INSULATION NEWS

Fringe Friday: All About That Refractory

HTD Size-PR LogoSometimes our editors find items that are not exactly “heat treat” but do deal with interesting developments in one of our key markets: aerospace, automotive, medical, energy, or general manufacturing. To celebrate getting to the “fringe” of the weekend, Heat Treat Today presents a Heat Treat Fringe Friday with this press release which describes the energy and sustainability benefits of a recent partnership between a supplier of refractory elements and the National Renewable Energy Laboratory.


Allied Mineral Products is providing refractory expertise on a new project that will collect and store unused renewable energy. They’ve teamed up with NREL (National Renewable Energy Laboratory) on the ENDURING project, which focuses on long-duration energy storage using heated particles. Funding was awarded from ARPA-E, a government agency advancing high-impact energy technologies in the early stages of development with the idea that some could be transformative and powerful for the future.

The process in development can collect excess electrical energy and convert it into thermal energy. With the help of refractories in a holding vessel, this thermal energy can be efficiently stored for days. When it is needed, the stored thermal energy will go through a heat exchange process and be converted back into electricity for use by commercial or residential customers.

Reducing heat loss is critical as the proposed facility would provide electricity for several days with low-cost particle thermal energy storage. Allied is also selecting innovative products for use in other areas of the proposed plant that would experience high temperatures and wear. Specimens and testing of different refractory materials are being provided by Allied in support of these goals.

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Refractory Manufacturer Completes Alabama Expansion

A Columbus, Ohio-based global manufacturer of monolithic refractories and precast refractory shapes combined two of their recently acquired facilities into one larger location.

Allied Mineral Products purchased Riverside Refractories in 2017, which included two Alabama locations – Anniston and Pell City. Allied moved the Anniston operation to the now expanded Pell City facility in hopes of better serving their local customer base in the southeast region.

Parker Morris

Upon completion of the Pell City facility, a fountain was dedicated to the Morris family (operators of the former Riverside Refractories) for their service to the refractory industry, local community and their employees. A plaque was presented to Parker Morris, one of the family members who operated Riverside Refractories for decades.

Allied has three other US manufacturing operations: Columbus, Ohio; Brownsville, Texas; and Chehalis, Washington.

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Refractory Supplier Celebrates Manufacturing Facility Expansion

A supplier of refractory products and services in North America recently celebrated the completion of its phase one facility expansion plan.

HarbisonWalker International (HWI) hosted a ribbon-cutting event at its manufacturing operations in White Cloud, Michigan, to celebrate completion of the first phase of an expansion that increases the floor space of the facility by 35%.  The project is part of a $9 million investment being made this year to significantly increase warehousing space along with the addition of new, advanced manufacturing and hydraulic press technologies.

Carol Jackson
President & CEO
HarbisonWalker International

“White Cloud is an extremely important facility that has been vital to our company and the community for more than four decades,” said Carol Jackson, chairman and CEO at HWI. “Historically, and especially in the past two years, the team at White Cloud has helped fuel our steel industry customers’ success by consistently delivering on their tremendous demand for the refractory products we produce here. We’re so proud of the great work our White Cloud employees do every day for our company and our customers.”

HWI’s White Cloud operations primarily produces refractory products that are utilized by the steel industry.

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Increasing Steel Demand Prompts Capital Investment by Refractory Supplier

A large North American supplier of refractory products and services is responding to domestic steelmakers’ increased capacity and solving their refractory challenges through several new initiatives.

Mirroring its steel customers’ investments to boost production capabilities and upgrade facilities, HarbisonWalker International (HWI) is investing to increase capacity by 25 percent in 2019 at key steel refractory facilities. In fact, approximately one-half of HWI’s capital investment dollars will have a direct positive impact on its steel industry customers. Much of the investment will be at its White Cloud, Michigan facility, which manufactures refractory products primarily for steelmakers.

HWI Announces Investments and Digital Refractory Transformation at Booth 1715; Carol Jackson, CEO, will Join Steel Industry Leaders as an AISTech 2019 Town Hall Forum Panelist
HWI Announces Investments and Digital Refractory Transformation at AISTech 2019

This is the latest in a series of capital investments that HWI has made at White Cloud over the past three years. In 2018, HWI integrated new equipment and technologies to modernize the facility.

