SMS group optimises durability of blast furnace 4 at ROGESA

Blast furnace 4 at ROGESA

Germany-based ROGESA Roheisengesellschaft Saar GmbH, has commissioned SMS group to carry out a comprehensive modernisation of blast furnace 4 (BF4) at its Dillingen plant which will extend its service life and ensure effective monitoring of the hearth lining. The contract includes the planning and delivery of the Paul Wurth hearth lining and multi thermocouple sensor probes (MTPs), as well as technical support during the installation phase.

The required upgrade is based on measurements taken in 2023, which indicated that the wear on the hearth of blast furnace 4 is more advanced than expected, and that the remaining wall thickness is approaching the wear limit. Built in the late 1970s, blast furnace 4 was enlarged and relined by Paul Wurth in 2003. It has a usable volume of 2,460m³ and an output of 6,400 tonnes per day. The last reline on Blast Furnace 4 took place in 2016.

For the new furnace lining, SMS plans to use Paul Wurth hearth lining technology, including carbon blocks, ceramic cups, and refractory materials, which are known for their durability and reliability. Well-designed equipment offers exceptional thermal insulation by maintaining the extremely high temperatures required for iron ore reduction.

Operational efficiency
In addition, it offers corrosion resistance by avoiding chemical attacks from molten iron and slag, and structural support by withstanding mechanical stresses and maintaining the furnace’s shape. The multi thermocouple sensor probes are designed to precisely determine and track hearth lining wear, thereby ensuring enhanced monitoring and operational efficiency.

The project is expected to be completed in the third quarter of 2025, with a shutdown time of only 55 days., and is the latest in a long line that demonstrates the long-standing relationship between SMS group and ROGESA. Previous collaborations have focused on hot blast stoves and refractory-related projects.

Martina Engelmann, project manager at SMS group in Germany, said: “We are delighted to continue our partnership with ROGESA on this important project. Our advanced hearth lining technology enables ROGESA to extend the life of their furnace, operate them more safely, and prevent forced shutdowns. After the big reline in 2003, it makes us proud to continue collaborating here in Dillingen.”

Dr Jürgen Hochhaus, operations manager of the blast furnace department at ROGESA, concluded: “We greatly appreciate SMS group in Germany for its flexibility and prompt responsiveness to our requests, which were critical to the success of this project. The company’s expert solutions, particularly its expertise in hearth lining and multi thermocouple sensor probes, will ensure the durability and safety of our operations.”