maintained by brushing or spraying a thin layer of RENO ElectroCoat ™ SP over the cleaned hot- face surfaces. This new coating contains all pure alumina /magnesia spinel minerals and will provide a natural hot-face maintenance surface refractory or tundish linings.

RENO ELECTRO SHELL COAT is a product that employs radiation heat wave deflection and bending characteristics. In many ladles, the design company does not provide enough space for the refractory to fully do its job. Many ladles are simply too thin-walled and are configured in2.5” to 4.5” thicknesses. The new product, RENO Electro Shell Coat, reduces the steel shell temperatures to help reduce ovality and flexing due to soft hot-steel shells.

RENO ELECTRO PETRA LINE is a marriage of our Electro bonding technologies and new spherical shaped aggregates. Spheres are the perfect shape for particle packing and can produce refractory products that are many times stronger and with much lower porosity than those produced using aggregates that are formed then crushed to expose internal cavities and rough jagged edges. These two technologies combined make one of the strongest and most stable refractory product. Although the water contents are reduced below 4.3%, the product flows as easy as self-leveling, self-flow products, which require 6.0 to 6.5% water for the same flow rates. RENO ElectroPump ™ Petra 70 can be placed in hard to flow areas such as the ladle safety lining or tundish safety linings to a 3.0 – 41⁄2 inch thickness.

Electric Arc Furnace

ELECTRIC ARC FURNACE DELTAS RENO ElectroCast ™ 86/with Large Aggregates. RENO’s new technology eliminates the lower temperature glass formations of calcium/aluminate cements and silica combinations. Open porosity allows the hot iron oxide gasses to penetrate and convert any free silica contained in the refractory to be converted into ferro-silicon metal. This then exfoliates and expands to degrade the refractory structure from the inside out. ElectroCast  ™ 86, made.

ELECTRIC ARC FURNACE SLAG ROLLSPre-Cast Slag Rolls made with RENO ElectroCast ™ FM – CR, can last longer than the current Graphite Electrodes. Coupled with the extreme high cost for the electrodes, this saves time and money. with all pure silica free minerals, eliminates these reactions for higher hot strengths in the erosion area near the exhaust port. The higher hot strengths and increased stability at high operating temperatures allow the refractory to perform longer. This longer life reduces maintenance costs and can increase production if a lost heat is recovered.

BENEFITS OF EXTENDED WATER PANEL LIFE RENO ElectroCast ™ FST / 4% HCA Fibers reduces the heat contacting the water tube, exhibits an electrical charge to repel arcing, reducing extreme metal fatigue, and extending the life by 200-400%. The additional panel life pays for the investment in this new refractory technology.

CONSTEEL HOODS With continuous melting furnaces that employs the heat energy drafted from the furnace over the steel scrap, the vibratory feeder units are designed with covered hoods. Normal steel scrap generates excess iron oxides that penetrate the refractory surfaces and reduce service performance and life. Some furnace operations will use the lower cost “shavings and borings” from machining operations, to lower their steel unit scrap costs. These borings and shavings are contaminated with cutting oils that ignite in the hot gas environment, and form flame torches inside the covered hoods. The flame impingement and excess heat coupled with the porosity in most refractory products drive the iron oxide laden gasses deep into the structure and shorten the performance life of the refractory products used in these units.

RENO has addressed this successfully with our gunned insulation, RENO GN 25 LW, which reduces energy losses and with a hot-face lining of our RENO NC 85, and finally a surface treatment is applied using our RENO Coat IT AL as a super-tough surface sealant. The insulation and hot face refractories are dried to 900° F / 482° C.

After cooling, the surface is treated with (2) 1/8” layers of RENO Coat IT AL, which provides a nano-tech coating that penetrates the surface pores and forms a white-ceramic surface that prevents the oxide infiltrations and re-directs the radiation energy.

Sparkbox

SPARK BOX AND GAS OFF-TAKE Many plants suffer erosion and refractory lining failure in these areas as the typical refractory products cannot resist the rapid heating conditions when new. Cement bonded refractories, typically have very low permeability characteristics at temperatures below250°F, (2-3 Millidarcies.) These tight structures cannot allow the steam gasses to escape readily and the end result is a shattered infrastructure with micro cracking. The surface pore sizes for cement products after drying and heating will range in sizes of 20-30 microns. This leads to open porosity and infiltration of the dust and contaminated gases existing in the furnace. We have addressed this with the use of RENO Jet Cast NC 85. This product has low permeability at 250°F, of approximately 40 Millidarcies, and the final pore size openings at operating temperatures are 2-3 microns in size. This allows for the rapid heat up at the onset of installation and then an acting sealant of the surfaces to inhibit vapor penetrations. For these reasons, our products have consistently outperformed all cement bonded products.

Tundish Linings 

TUNDISH LININGS Traditional Tundish Refractories consist of an insulation layer + safety lining cast with a low or ultra-low cement castable, and a hot-face with a dry vibrated or sprayed on magnesia refractory surface of 2-21⁄2 inches. The hot face refractories are replaced after each campaign, at a high cost. RENO’s new ElectroCast™ Technology exhibits extreme low permeability and high hot strengths.

