Authors: A. Sadri, P. Gebski, E. Shameli
The Twelfth International Ferroalloys Congress, INFACON XII, 2010 - Helsinki, Finland, June 6-9 2010
Abstract
Effective maintenance practices improve safety of the operating unit, enhance safety during maintenance periods, increase operating up-time and decrease the overall maintenance costs. This paper outlines the application of Hatch’s furnace condition monitoring program. Emphasis is placed on Acousto Ultrasonic- Echo (AU-E), a manually operated, non-destructive testing and evaluation (NDT & E) measurement system which determines the thickness and physical properties of the installed refractory components. The system is used to identify the refractory wear profile and to determine the positions of cracking, metal infiltrations and other anomalies, such as gaps and discontinuities within the linings. When the AU-E system is used after the rebuild and at regular time intervals, the results can be used to determine the degree and extent of the refractory deterioration. Moreover, data analysis and interpretation algorithms have been developed in order to identify areas of hydration, based on the AU-E results. Throughout the campaign, this information is applied to schedule the shutdowns, and to determine the extent of the repair.
In this article, we are discussing the main principles of the AU-E technique and its application, particularly for determination of hearth, sidewall, taphole and roof refractory conditions. In addition, two case studies are presented to demonstrate application of the AU-E technique in an electric furnace and a flash furnace.
