PRECAST REFRACTORY SHAPES

The company has more than 25 years’ experience as a leader in the design and manufacture of customised precast refractory shapes. With world-class production facilities, combined with licence agreements in engineering and design technology, the company has the capability to manufacture a wide range precast shapes for various applications.

Dickinson Precast Division was established in 1986, specialising in the manufacture of customised precast refractory shapes. The precast refractory shapes are manufactured off-site under controlled conditions, dried-out at our production facilities under stringent quality control measures, ensuring the manufacture of accurate moulds and final casting of special shapes to ensure an enhanced product service life. Precast refractory shapes offer the added benefits of ease of installation and shortened repair times.

Leaders in the development of applications for precast refractory shapes:
  • Excellent & State-of-the-art Production Facilities
  • Stringent Quality Control Measures
  • 3D Parametric Computer Modelling Software
  • Latest Polystyrene Cutting & Mould Design Technology
  • Overhead Cranage to Lift Large “Big Block” Precast Shapes
  • High Intensity Paddle Mixers
  • Reliable & Efficient Service
  • Ensuring Enhanced Service Life

With the latest technology available in the industry, combined with licence agreements in engineering and design technology in big block refractory precast shapes, the company has the capacity to manufacture a wide range of precast shapes for various applications. The company’s precast facility is adequately equipped with overhead cranes, that are highly capable of moving and hoisting big blocks from the casting area, to the drying furnace or load finished products onto trucks. The precast facility is well equipped and suitably designed with adequate space, enabling trucks to drive safely in and out of the facility for offloading and loading.








Furnace Applications:
  • Rotary Hearth Furnaces
  • Bogie Hearth Furnaces
  • Coke Ovens
  • Batch Furnaces
  • Boiler Plants
  • Aluminium Melting Furnaces
  • Rotary Kilns
  • Kiln Hoods
  • Precalciner
  • Sinter Plants
  • Continuous Annealing Furnaces
  • Shaft Kilns
  • Combusion Chambers
  • Power Stations
  • Walking Beam and Pusher-Type Furnaces
  • Cyclones for different applications



Furnace Applications:
  • Launders
  • Ladles
  • Burners
  • Feed Chutes
  • Bull Nose
  • TAD Damper
  • Cyclone Roofs
  • Kiln Hood Roofs
  • Cement Burner Lance
  • Coke Oven Bricks & Modules
STATE-OF-THE-ART TECHNOLOGY AND ENGINEERING

Every component is designed with the latest in 3D parametric computer modelling software and placed into mould assemblies to visually inspect the form and fit of our modules. Once our design and engineering have been reviewed and approved the designs, customers are able to view their final product and how it will be assembled before the component is manufactured.

New mould technology has also been introduced using the latest polystyrene and mould designs that employ state-of-the-art technology to produce the highest quality products for our customers. This system is much faster compared to utilizing plywood or metal moulds.



Our cutting edge technology, experience, innovation and design expertise furnishes the Division with great manufacturing flexibility and customized solutions that suit our customers’ individual needs.

The new technology includes a range of high intensity paddle mixers for much more consistent mixing with the capacity to mix from 50kg to 1000kg. The mixers have automatic water and mix timing functions. New adjustable high frequency vibrating tables able to handle big block casts, as well as a new adjustable programmable drying furnace capable of drying precast blocks from 2,5 meters to 10 meters in length.



COKE OVEN REPAIR MODULES PRODUCTION AND INSTALLATION

Dickinson Group of Companies concluded an exclusive license agreement with Vanocur Refractories LLC (USA) to manufacture and sell their patented Coke Oven Repair Modules using its patented raw material formula mix within South Africa. Our patented design technology is revolutionary in construction, quality, installation speed and performance.

Dickinson Precast Division in conjunction with Vanocur Refractories, provide a competitive advantage to clients through coke oven design and repair services. The company utilizes patented technology, the Modular Cast Block (MCB), along with personalized solutions to ensure that ovens are repaired in the most cost and time efficient manner thus adhering to and ensuring the highest quality, cost effectiveness and environmental compliance.

As an industry leader in design, repair, and installation, we are confident in the quality of our products and services. Our team, in collaboration with the client, will redesign and implement a strategy that best enhances the coke oven’s efficiency, longevity, and productivity. Our dedication to each customer and belief in the products is proof of Dickinson Group's leadership in coke oven refractory repairs and rebuilds.



Our step by step methodology includes the following:

  • Engineering
  • Mould Design & Production
  • Block Production
  • Delivery & Installation

MOULD DESIGN & PRODUCTION

Our latest mould design utilizes a combination of engineering expertise and precise CNC machinery to produce foam moulds, resulting in precise tolerances. One distinct advantage of disposable moulds is the ability to make immediate module design changes based on customer feedback.