The 2019 investment includes expansion to accommodate new warehouse and shipping space, which is being constructed with American-made steel. Additional manufacturing space will house new production technologies, including a new brick press and packaging line, manufacturing technologies that improve production efficiency and worker safety.

“The improvements will further optimize production, product quality, and delivery efficiencies for our steel customers,” said Carol R. Jackson, Chairman and CEO, HarbisonWalker International. “The new press and warehouse increase our capacity to supply our industry-leading products including mag carbon brick for steel ladles, electric arc furnaces (EAF), and basic oxygen furnaces (BOF). The new packaging line allows for increased handling safety and provides quality control benefits associated with our product.”

One year after announcing its plan to significantly invest in monolithic refractories manufacturing, HWI built and opened a new, state-of-the-art facility in South Point, Ohio in 2018. It is North America’s most technologically advanced refractories plant and one of the top globally. Featuring state-of-the-art processes and technology, the South Point plant is now fully operational and supplying steel industry products.

In addition to physical expansion and technology integration in its plants, HWI is evolving the refractory industry for the 21st century by taking a holistic approach to advancing its use of data. HWI is aggressively initiating programs to help customers transition numerous decision-making processes from experienced-based to data-based, through use of various sensor and data acquisition systems, for instance.

Through the expertise of its team and strategic partnerships with industry leaders, HWI is employing sensor technologies, such as infrared cameras, and also utilizing three-dimensional laser measurement to make digital twins of physical assets. These technologies, along with ‘edge’ software that can access datasets from various plant level sources, are helping HWI develop tools to increase product campaign life and improve worker safety. Performance data will also benefit future generations of HWI products.

The outcomes for steelmakers include closer collaboration for customized products and continuous improvement, optimizing throughput and analytical insights to find even more significant cost savings.

“HWI is working to transform data into process improvements and business intelligence that help steel industry customers work safer and smarter, with even better tools for knowledge sharing,” noted Jackson. “Combining our digital transformation with HWI’s proven products and the industry-leading expertise of our field services team, we’re effectively positioned to deliver for our steel customers today and in the future as our industries evolve together.”

HWI has also recently innovated and patented new functional product solutions that are helping steel customers further reduce downtime and increase performance. These solutions allow for faster, easier installation with improved ergonomics.

In addition to its products, HWI also provides around-the-clock support from the most extensive service team in the U.S. and offers dedicated iron and steel application specialists who provide highly customized solutions.

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Refractory Supplier Partners with Safety Equipment Provider for ECP Project

A leading supplier of monolithic refractory products recently partnered with a company that provides safety equipment for foundries to install four 166 sq ft emergency collection pits with 64 sq ft breakout inlets at a new foundry site in Warner Township, Michigan.

Allied Mineral Products is the U.S. representative for Silmeta Systems, which has installed over 500 emergency collection pits (ECP) worldwide, and the two companies collaborated in the integration of ECPs at the new facility under construction for EJ Americas, which provides metal fabrication products for  manhole covers and frames, junction boxes cleanout, monument boxes, and other related products.

During EJ’s review of the prospective suppliers for the foundry project, the team saw photos of an of an emergency collection pit (ECP). Since EPCs are new to the US market and most foundry teams have not seen them, the EJ staff was curious and wanted to know more. An ECP completely separates molten metal from any water present, eliminating the possibility of a steam explosion. The elimination of explosion risk coupled with the sizing of the pits to contain the full contents of the furnace results in no injuries or significant property damage due to furnace breakouts. After researching emergency collection pits, the leadership team decided to integrate ECPs into their new facility and contracted with Silmeta Systems, which is the only supplier of these type systems which had already installed ECPs in the US.

Allied serves as the one-stop shop in the U.S. for Silmeta ECPs, through their management of marketing, sales, and technical support in addition to producing the castables and managing construction.

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Refractory Products Manufacturer Expands with Purchase of Southern Supplier

A producer of monolithic refractory products, an employee-owned company headquartered in Columbus, Ohio, has expanded its manufacturing presence in the southeast through the recent acquisition of an Alabama refractory products supplier.

