A Copper Smelter, located in Central Russia, went into production in the 1940s. Since its inception, the plant has been modernized several times.
The plant operates two Copper Flash Smelting Furnaces with a unique equipment configuration. The boilers are located directly above the furnace’s uptakes, making the risk of water entering the furnace very high.
The plant has the capacity to produce 150 000 tonnes of copper matte per year. They had ambitious plans for production development.
High-Temperature Corrosion
Flue gas temperature inside the boiler reaches 1350°C/ 2462°F causing rapid metal wastage and slagging. Slagging could not be removed manually due to access issues.
Integrated Global Services (IGS) High Velocity Thermal Spray (HVTS) Application Timelines
- 2018
Pilot project to stop metal loss in the most dangerous area. 20m2 area protected from corrosion with HVTS.
Critical path: two days
- 2019
123m2 area protected from corrosion with HVTS.
Critical path: six days
- 2020
Visual and UT inspection, no metal wastage identified, slagging significantly reduced.
- 2021
Lower area is protected with HVTS.
Critical path: six days
Boiler Waterwall Protection
IGS’s HVTS solutions upgrade existing metallurgy to higher alloys that provide a barrier to mitigate corrosion and/or erosion in mission-critical equipment around the world. IGS has performed over 4,000 site projects and installed millions of square feet of reliable metal cladding surface protection.
IGS HVTS Solution Benefits
- Efficiency
Deslagging was the first major benefit achieved because of the HVTS application reported by the plant. The boiler slows down every month. During these periods plant management teams perform a visual inspection of the equipment. No slagging has been detected on the boiler wall. The efficiency improvement increased production in 2020 to 112% of design capacity.
- Lifetime
Boiler replacement is costly and time-consuming. IGS HVTS application prevented the degradation of the heat recovery steam generator, which previously lasted only 24 months. The trial application provided a clear side-by-side comparison.
- Reliability
Prior to the IGS HVTS application, the plant used to carry out emergency localised shell repair.
The Next Step
The plant has now included IGS HVTS technology in its best practices list. They plan to install IGS surface technologies onto the refractory surfaces and the convection section coils to eliminate slagging and increase the production rate.
IGS Comment
Sergei Merchev, IGS Manager who oversaw this project, commented: “Non-ferrous metallurgy presents a very severe environment, which truly puts our HVTS technology to the test. Our experience, expertise and collaborative approach made this application a success and produced undisputed value for the customer.”
