2017-Sustainable Industrial Processing Summit
SIPS 2017 Volume 1. Barrios Intl. Symp. / Non-ferrous Smelting & Hydro/Electrochemical Processing
| Editors: | Kongoli F, Palacios M, Buenger T, Meza JH, Delgado E, Joudrie MC, Gonzales T, Treand N |
| Publisher: | Flogen Star OUTREACH |
| Publication Year: | 2017 |
| Pages: | 264 pages |
| ISBN: | 978-1-987820-61-4 |
| ISSN: | 2291-1227 (Metals and Materials Processing in a Clean Environment Series) |
CD shopping page
Furnace and Acid Tower Refractory Lining Integrity Monitoring by Acoustic Techniques
Afshin Sadri1; Wai Lai Ying1;1HATCH, Mississauga, Canada;
Type of Paper: Regular
Id Paper: 203
Topic: 6
Abstract:
Process vessels such as smelting furnaces and acid towers are lined by refractory bricks. Degradation of the refractory lining in smelting furnaces begins since the start of the operation. For acid towers, the failure of castable refractory or the mortar between the refractories can cause high concentration acid leaks. Eventually the lining degradation becomes crucial and requires replacement. Since shutdowns are prohibitively expensive, it is desirable to identify the damaged areas and schedule maintenance shutdowns at the optimal frequency so as to reduce the cost of repair and shutdown periods. For this reason, non-destructive testing (NDT) techniques are developed to determine the lining condition while the vessels are still on-line. In this paper, we discuss the application of discrete Acousto Ultrasonic-Echo (AU-E) measurements and real-time continuous Acoustic Emission (AE) monitoring for the determination of refractory lining integrity in smelting furnaces and acid towers.
Keywords:
Furnace; Industry; Non-Ferrous; Smelting; Technology;References:
[1] Sadri, & G. Walters, (2005, August). Determination of refractory and castable quality in operating industrial furnaces, using a stress wave reflection technique. Proceedings of the Materials Degradation: Innovation, Inspection, Control and Rehabilitation Symposium, COM2005. Calgary, Alberta, Canada.[2] Sadri, M. Lachemi, & G. Walters, (2005, June). Determination of refractory lining thickness and quality in operating industrial furnaces using a stress wave reflection technique. Proceedings of First CSCE Specialty Conference on Infrastructure Technologies, Management and Policy. Toronto, Ontario, Canada.
[3] Sadri, (2008). An introduction to stress wave non-destructive testing and evaluation (NDT&E) of metallurgical furnaces and refractory condition monitoring. CINDE Journal, 29(2), 7-11.
[4] Sadri, & R. Timmer, (2006, May) Blast furnace non-destructive testing (NDT) for defect detection and refractory thickness measurements, AISTech 2006, Proceedings for Iron and Steel Technology Conference, Vol. II, Cleveland, Ohio, USA.
[5] Sadri, I. Gordon, & A. Rampersad, (2007, May). Acousto ultrasonic-echo (AU-E): A non-destructive testing technique for blast furnace hearth refractory condition monitoring., AdMet 2007, Proceedings of International Conference Advances in Metallurgical Processes and Materials, Vol. 2. 77-85, Dnipropetrovsk, Ukraine.
[6] Sadri, P. Marinelli, E. Doro, P. Gebski, & A. Rampersad, (2009, May). Comparing the accuracy of acousto ultrasonic-echo (NDT), finite element analysis (FEA), and drilling when obtaining a blast refractory lining wear profile; AISTech 2009, Proceedings of Iron and Steel Technology Conference, St. Louis, Missouri, USA.
[7] Sadri, & P. Gebski, (2009, October). Non-destructive testing (NDT) and inspection of the blast furnace refractory lining by stress wave propagation technique. Proceedings of the 5th International Congress on the Science and Technology of Ironmaking (ICSTI’09); 951-955, Shanghai, China.
[8] Sadri, P. Gebski, K. Mirkhani, & W.L. Ying, (2011, October) Monitoring refractory lining in operating furnaces by acousto ultrasonic-echo technique; Proceedings of Conference of Metallurgists, Com 2011; Montreal, Quebec, Canada.
[9] Sadri, P. Gebski, & E. Shameli, (2010, June). Refractory wear and lining profile determination in operating electric furnaces using stress wave non-destructive testing (NDT). Proceedings of the Twelfth International Ferroalloys Congress, INFACON XII. 881-890. Helsinki, Finland.
[10] Sadri, W. L. Ying, & P. Gebski, (2013, December) Application of specialized non-destructive testing (NDT) for operating copper process vessels. Proceedings of Eight International Copper Conference 2013, Instituto de Ingenieros de Minas de Chile (IIMCh). 813-833Santiago, Chile.
[11] Sadri, P. Gebski, V.P., Rojas, S. R. Ibanez & C. W. Diaz., (2008, September) Inspection and evaluation of refractory lining for slag cleaning furnace and Teniente reactor at Fundición Hernán Videla Lira Empresa Nacional De Minería (ENAMI). Proceedings of MAPLA 2008, International Conference in Mine Plant Maintenance, Edited by Eduardo Nilo, Raul Stegmaier and Patrico Guzman, September 3-5, 2008, Santiago, Chile.
[12] Sadri, W. L. Ying, & B. Dempsie, (2013, September), Preventing costly smelting furnace and process vessel run-outs (both in English and Spanish versions), Proceedings of MAPLA 2013, 10th International conference in Mining Plant Maintenance, Edited by Sergio Armstrong, Peter Knights, José Bolaños, and Edmundo Mares, Santiago, Chile.
[13] Sadri, K. Mirkhani & W. L. Ying, (2012, September) Utilization of innovative NDT and condition monitoring techniques for improving maintenance strategies of process vessels, Proceedings of MAPLA 2012, 9th International conference in Mining Plant Maintenance, Edited by Victor Babarovich, Alvaro Endo, Rodrigo Pascual, and Raul Stegmaier, Santiago, Chile.
[14] E. R. Miller, (1987): Acoustic Emission Testing: Nondestructive Testing Handbook, The American Society for Nondestructive Testing (ASNT), 5.
A. A. Pollock, (1989): Acoustic Emission Inspection: Metals Handbook. 9th Ed., ASM International, 17: 278-294.
[15] P. Gebski, A. Sadri, W. L.Ying, D. George-Kennedy, C. Nexhip, D. Krippner, & R. Kaur, (2013): Advances in Continuous Monitoring of Water-Cooled Tapblocks for Pyrometallurgical Furnaces, CIM Journal, 4-1: 1-12.
A. Sadri A., W. L. Ying, J. Armitage, & B. Dempsie, (2013): Advances in Continuous Monitoring of Water-Cooled Tapblocks for Pyrometallurgical Furnaces, CIM Journal, 4-1: 1-12. Metallurgical Vessel Monitoring: A Technology Cross-Pollination Experience between Concrete and Mining Structural Health Monitoring, Non-Destructive Testing (NDT) and Applied Geophysics, Conference of Metallurgists (COM).
[16] P. Gebski, & A. Sadri, (2012): Structural Integrity Monitoring of Smelting Furnaces Based on Acoustic Emission Data Acquisition and Analysis, 18th World Conference on Non-destructive Testing.
[17] P. Gebski, A. Sadri, & W. L. Ying, (2011): Development of the System for Furnace Integrity Monitoring Based on Real-Time Continuous Acoustic Emission Data Acquisition and Analysis, Conference of Metallurgists (COM).
[18] S. J. Vahaviolos, “ASTM Acoustic Emission: Standards and Technology Update”, Issue 1353. 1999. Ed.