Project overview
In May 2021, Gia Anh Investment Trading Co., Ltd. carried out a wear protection project for the coal mill at VICEM Tam Diep Cement Plant. The scope of work covered the coal mill housing and the BV06 rotary valve, using KALCRET hard compound.
The coal mill supplies pulverized coal for the clinker production process; therefore, an adequate and reliable coal supply to the rotary kiln must be maintained. During the site inspection, GAC identified wear on the coal mill housing caused by operating conditions.
If left untreated, the wear could continue to progress and perforate the coal mill housing, causing coal leakage and affecting the coal supply to the rotary kiln. Based on the site assessment, GAC proposed applying KALCRET hard compound to protect wear-prone areas.
The installation process included surface preparation, welding of steel mesh, application of the KALCRET wear-resistant lining, finishing, and equipment handover. The GAC team had received manufacturer training and carried out the work in accordance with applicable safety and quality requirements.
Customer challenges
Coal mill housing wear
Wear had developed on the coal mill housing during operation
Risk of housing perforation
If the wear continues to progress without appropriate corrective measures, the coal mill housing may eventually be perforated
Coal leakage
If the housing is perforated, coal may leak from the equipment, reducing the amount of coal supplied to the rotary kiln
Impact on coal supply to the rotary kiln
The coal mill must provide adequate coal for clinker production. Therefore, housing perforation and coal leakage may directly affect the coal supply to the rotary kiln
CURRENT CONDITION OF THE COAL MILL
The coal mill housing exhibits wear after a period of operation
Project objectives
PROTECT CRITICAL EQUIPMENT AREAS
Implement a wear protection solution for the coal mill housing and BV06 rotary valve at VICEM Tam Diep Cement Plant
MINIMIZE THE RISK OF HOUSING PERFORATION
Apply a protective lining to wear-prone areas to minimize the risk of coal mill housing perforation and coal leakage during operation
MAINTAIN COAL SUPPLY TO THE KILN
Maintain the required coal supply to the rotary kiln while supporting reliable long-term operation of the coal mill
Project execution process
Site condition assessment
Inspect the coal mill housing and BV06 rotary valve to identify and document wear at the areas requiring treatment
Risk assessment
Assess the risk of further wear progression that could lead to coal mill housing perforation, coal leakage, and disruption to the coal supply to the rotary kiln
Develop the wear protection plan
Propose the use of KALCRET hard compound to repair and protect wear-prone areas
Surface preparation
Prepare the required materials and clean the surfaces to be treated prior to installation
Steel mesh welding
Weld steel mesh onto the prepared surfaces
Installation and handover
Install the KALCRET wear-resistant lining, complete the surface finishing, and hand over the equipment in accordance with safety and quality requirements
Project results
COMPLETED WEAR PROTECTION AT TWO LOCATIONS
GAC implemented the wear protection solution on the coal mill housing and BV06 rotary valve according to the plant-approved installation plan
KALCRET LINING INSTALLATION COMPLETED
The treatment areas were cleaned and fitted with welded steel mesh before the KALCRET hard compound lining was applied
WORK COMPLETED AND EQUIPMENT HANDED OVER
The GAC team completed the installation and finishing work and handed over the equipment in line with required safety and quality standards
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.
Ms. Tran Thi Hoa
Project Management Board - VICEM TAM DIEP
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