Project Overview
On September 20, 2024, Gia Anh Investment Trading Co., Ltd. (GAC) delivered 74 steel pipes lined with KALCRET hard compound to the Raw Material Plant at the Hoa Phat Dung Quat Steel Complex. The order was delivered 20 days ahead of the contractual schedule.
The pipeline system conveys ore slurry, consisting of 0.074 mm ore particles and water, from the grinding mill to the cyclone system, thickener, agitation tank, and filter press system. After a period of operation, the pipeline developed ruptures and perforations at multiple locations, requiring repeated patch repairs. The system needed to be replaced to ensure stable operation of the raw material processing workshop and meet the required production capacity.
To extend the service life of the system, GAC proposed a monolithic cast KALCRET hard-compound lining inside the ore slurry pipeline. The KALCRET lining was cast to match the dimensions of each pipe section, bend, and elbow in Vietnam, following Kalenborn procedures and under Kalenborn supervision.
Customer challenges
Ruptures and perforations at multiple locations
After prolonged operation, the ore slurry pipeline developed ruptures and perforations at multiple locations and required replacement
Repeated patch repairs after perforation
Several perforated pipe sections required patching and repair during operation
Abrasive ore slurry environment
The pipeline continuously conveys a slurry of 0.074 mm ore particles and water, requiring the internal surface to withstand both abrasive wear and erosion
Impact on operation and production capacity
The deteriorated pipeline system needed to be replaced to ensure stable operation of the raw material processing workshop and meet the required production capacity
CURRENT CONDITION OF THE ORE SLURRY PIPELINE SYSTEM
The ore slurry pipeline sections have developed ruptures and holes
Project Objectives
COMPLETE 74 ORE SLURRY PIPES
Complete and deliver 74 KALCRET-lined steel pipes to replace the deteriorated pipe sections
IMPROVE ABRASION AND EROSION RESISTANCE
Use KALCRET hard compound with a hardness above 8 Mohs to protect internal pipe surfaces against abrasion and erosion from ore-and-water slurry
EXPECTED SERVICE LIFE
The KALCRET-lined pipe solution is expected to provide a service life of approximately four years for the ore slurry pipeline system
Project execution process
Assess the existing condition
Identify pipeline locations with ruptures and perforations, including sections previously repaired during operation
Determine operating conditions
The system conveys slurry consisting of 0.074 mm ore particles and water from the grinding mill to subsequent processing stages
Select the KALCRET solution
GAC proposed using KALCRET hard compound to form a monolithic cast lining inside the ore slurry pipes
Fabricate to pipe dimensions
The KALCRET lining was produced to match the dimensions of each pipe section, bend, and elbow in the system
Cast the monolithic KALCRET lining
The monolithic KALCRET hard-compound lining was cast in Vietnam in accordance with Kalenborn procedures
Supervise, certify and deliver
The production process was supervised by Kalenborn specialists. The finished products were quality-certified by Kalenborn before GAC delivered the 74 pipes to the customer on September 20, 2024
Project results
DELIVERY OF 74 KALCRET-LINED PIPELINES
GAC completed and delivered 74 steel pipes lined with KALCRET hard compound to the Raw Material Plant at the Hoa Phat Dung Quat Steel Complex on September 20, 2024
DELIVERED 20 DAYS AHEAD OF SCHEDULE
The order was delivered 20 days ahead of the contractual schedule
SUPERVISED AND CERTIFIED BY KALENBORN
The KALCRET casting process in Vietnam followed Kalenborn procedures under the supervision of Kalenborn specialists. The finished products were quality-certified by Kalenborn
“We highly appreciate Gia Anh’s professionalism and ability to meet the project schedule. The KALCRET cast lining solution has helped improve the operational reliability of the ore conveying pipeline system at Dung Quat while significantly reducing annual maintenance costs. Completing the delivery 20 days ahead of schedule was a highly commendable achievement.”
Mr. Nguyen Van An
Project Management Board - Hoa Phat Dung Quat
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