Jon Tabor, Chairman and CEO, Allied Mineral Products. Photo credit: Janet Adams/BizJournals

Allied Mineral Products, Inc., with twelve manufacturing facilities in eight countries, three precast shapes facilities, and two research and technology centers, has purchased family-owned and -operated Riverside Refractories, Inc, adding taphole clay to its line of industry-leading refractory products and extending a reach into the steel industry, including international operations. The sale includes Riverside’s Pell City, Alabama, manufacturing operation, monolithic and pre-cast refractory shapes products, refractory coatings and mortars and high-alumina and anhydrous taphole clay products.

“Riverside is a natural to join the Allied family,” said Jon R. Tabor, chairman and CEO of Allied. “They have outstanding products, expertise in the manufacture of taphole clays, a skilled workforce, and an employee-driven culture that is a perfect fit with Allied’s. After our recent acquisition of Pryor Giggey Co., which included a facility in Anniston, Alabama, Allied is poised for a significant manufacturing presence in the Southeast.”

John Morris, President of Riverside

“As the marketplace continues to be more competitive, [Riverside] realized we needed to align with a strong company to ensure we could continue to serve our customers and provide security for our employees,” said John Morris, president of Riverside. “With this sale, we know our customers and employees will benefit and that was very important to us. We are excited that Allied’s global manufacturing network and worldwide sales presence will provide a platform to market the Riverside product lines internationally. We could not be in better hands.”

“The Morris family has been a force in the refractory industry for over 60 years,” added Tabor. “We have great respect for what they have achieved at Riverside. There is great value in the brand and in the name, and we look forward to carrying on their tradition of great products and customer service.”

Riverside’s production facility in Pell City, Alabama, joins Allied’s existing U.S. manufacturing operations in Columbus, Ohio; Brownsville, Texas; Chehalis, Washington; and Anniston, Alabama.

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RHI, Magnesita Combine Creating a Leading Refractory Company

RHI and the controlling shareholders of Magnesita, GP and Rhône (“Magnesita’s Controlling Shareholders”), have reached an agreement to combine the operations of RHI and Magnesita to create a leading refractory company. The combined company, to be named RHI Magnesita, will be established in the Netherlands and listed in London.

Accordingly, RHI’s Management Board has agreed to sign a share purchase agreement with Magnesita’s Controlling Shareholders regarding the acquisition of a controlling stake of at least 46%, but no more than 50% plus one share of the entire share capital in Magnesita, pending RHI’s Supervisory Board approval.

The consideration for the 46% stake will consist of cash amounting to € 118 million and 4.6 million new shares to be issued by RHI Magnesita.

A subsequent mandatory tender offer will be launched as a result of which a maximum number of 5.4 million RHI Magnesita shares will be issued, bringing the total number of newly issued RHI Magnesita shares to up to 10.0 million. The offer will also include a cash-only alternative amounting to € 8.19 per Magnesita share.

As a result of the transaction, GP, Magnesita’s largest shareholder, will become a relevant shareholder of RHI Magnesita and will be represented on its board of directors.

Following registration of the corporate restructurings, RHI’s shares will cease to be listed on the Vienna Stock Exchange. RHI’s migration from Austria and listing in London are subject to approval by RHI’s shareholders’ meeting. The transaction is also subject to approvals by relevant competition authorities. The place of effective management will be Austria.

The transaction is expected to complete in 2017. Both companies will remain completely separate and independent until then RHI Magnesita will be a leading refractory company with an enhanced growth profile due to improved regional presence and complementary asset portfolios. RHI, based in Austria, is a global supplier of high-grade refractory products, with 2015 revenues of € 1,753 million Brazil-based Magnesita is a global provider of integrated refractory solutions, services and industrial minerals, with revenues of US$ 1,013 million (€ 914 million) in 2015

Transaction Overview
RHI AG (“RHI”) and the controlling shareholders of Magnesita Refratários S.A. (“Magnesita”), investment vehicles affiliated with GP Investments (“GP”) and Rhône Capital (“Rhône”, and together with GP, “Magnesita’s Controlling Shareholders”), announce that they have reached an agreement to combine the operations of RHI and Magnesita to create a leading refractory company to be named RHI Magnesita.

