Hood of Converters #1 and #2 Wear Resistant Coating
January 10th, 2011
1
Hood of Converters #1 and #2 Wear Resistant Coating – Current Situation
Current Situation:
GAS COOLER
• The fixed and movable hoods of AMT Steel Shop
Converters 1 and 2 present high level of wear in
their cooling pipes leading to water leaks, which
increases the risk of operational accidents and D
OD
OO
emergency shutdowns in the converters. HHO
DD
XXEE
FFII
Water
WaterLeakage
Leakage LEE
BBL
• In order to carry out manual interventions, it is GAS CLEANER A
VA D
OV OD
MMO HOOO
necessary to cool the system, depressurize and H
drain the hoods, clean the internal walls and to
assemble scaffolds. These are long term activities
which cause production losses.
BOF
Wore areas Skull Building up
2
Hood of Converters #1 and #2 Wear Resistant Coating:
Evolution of production and the main equipments improves
Present revamping planning
Received diagnosis results from SMS, SVAI, SPCO and AM R&D. Emitted invitation for hood supplier and received the proposals
Contract for hood skulling, hood wearing and skirt diagnosis 2010
2011
Start of problems of hood skull build up. New study for Hood’s change during BF#1 relining 2009 2012
Start up of BOF #3 2008
Inconel layer application on movable and fixed hood (finished in Jan/08)
2007
New BOF de-dusting system, FO2: 66.000 Nm3/h, BOF gas recovery star up 2006
2004
Decreased of hood’s leaks problems:
BOF’s vessel change , Heat size: 315 t, 0.765 m3/t → 0.698 m3/t) around 88 h per year.
Increased production losses due to
2000 skull cleaning and inspection around
Blast Furnace #2 start up, FO2: 62.000 Nm /h
3
630 h per year.
1998
New scrubber, FO2: 60.000 Nm3/h 1997
Production losses due to hood’s leaks around 440h per year.
1993
Start hood Inconel layer application.
FO2: 52.000 Nm3/h 1992
FO2: 48.000 Nm3/h 1990
Changed the BOF vessel in 2000 and postpone Hood’s revamping until
1988 BF#1 relining
Start project to change the BOF Vessel and Hoods
FO2: 42.000 Nm3/h
1983 Start problems of water leakage at hoods From this point was developed many
Start up Heat size: 280 t alternatives to solve leaks problems
3
Hood of Converters #1 and #2 Wear Resistant Coating:
Historic of problems
Because of the continuous increase of production by mean of the oxygen flow rate increase (42.000 to
66.000 Nm³/h) the BOF gas velocity and the amount of dust increased proportionally, causing a elevate
wear rate.
O2 FLOW GAS VELOCITY WEAR + WATER LEAKEGES
ArcelorMittal actions:
• Aiming to reduce the abrasion wear on the pipes in the hoods critical areas, a coating of INCONEL has
been manually welded applied, resulting in a important reduction of leakages and maintenance
interventions (see figures)
• As resulting of manually welded INCONEL coating the pipes surface was not smooth enough and a
deposit of skull started to build up on the walls of fixed and movable hoods, and the expected result was
not accomplished.
• Application of INCONEL – 2007 and 2008.
• Skull formation problems started in February 2008
• To prevent the skull formation, which led to operation shutdown in the converter, the INCONEL coating
was ground, in order to reduce the roughness. Thus, the pipes were exposed to wear from abrasion
increasing the incidence of water leaks.
4
PRODUCTION LOSSES DUE TO HOODS WATEH LEAKEGES
BOF #1 AND #2 - 2004 to 2009
600
500 Inconel aplication from july/2006 to january/2008
400
Hours
300
200
100
0
2004 2005 2006 2007 2008 2009
BOF# 01 304 157 112,5 76,1 75 14,5
BOF#02 222 204 215 83 64,5 22
BOF#1 + BOF#2 526 361 328 159,1 139,5 36,5
BOF# 01 BOF#02 BOF#1 + BOF#2
Obs.: In 2009 the leaks were mainly caused by excessive grind of the inconel coating.
