Project Overview
Customer challenges
Ceramic lining detachment
After a period of operation, the ceramic tiles inside the slag discharge pipeline began to detach from the surface
Wear from material with a hardness of around 7 Mohs
The lining must withstand abrasion from material with a hardness of approximately 7 Mohs as the slag is conveyed to the settling tank
Sulphur-containing environment
The sulphur-containing operating environment requires the lining to provide chemical corrosion resistance
Operating temperature of 70–80°C
The lining must maintain its mechanical properties at operating temperatures of approximately 70–80°C
CURRENT CONDITION OF THE SLAG DISCHARGE PIPELINE SYSTEM
The internal ceramic lining detached after a period of operation
Project Objectives
RESIST WEAR FROM MATERIAL AROUND
7 MOHS
Select a lining capable of handling hard material flow and meeting the wear resistance requirements of the slag discharge pipeline system
MEET OPERATING ENVIRONMENT REQUIREMENTS
Use a solution that provides chemical corrosion resistance in a sulphur-containing environment while maintaining mechanical properties at temperatures of approximately 70–80°C
EXPECTED SERVICE LIFE
GAC expects the KALCRET lining solution to provide a service life of approximately three years for the slag discharge pipeline system
Project execution process
Assess the existing condition
Assess the condition of the ceramic tiles inside the slag discharge pipeline after they had detached during operation
Determine operating conditions
Determine the lining requirements: wear resistance to material with a hardness of approximately 7 Mohs, corrosion resistance in a sulphur-containing environment, and retention of mechanical properties at 70–80°C
Select the KALCRET solution
GAC proposed using KALCRET hard compound to line the inside of the pipeline and coat the flange surfaces
Design to system dimensions
The KALCRET lining was designed to match the dimensions of each pipe section, bend, and elbow in the slag discharge 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 directly quality-certified by Kalenborn before GAC delivered them to the customer
Project results
DELIVERED THE KALCRET-LINED PIPE BATCH
On September 20, 2024, GAC delivered a batch of steel pipes lined with KALCRET hard compound for the slag discharge pipeline at the Ironmaking Plant, Hoa Phat Dung Quat Steel Complex
COMPLETED MONOLITHIC CAST LINING SOLUTION
KALCRET was applied inside the pipeline and on flange surfaces, matching the dimensions of the pipe sections, bends, and elbows
SUPERVISED AND CERTIFIED BY KALENBORN
The production process in Vietnam was carried out in accordance with Kalenborn procedures and under the supervision of Kalenborn specialists. The finished products were directly 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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Global Experience Library
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Key Clients
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