Our design includes:

  • Removal of all steel anchors; the top flange is sufficient for holding the refractory
    inside the tundish box, and is similar to brick linings.
  • Sand Blasting of the steel shell.
  • Spray a 1⁄4” Layer of RENO Electro Shell Coat for Insulation.
  • Install a 41⁄2” layer of 70% bauxite brick for the walls and floor safety lining.
  • Cast the Hot-Face lining with our RENO ElectroCast™  FST in the floor and lower
    walls.
  • Cast a 12-14” band around the top with RENO ElectroCast™  FM-CR to protect the slag line.
  • Maintain the hot-face with a periodic layer of RENO ElectroCoat SP and after 4-6 months, veneer cast using the
    RENO ElectroCast™  FST and RENO ElectroCast™  FM – CR.

By lining the tundish with our RENO ElectroCast™  FST product for the floor and lower walls then installing an upper wall–Slag-Line with RENO ElectroCast™  FM/CR, the tundish can operate without a sacrificial maintenance refractory. This will save several hundred thousand dollars per year. Also, the actual hot-face refractory covering allows slags and vapors to infiltrate the slag lines and the areas adjacent to the snorkel entrance. The RENO-System for ElectroCast™ and ElectroCoat will prevent or greatly reduce this required maintenance issue.

TUNDISH MAINTENANCE Refractory surfaces are kept slick and clean with our RENO ElectroCoat SP. This is a pure magnesia and magnesia – alumina spinel refractory surface treatment which displays almost zero permeability. This surface treatment keeps the steel clean and reduces nozzle clogging. A 3mm to 6mm layer is all that is necessary.

TUNDISH IMPACT & TURBULENCEINHIBITOR Turbulence Inhibitors are tasked to provide a consistent calm pool inside the tundish. The RENO ElectroCast™  Petra 70 product has a higher temperature resistance will maintain its shape and durability under the snorkel stream. RENO ElectroCast ™ FM -CR can be used for end to end charging and pure impact pad resistance.

TUNDISH COVERS RENO makes the best tundish covers, which are made from proprietary engineered system of internal reinforced refractory which remains stable, straight, and long lasting. These pre-cast covers are made with our RENO ElectroCast ™ 86 & 3% HCA Fibers.

Ladle Linings 

LADLE WELL BLOCKS & POROUS BLOCKS Ladle Well Blocks and Porous Blocks must last in accordance with a balanced refractory life according to the bottom, walls, and slag line changes. If the opportunity exists whereas a longer lasting block system can extend the campaign before changing, then the reduced stresses may add additional life for the walls and slag line, etc. Post mortem examination revealed steel and slag wetting with all known refractory structures due to the liquid steel pressure forced into any open porosity of the refractory structure. RENO’s new technology products like, RENO ElectroCast ™ FM/CR exhibits high hot strength and extremely low porosity and permeability at operating temperatures, and will increase the durability for the block, or reduce the patches required to obtain the balanced number of heats.

RENO ElectroCast ™ FST can be used to cast around the well blocks and porous blocks as well as a hot-patch product.

PRE-CAST LADLE BOTTOMS With the new ElectroCast ™ Technology, more life can be achieved due to its superior mineral synthetization and bonding strength, and resistance to high pressure erosion. The two products for this application will be RENO ElectroCast ™ FST for the bottom, and RENO ElectroCast ™ FM-CR for the impact zone.

Ladle lip ring applications

LADLE SAFETY LININGS Safety linings must tolerate multiple campaigns of hot face brick repairs and replacements. Mullite minerals do not perform as well as bauxite compositions in these applications as sometimes the dolo-brick may be missed, and molten steel touches the safety lining for one heat. RENO ElectroCast ™ Petra 70 will form a super-strong and trouble-free safety lining behind the hot-face bricks to even out any shell deformities or ovality in the steel ladle. A smooth and even surface allows brick layup to be tighter for greater sealing characteristics.

BRICK RETAINER RINGS RENO’s Pre-Cast shapes manufactured with our RENO Guard Technology is recommended. This concept uses a high concentration of steel fibers and a refractory slurry. These Retainer Rings can tolerate extreme abuse from de- scale equipment and thermal shock conditions to keep the brick linings tight and under compression.

LADLE COVERS These covers are cast and dried without RENO ElectroCast ™ 86 and SS fibers; they are ready to put into service. Robust internal steel reinforcement and the removal of the traditional steel skin allows heat to be vent through the cover and last longer. Higher thermal flows reduce skin corrosion under and next to the bath.

LADLE LMF DELTAS RENO ElectroCast ™ 86/with Large Aggregates. RENO’s new technology eliminates the lower temperature glass formations of calcium/ aluminate cements and silica combinations. ElectroCast™ eliminates these reactions for higher hot strength and the lower permeability and resists vapor infiltrations. The higher hot strengths and resistance to vapors allow the refractory to last longer. This longer life reduces maintenance costs for changing and can increase production if a lost heat is recovered.