5
Hood of Converters #1 and #2 Wear Resistant Coating – Technical Solution
Due to the risk of operational accidents resulting from water leaks inside the converters and great
production loses because of unscheduled shutdowns besides not fulfilling the production plans, the
following is proposed:
Movable Hoods
• Replacement of the existing hoods (end of life span) for new hoods, made from pipes coated with
INCONEL (wear resistant material) only on the more exposed to abrasion areas (see sketch).
• The pipes will be coated by automatic welding machines to ensure a more smooth surface. They will be
imported and assembled on the movable hoods during manufacturing process.
Fixed Hoods
• Replacement of the critical (see sketch) pipe panels for new ones with INCONEL coating. This
replacement will be carried out during the reline and maintenance shutdowns of converters 1 and 2.
• The pipes will be coated by automatic welding machines to ensure a more smooth surface. They will be
imported and assembled on the hoods during the reline and maintenance shutdowns.
Comment:
This project is a capex, because it fill out all requirements of AMIP (ArcelorMittal Investment Procedure):
• The movable hoods and pipes panels will be changed to a new technology using coated pipes to protect
against wear.
• They are specific components to primary dedusting of Converter #1 and #2, with life time bigger than
one year.
6
Hood of Converters #1 and #2 Wear Resistant Coating – Technical Solution
MANUALLY WELDED COATING (ATUAL) AUTOMATIC WELDED COATING (PROPOSAL)
AS WELDED
AFTER
GRINDING
7
Hood of Converters #1 and #2 Wear Resistant Coating – Technical Solution
Coating Area – 260 m² Coating Area – 310 m²
Panels weight – 7,5 t Panels weight – 7,5 t
Fixed hood – Areas to be coated Movable hood - Areas to be coated
•The blue areas are the wear and corrosion critical regions, where shall be replaced.
•Benchmark plants in ArcelorMittal Group - Inconel 625 coating on their hoods with excellent results.
AM Dofasco; AM Gent; AM Florange (France) in 2006 and 2007; AM Fos/Mer (France) - in 2008/2009/2010;
and AM Aviles (Spain) in 2005; .
8
Hood of Converters #1 and #2 Wear Resistant Coating
Budget Breakdown
Engineering / Management 150.000,00
1 Management 90.000,00
Engineering 60.000,00
Supply 4.400.000,00
2 Local Suplly (Movable Hood) 1.800.000,00
Imported (Movable and Fixed Coated pipes) + transp 2.600.000,00
3 Erection and Tests 2.200.000,00
Supervision of third parties in the country 50.000,00
4 Electrical 0,00
Mechanical 50.000,00
TOTAL 6.800.000,00
Tax recovery estimate 1.000.000,00
Total budget incl. tax recovery 5.800.000,00
9
Hood of Converters #1 and #2 Wear Resistant Coating
Budget Development (Without taxes recovery)
1 – Engineering / Management – US$150,000
• Estimated based on know cost of others projects
2 - Supplying – US$4,400,000
• Imported coated pipes - Total length: 6,000 m x US$428/m = US$2,568,000 - Based on proposal of
supplier: AQUILEX WSI ( Georgia – USA)
• Fabrication of the movable hoods and panels – US$1,800,000 - Based on proposal of local supplier
3 – Replacement of the movable hoods and panels of the fixed hoods – US$2,200,000
• Movable hoods: 2 x US$400,000 = US$800,000
• Panels of the fixed hoods: US$1,400,000
• Prices based on contract for similar jobs with local erection company
4 – Supervision – US$50,000
• Estimated based on proposal of Aquilex
Disbursement Breakdown (With taxes recovery)
Hood of Converters #1 and #2 Wear Resistent Coating
Disbursement Breakdow - US$ Value
Year
2011 2012
2Q 3Q 4Q 1Q 2Q
20.000 1.260.000 1.720.000 2.400.000 400.000
3.000.000 2.800.000
10
Hood of Converters #1 and #2 Wear Resistant Coating
Time Schedule
11
