Project overview
At the Pelletizing Plant – Hoa Phat Dung Quat, fine coal powder is fed from the silo through the pipeline system. Two parallel conveying lines connected to Y3 are then fed into the pelletizing furnace.
During operation, the coal stream is continuously conveyed at a pressure of 7–8 bar, causing erosion on the inner surface of the pipeline. The wear is concentrated at locations where the flow changes direction, including 90° and 30° elbows and the Y3 junction. These are areas where localized wear, perforation and repeated welding repairs frequently occur.
Based on the actual condition and identified wear mechanism, GAC proposed replacing frequently damaged components such as elbows, Y3 fittings and straight pipe sections with Kalcret-lined structures. The solution focuses on directly protecting locations subjected to high impact from the high-pressure coal stream.
Customer challenges
Erosion under high pressure
The fine coal stream is continuously conveyed at a pressure of 7–8 bar, causing erosion on the inner surface of the pipeline
Elbows were subject to rapid wear
At locations where the flow changes direction, coal particles directly impact the elbow wall at flow changes, increasing erosion
Y3 junction subjected to severe impact
The Y3 junction is frequently exposed to direct impact from the coal stream, resulting in damage during operation
Frequent welding repairs were required
Locations with wear and perforation required repeated welding repairs to maintain pipeline operation
CURRENT CONDITION OF THE COAL INJECTION PIPELINE
Elbows and straight pipe sections showed localized damage
PROJECT OBJECTIVES
IMPROVE EROSION RESISTANCE
Use materials with suitable hardness and erosion resistance for fine coal conveyed under high pressure
PROTECT CRITICAL LOCATIONS
Focus wear protection on components subjected to significant impact, particularly elbows and the Y3 junction
REDUCE WELDING REPAIRS
Replace components that had suffered repeated perforation and welding repairs with structures incorporating an internal wear-resistant lining
Construction process
Assess the existing condition
GAC identified locations with frequent wear and perforation and recorded the current condition of the coal injection pipeline
Analyze the erosion mechanism
Fine coal conveyed at a pressure of 7–8 bar causes concentrated erosion, particularly at elbows and flow junctions
Select Kalcret material
GAC selected Kalcret with a hardness of approximately 8 Mohs and compressive strength of approximately 70 N/mm² as the protective lining material
Design Kalcret-lined components
The components were designed using a 3.5 mm-thick SS400 steel shell, combined with an internal Kalcret lining
Apply a monolithic lining
Kalcret was cast inside the components to form a continuous protective lining on the inner surface of the steel shell
Complete the connections
The components were designed with suitable flange connections for installation and integration with the existing pipeline system
Project results
COMPLETED THE EROSION PROTECTION SOLUTION
GAC completed the solution using a Kalcret lining for components directly exposed to the high-pressure coal stream
COMPLETED THE CONFIGURATION FOR EACH LOCATION
The solution package includes DN175 straight pipe sections with a length of 3,000 mm, 90° elbows, 30° elbows and DN175 Y3 fittings, corresponding to the different installation locations along the pipeline
36-MONTH WARRANTY
According to the technical proposal, GAC provides a 36-month warranty for the proposed 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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