Accordingly, RHI’s Management Board has agreed to sign a share purchase agreement (“SPA”) with Magnesita’s Controlling Shareholders regarding the acquisition of a controlling stake of at least 46%, but no more than 50% plus one share of the total share capital in Magnesita (the “Transaction”), pending RHI’s Supervisory Board approval. The purchase price for the 46% stake will be paid in cash amounting to € 118 million and 4.6 million new shares to be issued by RHI Magnesita, a new RHI entity to be established in the Netherlands and listed in London. Based on RHI’s six-month volume-weighted average price (“VWAP”) of € 19.52, the implied value of the 46% stake amounts to € 208 million.

As a result of the transaction, GP will become a relevant shareholder of RHI Magnesita. The combined company’s corporate governance will be constituted on a one-tier board structure while GP will be represented on the board of directors. All RHI Magnesita shares issued as a result of the Transaction and subsequent mandatory tender offer will be subject to a minimum 12-month lock-up period.

The resulting combination will be a leading refractory company. Refractories are materials that retain their strength at high temperatures and are used in various industrial processes in the steel, cement, nonferrous metals, glass and chemicals industries. The combination will bring under one roof two complementary businesses, both in terms of products and geographical footprint. RHI, based in Austria, is a global supplier of high-grade refractory products, with 2015 revenues of € 1,753 million and adjusted EBITDA of € 198 million. Brazil-based Magnesita is a global provider of integrated refractory solutions, services and industrial minerals, with revenues of US$ 1,013 million (€ 914 million) and adjusted EBITDA of US$ 145 million (€ 131 million) in 2015.1

The completion of the transaction is amongst others subject to

(i) approvals by the relevant competition authorities,

(ii) the migration of RHI to the Netherlands,

(iii) the listing of RHI Magnesita’s shares in the premium segment of the Official List on the Main Market of the London Stock Exchange and

(iv) RHI’s shareholders not having exceeded statutory withdrawal rights in an amount of more than € 70 million in connection with organizational changes preceding RHI’s migration from Austria.

The migration and the preceding organizational changes in Austria require qualified approval by RHI’s shareholders’ meeting. If the transaction is terminated for reasons not under the control of Magnesita’s Controlling Shareholders, an aggregate break fee of up to € 20 million is payable by RHI to Magnesita’s Controlling Shareholders.

The migration of RHI to the Netherlands and the subsequent listing on the London Stock Exchange have the objective of reinforcing and underlining the truly international scope of the enlarged combined company, enhancing its capital markets presence and maximizing value potential for the company’s shareholders. The migration of RHI will be effected by RHI Magnesita becoming the ultimate holding company of RHI Group and the shareholders of RHI will cease to hold shares in RHI and instead hold RHI Magnesita shares. Following registration of the corporate restructurings, RHI’s shares cease to be listed on the Vienna Stock Exchange. The place of effective management of RHI Magnesita will be Austria.

The transaction is expected to complete in 2017. Until then, the two companies will remain completely separate and independent. Therefore customers, suppliers, employees and other stakeholders should expect no change in management teams, commercial relationships, supply chains and product offerings during this period.

Mandatory Tender Offer
Following completion of the transaction, a mandatory tender offer will be launched by RHI Magnesita or one of its affiliates (“Offer”) for the remaining shares in Magnesita. As part of the Offer, a maximum number of 5.4 million RHI Magnesita shares will be issued, resulting in an aggregate number of no more than 10.0 million newly issued shares to finance the acquisition. The Offer will include the option to sell shares on the same payment terms as the transaction as well as a cash-only alternative amounting to € 8.19 per Magnesita share (subject to certain adjustments according to the SPA). If some or all of Magnesita’s other shareholders elect not to receive RHI Magnesita shares in the Offer, Magnesita’s Controlling Shareholders have committed to purchase additionally at least 1.9 million and at most 3.4 million of the remaining new RHI Magnesita shares, thereby increasing their total number of RHI Magnesita shares to a maximum of 8.0 million. RHI may decide to combine the Offer with a delisting offer and/or a voluntary offer to exit Magnesita from the “Novo Mercado” listing segment. The Offer will follow applicable Brazilian laws and regulations. Any RHI Magnesita shares that are not taken up in the Offer by Magnesita’s shareholders may be either placed into the market or with institutional investors.

