Project overview
At the Hoa Phat Dung Quat Coking Plant, coke is quenched, crushed and screened by size. Coke below 10 mm is used as fuel, while particles above 10 mm are conveyed to the Ironmaking Plant for blast furnace operation.
The screening plates operate at approximately 260 tons/hour for 20–24 hours/day. Coke particles of 10–80 mm, with a bulk density of approximately 70°C and a material layer thickness of about 5 m, continuously expose the plates to abrasion, severe impact and vibration.
After approximately 6 months of operation, GAC found cracking, chipping and localized debonding in the existing ceramic lining. GAC therefore proposed a zoned material configuration: Kalmetall W100 for coke-contact surfaces, Hardox 500 TUF for impact-resistant areas, and SS400 steel for non-contact supporting structures.
Customer challenges
High-intensity impact load
Coke particles with sizes ranging from approximately 5 m, creating strong impact on the screening surface
Ceramic cracking and breakage
The existing ceramic lining was unable to withstand severe impact, resulting in cracking and breakage during operation
Ceramic lining debonding
After cracking and vibration, the ceramic lining became detached from the steel frame, reducing the protective layer on the screening surface
Screening plates degraded after a short service period
Through inspection of screening plates removed after approximately 6 months of operation, GAC recorded multiple damaged ceramic areas
CURRENT CONDITION OF THE COKE SCREENING PLATES
Ceramic plates showed cracking, breakage and debonding from the steel frame after a period of operation
PROJECT OBJECTIVES
IMPROVE ABRASION AND IMPACT RESISTANCE
Use a material combination better suited to hard, large coke particles and continuous screening vibration
PROTECT SURFACES DIRECTLY EXPOSED TO COKE
Focus wear-resistant materials on areas that directly and continuously contact the coke stream during screening
LIMIT RECURRING DAMAGE
Address the causes of cracking, breakage and lining debonding by selecting a material configuration more suitable for the function of each area on the screening plate
Construction process
Survey operating conditions
GAC assessed screening capacity, particle size, temperature, bulk density and impact load acting on the screening plates
Analyze the existing ceramic condition
Cracked, broken and debonded ceramic areas were assessed to determine the main damaged locations
Select Kalmetall W100
Surfaces directly exposed to coke were specified with Kalmetall W100, 10+10 mm
Arrange Hardox 500 TUF
Impact-bearing details were specified using Hardox 500 TUF to meet abrasion and impact resistance requirements
Allocate materials by functional zone
SS400 steel was used for the lower supporting structure that does not directly contact the coke
Design for each screening plate configuration
GAC developed slotted screening plates and solid plates, with overall dimensions of 1,200 × 590 mm for Screening Machine No. 2
Project results
COMPLETED THE MATERIAL CONFIGURATION FOR EACH FUNCTIONAL ZONE
The solution combines Kalmetall W100, Hardox 500 TUF and SS400, arranged according to the working conditions and functions of each area on the screening plate
COMPLETED TWO SCREENING PLATE CONFIGURATIONS
The design package comprises slotted screening plates and solid plates for Screening Machine No. 2, with detailed configurations suitable for impact and screening requirements
12-MONTH WARRANTY FOR THE SOLUTION
According to the proposed solution, GAC provides a 12-month warranty for the new screening plate solution
“We highly appreciate Gia Anh’s professional expertise and implementation capabilities. The construction process was carried out in accordance with the required procedures and technical standards, helping Kalenborn monitor and evaluate the installation quality.”
Mr. Nguyen Van An
Project Management Board - Hoa Phat Dung Quat
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