25/11/24

Successful Shotcast Deployment at ThyssenKrupp Steel’s Hamborn Blast Furnace

INTOCAST AG, in collaboration with PRG, successfully applied a protective lining to the upper blast furnace shaft at ThyssenKrupp Steel’s Hamborn HO-8. This intricate operation used advanced Shotcast technology and was completed ahead of schedule, demonstrating the power of effective teamwork and innovative solutions in industrial maintenance.

The task involved applying a dense concrete lining to the furnace’s upper shaft to protect the cassettes located just below the furnace top. With a tight time window and the complex conditions of a 40-meter-high platform, precision was critical.

Shotcasting, a highly developed technique, involves using a remote-controlled system to apply a dense concrete lining in 360° layers. Unlike traditional gunning materials, Shotcast uses less water, resulting in lower porosity, greater strength, and extended service life for high-temperature environments like blast furnaces. Equipped with high-pressure pumps and a specialized hardening agent, the process ensures a durable repair while minimizing downtime.

INTOCAST partnered with PRG, a subsidiary of the Pirson Group and a renowned expert in installing blast furnace refractories. Leveraging PRG’s advanced evaluation methods, including drone technology for precise damage assessment, the team worked closely with ThyssenKrupp Steel to plan, execute, and deliver this project. Multiple technical meetings and meticulous planning focused on safety, timing, and execution. Using a mobile crane, the equipment was transported to the platform, where PRG’s shooter was set up. The remote-controlled system then applied the protective layer with a feed rate of 7.5 t/h.

Thanks to seamless coordination and the use of innovative technologies, the project was completed ahead of schedule, with the platform returned clean and operational to the client. The reinforcement ensures increased furnace efficiency, reduced downtime, and extended service life—a win-win for ThyssenKrupp Steel.

This success underscores INTOCAST’s commitment to precision engineering and customer satisfaction. With EXPERT partners like PRG, the company continues to deliver effective solutions tailored to complex industrial needs.