Furthermore, all moulds are produced on CNC machines to cut down on mould manufacturing and storage costs. By cutting moulds on an “as needed” basis, we are able to make rapid design changes.

Once the mould has been designed, a three dimensional drawing file is sent to one of our CNC milling stations and the mould parts are cut from large foam blocks. Our foam moulds must pass a rigorous quality inspection before they are poured to insure the manufacture of the highest quality modules.

By automating the mould production phase the amount of time required for mould assembly has been significantly reduced. This improved process has also substantially reduced the need for unique and expensive steel mould parts, thus reducing costs and lead time.



DELIVERY

At this stage of production, the blocks are carefully measured and visually inspected one final time. Thereafter the blocks are well labelled, palletized and wrapped with a protective material. Foam inserts and wood blocking are also utilised to protect the modules during loading, shipment and delivery.



INSTALLATION

As a coke oven operator, the last thing you welcome is disruption in your operations. It is time to experience a quick oven rebuild with minimal interference. Each Big BLOCK module replaces 27 bricks, and are installed with rigging equipment replacing the cost of 60 skilled bricklayers with 10-12 in-house personnel or riggers. Also provides the benefit of significantly reducing the number of joints on the coke oven walls as 150 modules of the big blocks replaces more than 4 000 normal silica bricks.

Labour Efficiency

You can eliminate up to 2/3 of the required labour hours necessary for installation by traditional methods. The Modular Cast Block (MCB) takes the place of nearly 30 traditional silica shapes. In addition, the installation of the MCB can be done with in-house employees opposed to costly bricklayers.



Faster Installation

In addition to saving you on labour, the MCB saves time. A three month process, which can be a drain on productivity and revenues, is reduced to mere weeks. The large modular blocks, with the tongue and groove design, helps to streamline the process of installation. As the blocks are customized, the repair process becomes intuitive. The oven taper is BUILT INTO the modules. The guess work is taken out of building coke ovens. Unlike traditional silica bricks that require multiple weeks for start-up, Vanocur modules take less than 48 hours of heat up before the flues can be brought back into operation.



Safer Operations

We are all looking for methods to create a safer work environment. Historically, most accidents occur within the groups of "outside contractors" and "maintenance"; coke oven repairs fall under both of these categories. Let Dickinson Group help you rebuild your coke ovens as safely as possible. A shorter demolition and rebuild with fewer workers equals less opportunities for an accident.

What working with Dickinson Group means for you:

  • Getting 40+ years of expertise in managing critical maintenance repairs.
  • Our project managers are experienced coke oven operators who understand the challenges of the industry.
  • Massive cost savings through the years and improved battery life.
  • Streamlined installation requires 75% less manpower to complete construction.
  • Reduced operating and maintenance costs equals minimal loss of coke production and significantly reduced impact on plant profitability.
  • Maintenance free modules and reduced post-maintenance costs.
  • Increased of regulatory compliance.

Why use Vanocast?

  • Vanocast is Vanocur’s exclusive material
  • Reduces gas usage due to increased heat transfer rate over traditional silica
  • Reduces spalling and cracking due to thermal shock
  • Significantly less spraying and patching

EXCELLENCE IN DESIGN

Closed Flue Design
  • Does not allow for oven gas to flow into flue if a mortar joint fails.
  • Increased modular strength to reduce breakage blow-outs caused by stickers or overheated walls.
Horizontal Design
  • Combining the horizontal with the slider and transition courses increases the durability.
  • Decreased incidence of blow-outs, cave-ins or cracking.



SHAPES FOR CEMENT PLANTS

Dickinson Precast Division through extensive research and development; has been developing, designing, manufacturing and supplying state-of-the-art and innovative precast refractory shapes for the cement pyrometallurgical process lines for the past three decades.



The division’s range of products for the Cement Industry include the following:

  • Kiln Hood
  • Bull Nose
  • Cyclone Roofs
  • Burner Pipes
  • TAD Damper

The customised precast shapes offer the added benefit of ease of installation and shortened repair times. The complete sections are manufactured off-site under controlled conditions and dry-out at our production facilities, and stringent quality control measures, ensuring the manufacture of accurate moulds and final casting of special shapes to ensure enhanced product service life.

KILN HOOD

The company designs, manufactures, supplies and installs complete precast kiln hoods for cement plants. The scope includes structural, mechanical and refractory works. The precast kiln hood has been successfully installed on various Cement Plants for the large, global, diversified cement and lime companies in sub-Saharan Africa.














