Technical Paper


www.ireng.org


Figure 7: Rotary dryer for minerals


Over the 6 years as part of the BH-F group sales increased with a focus on the glass industry, export and specifically sales to the US.


1992 marked a milestone for the company with the celebration of the Centenary; 100 years of manufacture.


This was shortly followed in 1993 by the break-up of the B-HF group and DSF became the subject of a management buyout. The name was subsequently changed to DSF Refractories & Minerals Ltd; not only to distinguish the new company but also recognise the mineral processing section of the business which accounted for between 30-35% of turnover.


The 90’s saw a decline in DSF’s steel industry sales with basic steel ladle bricks gaining prominence over siliceous and high alumina compositions. The focus moved to the glass industry with many new products developed.


The sand pits which had been the foundation of the company were closed; nature took over and these are now designated sites of scientific interest for flora and fauna.


The Present


The new millennium saw a second buyout of DSF with ownership resting with the executive directors since 2003.


This MBO heralded a period of dynamic growth and investment, building on many years of work with major glassmakers and furnace designers worldwide and extensive product development.


In just a few years, DSF have commissioned two new kilns; an intermittent 1700°C kiln; the largest of it’s type in Europe and a 1500°C kiln that has added a further 4,000 tonnes per annum to firing capacity.


New grinding equipment has been installed; a triple head, state of the art Wassmer fully automatic grinder along with smaller single head grinders thus increasing the production capacity for large ground glass tank subhearth, tin bath and insulating blocks, forehearth roof and channel blocks.


In 2006 a strategic decision was made that the company should grow to avoid stagnation; with sales restricted by the available capacity at the Friden site (despite investment) in conjunction with lost sales for some of the more


22


Figure 8: Mr Derek Whelpton (former MD) and the 11th the Centenary Celebrations


Duke of Devonshire at


standard compositions, it was decided to create a manufacturing presence in China; a WOFE (wholly owned foreign enterprise).


A suitable site was found in TEDA in Tianjin just 2 hours from Beijing; the official opening of “DSF Refractory Materials (Tianjin) Co.Ltd” was in April 2009.


Due to several negative impacts on the Chinese business, some imposed and some market driven; DSF closed operations in 2012, although the Chinese developed/manufactured products were of a high standard and accepted in the very conservative refractory sector for glass manufacturing.


This has not however discouraged the company to seek penetration into new markets utilising a combination of both innovative and “traditional” materials.


In recent years DSF has become a significant supplier to the carbon black industry and is now acknowledged on a global basis.


Carbon black is ubiquitous; present in all things black from pigments to tyres, it is manufactured at extreme temperatures (1870-1900°C) from the incomplete combustion of heavy oil products.


DSF are known as problem solvers and using this philosophy for the carbon black market new spinel materials have been introduced alongside traditional pure alumina (99.7%), albeit in the latter case DSF have revolutionised design and operation by the introduction of a cast and yet thermally shock resistant material; ideal for the water quench section of carbon black reactors.


Over the last few years DSF have researched the petrochemical market and whilst this is an “ultra” conservative market sector for refractories, DSF have become an established name in conjunction with the commencement of supply.


The Future


An outside perspective of Friden would conclude that DSF has few advantages. A rural location, DSF is far from decent transport links, nearly all raw materials are imported and 2/3 of production is exported; there are no super- efficient automatic presses working in conjunction with robots


ENGINEER THE REFRACTORIES September 2017 Issue


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