LADLE PRE-HEAT WALLS These walls must endure countless heating and cooling cycles. RENO NC Gun 70 with 3% SS fibers can take years of abuse without damage. RENO holds a USA / Canada / Mexico / EU patents for this new technology. Rather than use large equipment for shot-creteing, our NC Gun products can provide equal or better results as shot-crete installations but does not require the expensive and large bulky equipment for the installation job. RENO NC Gun 70 is recommended for this application as it is a pure mullite, no-cement, sol-gel technology that is thermally stable and can withstand more heating and cooling cycles than traditional gunned or cast products.

Reheat Furnace Hearths 

REHEAT FURNACE HEARTHS High Alumina Fused Blocks are often laid in rows with an economical castable pump-cast in between. These blocks must be inventoried and secured at a high cost. RENO ElectroCast ™ SB will perform equally to the electro-fused blocks as the bond strengths are so strong and the permeability so low that the mill scales do not stick to these blocks or to the castable, RENO ElectroPump Petra 70, placed between the rows of skid blocks. Quick turnaround time and long lasting hearths will result in higher quality steel production at a lower overall cost.

Miscellaneous Linings 

LADLE LMF DELTAS RENO ElectroCast ™ 86/with Large Aggregates RENO’s new technology eliminates the lower temperature glass formations of calcium/ aluminate cements and silica combinations. ElectroCast ™ eliminates these reactions for higher hot strength and the lower permeability and resists vapor infiltrations. The higher hot strengths and resistance to vapors allow the refractory to last longer. This longer life reduces maintenance costs for changing and can increase production if a lost heat is recovered.

VACUUM DE-GAS HOODS These hoods can experience splashed metal and slag during the alloying process. We recommend our new Forsterite product for covers, RENO ElectroCast ™ FST / LA for these applications.

SLAG POT PROTECTION For many years, RENO has supplied a slag-pot coating and spray equipment system for maintaining a slick pot coating for smooth slag ejections. Our product, RENO Blak ICE 2, is not the typical clay / water mixture. These products typically crack and flake and do not tolerate the occasional steel incursion into the slag pots. The methods required to un-stick pots that rely on the low cost products, many times result in damage to the cast iron pots, which require extensive welding repairs. Our productis a silica/carbon composition with lower water and porosity to provide a stable coating and surface sealant. Many operators exclaim the virtues for the non- stick surfaces which allows consistent and easy slag expulsions.

Mini Mills Products and Applications

ApplicationProduct
Water Panels in EAFRENO ElectroCast™ FST / with 3% HCA Fibers or RENO Pipe Shield CR
Deltas for EAFRENO ElectroCast™ 86/with Lg. Aggregates
Slag Rolls for EAFPre-Cast made with RENO ElectroCast™ FM- CR
Con-Steel CoversRENO GN 25 LW + RENO NC 85 + Coat it AL
Tundish LiningsRENO Electro Shell Coat + 70% Safety
Brick+ RENO ElectroCast™ FST / RENO
ElectroCast™ FM - CR
Tundish MaintenanceRENO ElectroCoat SP / RENO PL 349- CRM /
Veneer Cast each (6) Months
Tundish Turbulence InhibitorPre-Cast made with RENO ElectroCast™ Petra 70 / Petra 85
Tundish CoversPre-Cast made with RENO ElectroCast™ 86
/ Large Aggregates / 3% HCA Fibers; after
baking, a 1/8” layer of RENO ElectroCoat
SP is applied
Ladle Well BlocksPre-Cast with RENO ElectroCast™ FM - CR
& Porous Blocks Maintained with RENO
ElectroCast™ FST
Ladle BottomsPre-Cast with RENO ElectroCast™ FST / Lg.
Aggregate + RENO ElectroCast™ FM - CR
Impact Zone
Ladle Insulation3/16 Inch of RENO Electro Shell-Coat
Ladle Safety LiningsCast with RENO ElectroPump™ Petra 70, or
Shot-crete with RENO ElectroPump™ Petra
70 / with Pre-Diluted Sodium
Silicate
Ladle Hot-Face WallsRENO ElectroCast™ FST
Ladle Hot-Face Slag-LineRENO ElectroCast™ FM - CR
Ladle Lip Retainer RingsPre-Cast Shapes made with RENO Guard
Technology
Ladle CoversRENO Cast 8067 with 4% HCA Fibers
LMF DeltasRENO ElectroCast™ 86 / Large Aggregates
Vacuum De-Gas HoodsCast with RENO ElectroCast™ FST / LA
Reheat Furnace HearthsPre-Cast Skid Blocks made with RENO
ElectroCast™ SB, and RENO ElectroPump™
70
Reheat Furnace Side WallsInsulation – RENO Lite Gun 40 / Hot Face
RENO Jet Cast 66, after water removal,
spray 1/8” of RENO ElectroCoat SP to reflect
radiation back into the steel
Spark Box and Gas Off-TakeRENO Jet Cast NC 85
Ladle Pre-Heat WallsRENO NC Gun 70 / with 3% HCA Fibers
Slag Pot Surface SealantRENO Blak ICE 2

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