BULL NOSE

The cooler bullnose is a critical portion of the cement plant pyrometallurgical process line. The cooler bullnose must withstand extreme heat, corrosion, abrasion and erosion for efficient clinker production and sustainable availability of the production line. The Cooler Bullnose that are cast {in situ} seldom reach their full life span as they are prone to premature failure. Dickinson Group’s Precast Division has over the years custom designed state-of-the-art Precast Cooler Bullnose sections that excel in the most harsh process environments and outclass the conventional cast in situ design in both thermal, physical and chemical properties.



The unique Bullnose Design has been adopted by most of the large, global, diversified cement and lime companies in sub-Saharan Africa.

CYCLONE ROOFS

The precast cyclone roof is a breakthrough technology for eliminating casting and gunning of monolithic materials on cyclone roofs. The precast roof eliminates major problems associated with insitu gunning and casting such as material rebound wastages and heat up problems.



BURNER PIPES

Casting of Burners insitu is always troublesome for most cement plant production and process personnel, especially given the proper heat-up procedure that is a basic requirement during this process. Our company offers a remedy for this problem through precasting of burners in our in-house facilities. The burner gains all the inherent benefits associated with Precast Shapes such as casting under controlled conditions, dry-out at our production facilities, stringent quality control measures, ensuring the manufacture of accurate moulds and final casting.

SHAPES FOR NON FERROUS INDUSTRY

Dickinson Precast Division designs, manufactures and supplies specially designed and purpose built precast refractory shapes for the non-ferrous industry. The range of precast shapes includes specialty shapes for various non-ferrous smelters in the aluminium, copper and ferro-nickel industries. The shapes are modular designed under stringent quality control procedures ensuring faster and easier installation, shortened repair times and easier slag removal due to lower porosity.



The range of shapes for the non-ferrous industry include the following:



  • Sinter Hoods
  • Shaft Kilns
  • Burners
  • Launders
  • Ladles
  • Feed Chutes
  • Combustion Chambers



BENEFITS OF PRECAST REFRACTORY SHAPES

Precast shapes offer the added benefit of ease of installation and shortened repair times. Manufactured off-site under controlled conditions and dry-out at our production facilities, and stringent quality control measures, ensuring the manufacture of accurate moulds and final casting of special shapes to ensure enhanced product service life:

  • Consistent and controlled manufacturing process
  • Unique purpose developed materials and shapes for each application
  • Work done off site resulting in minimum interface with production
  • Areas of higher wear can be engineered with optimal refractory materials
  • Easier slag or dross removal due to lower porosity
  • Less down time due to quicker installation and heat-up times are minimized
  • Shapes from 1 kg to 9 metric tons, resulting in less joints and faster installation






WHY BIG BLOCK PRECAST SHAPES?

Big Block Solutions have been introduced with less joints which improves resistance to hot metal penetration and reduces gas emissions.


As a faster installation method, the new precast technology enables the installation method to be a rigging function which requires less personnel on site.



  • Large cast sections versus bricks ensures less joints and faster installation
  • Intricate shapes and purpose designed products that would not normally be possible with bricks or conventional monolithic installation methods
  • Hot repairs can be speedily done on furnaces
  • Better consistency of product and installation
  • Lower carbon footprint and emissions
  • Large modular blocks streamlines installation
COST SAVINGS

Dickinson Group understands the importance of staying competitive in a global market. Our patented product provides immediate and future cost savings.



Fewer Installers

A typical through-wall rebuild with traditional silica brick would require 60 skilled bricklayers. Dickinson-Vanocur module rebuilds average between 10 and 12 labourers/riggers.

Riggers vs Bricklayers

Unlike traditional repairs, Dickinson Group repairs do not require skilled bricklayers. Our big BLOCK modules replace approximately 30 brick, and are installed with rigging equipment. In a time where skilled bricklayers are at a premium, the installation cost can be greatly reduced by using either in-house personnel or contracted labourers/riggers.


Minimal Loss of Coke Production

Total average completion for a double through-wall replacement from push-out to charge-in is 30 days. This can be accomplished through a combination of mechanical demolition and installation of modules that are displacing approximately 30 traditional silica bricks at one time.

Reduced Post Maintenance Costs

With the use of VANOCAST, spalling and cracking due to thermal shock are greatly reduced. This translates into reduced need for spraying and patching.




GALLERY



                



CORPORATE HEAD OFFICE
Tel: +27 (0) 16 421-3720
Fax: +27 (0) 16 422-1038
Email: sales@dgrp.co.za



10 Smuts Avenue
P.O. Box 63, Vereeniging
1930. South Africa