Wear protection project for the powdered slag conveying pipeline – Raw Material Plant

Wear protection project for the powdered slag conveying pipeline – Raw Material Plant – Hoa Phat Dung Quat

Project overview

At the Raw Material Plant – Hoa Phat Dung Quat, after being ground, S95 slag powder is conveyed through the pipeline system to the storage silo. The slag powder has high hardness and is conveyed at a pressure of up to approximately 0.7 MPa, continuously acting on the inner surface of the pipeline.

After a period of operation, the system showed localized wear at multiple locations. Damage was concentrated mainly at elbows, where the material stream changes direction and creates greater impact. Repeated welding repairs directly affected the operating efficiency of the system.

Based on the actual operating conditions, GAC proposed replacing frequently damaged elbows with steel-shell elbows incorporating a monolithic Kalcret wear-resistant lining. The elbows were designed for each specific angle and installation position, focusing on protecting areas with a high risk of wear.

Project overview - Wear protection project for the powdered slag conveying pipeline – Raw Material Plant – Hoa Phat Dung Quat

CUSTOMER

Customer challenges

Slag powder causes abrasive wear

The high-hardness slag powder continuously rubs against the inner surface of the pipeline

Elbows are subject to severe wear

At flow-direction changes, slag particles concentrate their impact on the inner wall of the elbow, increasing the wear rate

Pipeline sections suffered localized perforation

After a period of operation, the system developed localized perforation at several locations along the pipeline

Frequent welding and repairs

Repeated repairs were required at perforated locations, resulting in frequent intervention during operation

CURRENT CONDITION OF THE PIPELINE SYSTEM

Elbows at multiple locations showed localized wear and perforation during operation

PROJECT OBJECTIVES

IMPROVE WEAR RESISTANCE

Create a high-hardness protective layer inside the elbows to withstand continuous impact from slag particles during conveying

PROTECT FLOW-DIRECTION CHANGE LOCATIONS

Focus the wear protection solution on elbows where slag particles frequently change direction and strongly impact the inner surface

REDUCE RECURRING DAMAGE

Replace frequently damaged elbows with structures incorporating an internal wear-resistant lining, thereby limiting perforation and repeated repairs

SOLUTION

Construction process

Assess the existing condition

GAC identified locations with frequent wear and perforation, focusing on the elbows along the pipeline

Analyze the wear mechanism

The high-hardness slag powder is conveyed at a pressure of up to approximately 0.7 MPa, continuously acting on the inner surface of the elbows

Select Kalcret material

GAC selected Kalcret with a hardness of approximately 8 Mohs as the internal wear-resistant lining material

Design for each installation position

The elbows were designed with angles of 30°, 45°, 90°, 135°, with a bending radius of R300 mm, to suit each actual installation location

Apply a monolithic Kalcret lining

Kalcret was cast monolithically inside the elbows to form a protective layer on the surface directly exposed to the slag stream

Fabricate wear-resistant elbows

The elbows were fabricated using a 6.5 mm-thick SS400 steel shell, combined with an internal 30 mm-thick Kalcret lining

Project results

COMPLETED THE WEAR PROTECTION SOLUTION

The elbows were designed with a 30 mm-thick Kalcret lining, focusing on protecting surfaces directly subjected to the impact of the slag stream

COMPLETED THE ELBOW CONFIGURATION FOR ACTUAL PIPELINE CONDITIONS

The design package comprised 9 Kalcret-lined elbows with angles of 30°, 45°, 90° and 135°, corresponding to the installation locations along the actual pipeline

3-YEAR WARRANTY FOR THE SOLUTION

According to the technical proposal, GAC provides a 3-year warranty for the proposed solution

Wear protection project for the powdered slag conveying pipeline – Raw Material Plant – Hoa Phat Dung Quat - Project gallery

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