Financial Terms of the Transaction
Based on RHI’s six-month VWAP of € 19.52, the implied value for the entire share capital of Magnesita will be € 451 million, 45% above Magnesita’s market capitalization as of October 4, 2016.2 The transaction will be financed by additional debt and the issuance of 4.6 million RHI Magnesita shares to Magnesita’s Controlling Shareholders. The transaction will increase RHI’s current financial leverage, measured as net debt to EBITDA, to 4.0x at closing of the transaction when assuming an acquisition of Magnesita’s entire share capital. RHI expects, however, that leverage will decline to below 2.0x by 2020 as a result of the strong cash generation profile of the newly combined company. Magnesita will continue to finance itself on a standalone basis without credit support from RHI Group. Before or at completion of the transaction, Magnesita is expected to adopt RHI’s accounting practices, which, according to RHI, could lead to significant, however substantially non-cash adjustments in Magnesita’s book equity value.

Enhanced Growth Profile and Global Footprint
The combination of RHI and Magnesita represents a unique opportunity to accelerate growth in certain regions, resulting from the high complementary of the businesses both in terms of geographic footprint and products.

Magnesita’s presence in South America and the United States fits well with RHI’s presence in Europe and Asia. It results in strengthened geographic clusters of the combined company by adding production facilities in several markets in which RHI and Magnesita are lacking capacity on their own. This combination will also strengthen the competitive position against the Chinese refractory industry, which is expected to consolidate in the coming years as announced by the Chinese government. Moreover, Magnesita’s position in dolomite-based products is highly complementary to RHI’s asset portfolio, which traditionally has a strong focus and an excellent market reputation for high-quality magnesite products.

The combination of RHI and Magnesita will enable the combined company to offer its customers an even broader product and service portfolio thereby delivering enhanced value-add. Additional potential for value creation will be realized through synergies and the implementation of common proven standards of operational and commercial excellence.

Significant Value Creation and Synergy Potential
The Transaction will result in meaningful synergies in the following key areas, amongst others:

(i)      a highly complementary offering of value-added products and services as a result of the combination of both product portfolios;

(ii)     a more efficient cost structure, benefitting from economies of scale in important operational areas such as raw materials supply, freight, marketing and administration, as well as an optimized operational set-up leading to enhanced flexibility in production and an improved cost basis;

(iii)    an optimized working capital structure, especially given Magnesita’s presence in the Americas, by means of improved inventory management and related costs, resulting from the complementary regional footprint of RHI and Magnesita’s operations and customer base; and

(iv)   a relevant reduction in capital expenditure requirements and maintenance costs.

As a result of the transaction, RHI expects minimum net run-rate synergies on EBIT level of approx. € 36 million by 2020. However, RHI is optimistic that as a result of the Offer, RHI Magnesita’s stake in Magnesita will significantly exceed 46%. In this case, RHI expects substantially higher synergies of approx. € 72 million, especially in the areas of enhanced production efficiency and cost benefits in research and development, marketing and administrative functions. In addition, capital expenditure synergies are expected to amount to between € 2 million and € 7 million annually, while aggregate working capital savings of € 40 million are expected in the coming years.

Cash integration costs as a result of the transaction are expected by RHI to be of the magnitude of € 50 million to € 90 million, while non-cash integration costs, effectively write-offs, should vary between € 20 million and € 35 million, depending on the amount of Magnesita shares acquired pursuant to the Transaction and subsequent Offer. Both cash and non-cash integration costs will mainly crystallize in 2017 and 2018.

Increased Financial Targets
As a result of the transaction, RHI’s mid-term financial targets will surpass RHI’s current targets. RHI expects the combined company to generate fully consolidated revenues of € 2.6 billion to € 2.8 billion (previously € 2.0 to € 2.2 billion) with an operating EBIT margin of more than 12% (previously more than 10%) by 2020. It projects a cumulative operating cash flow of approx. € 1.1 billion for the period from 2017 to 2020 for the combined business, assuming an acquisition of Magnesita’s entire share capital.

RHI expects RHI Magnesita to pay stable dividends in 2017 and 2018, in line with RHI’s previous years’ payment levels. In the mid- to long-term, however, RHI Magnesita aims to increase its dividend payments, as a result of stronger cash flow generation resulting from synergies, organic growth and de-leveraging of the company’s capital structure.

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