According to a press release from Kametstal, the converter shop of the enterprise, part of the Metinvest Group, has achieved a record service life for the lining of converter No. 2. While the guaranteed refractory life is 4,500 heats, the actual result reached 5,815 heats—a 29% increase. The economic impact of implementing this solution on a single unit exceeds $440,000. This demonstrates the practical value of technological improvements in enhancing the efficiency of steelmaking operations.
Factors Driving the Increase in Refractory Life
A key factor was the implementation of a new technology for forming a protective slag coating, developed by the plant's refractory and thermal engineering department. Instead of raw dolomite, magnesium flux was introduced into the process, allowing for the formation of a more uniform and stable protective layer. As a result, local wear on the lining decreased, and the risk of burn-throughs, which previously shortened the maintenance cycle, was significantly reduced.
Additional benefits came from a substantial reduction in material consumption. Previously, 5-6 tons of dolomite were used per heat; after switching to the new approach, consumption dropped to approximately 700 kg of magnesium flux. Furthermore, the need for additional material calcination was eliminated, positively impacting energy consumption. Crucially, the slag began to form a dense protective layer on the converter walls rather than eroding the refractory lining.
To monitor the unit's condition, the enterprise utilizes laser scanning of the converter's internal surface. This approach allows for the creation of a 3D model to accurately assess the thickness of the protective layer in different zones. This makes the slag coating process more manageable based on heat parameters, unit condition, and iron quality. A similar solution is already being applied to converter No. 1, indicating the potential for scaling the technology.
Impact on the Steel Market and winox.ua Solutions
For the steel market, these changes hold both operational and economic significance. Extending the lining life, reducing unit costs, and lengthening maintenance intervals directly affect the cost of steel production and the stability of equipment utilization. Consequently, the manufacturer gains additional flexibility in production planning and enhances its competitiveness. For consumers, this translates into more predictable supplies and reduced sensitivity to production disruptions.
In such a market environment, the reliability of the metal supply chain becomes paramount. As a supplier of rolled metal, stainless steel, and non-ferrous metals, winox.ua focuses on maintaining a stable inventory and ensuring product quality for industrial clients. When metallurgical plants implement technologies that reduce costs and improve production predictability, it creates better conditions for the entire B2B market. For its part, winox.ua offers certified rolled metal and carefully selects manufacturers according to modern industrial requirements.
Notably, Kametstal is concurrently implementing a capital repair program for its main equipment for 2026, with the overhaul of converter No. 2 being the first major stage. This indicates that the enterprise is combining specific technological improvements with systemic modernization of its production base. For the Ukrainian metallurgy sector, such practices are vital as they simultaneously improve the efficiency, reliability, and lifespan of equipment. In the long run, these solutions form the foundation for more sustainable metal production and a competitive rolled metal market.