Partial Relining

at POSCO COREX
Feb. 2003
1st Campaign Operation
0
500
1000
1500
2000
2500
3000
95 96 97 98 99 00 01 02
P
R
O
D
U
C
T
I
O
N

(
T
/
D
)
900
1000
1100
1200
1300
1400
1500
F
U
E
L

R
A
T
E

(
K
g
/
T
-
P
)
Production(T/D)
Fuel Rate
Jun.96 Normal Production
1,900T/D, 5Days Continuous
Sept.00 3 Million Ton
Production after Start-up
Aug~Oct (79 Days)
Relining
Jan.03
Jan.03

80
85
90
95
100
95 96 97 98 99 00 01 02
W
O
R
K
I
N
G

R
A
T
E

(
%
)
Working Rate
Partial Relining
FINEX REACTORS
Repair Hot Cyclone Refractory
Relining Scope
Install flanges for COREX/FINEX
switchover valves
Rebuild Charging System
Reinforce Cooling Capacity
Replace Shell/Stave
Replace Refractory
1280 mm
(Micro Pore Carbon)
880 mm
(Micro Pore Carbon)
Bottom
Carbon
Refractory
575mm x 4pieces 330mm x 7pieces
Tap Hole
Refractory
Copper Stave
( High Al2O3 Refractory )
FCD Stave
( SiC Refractory )
Melting
Area






( SiC Refractory )






( SiC Refractory )
Replace
Stave
After Before
Ledge Type
Include Refractory
Cooling System
Thickness
(mm)
1800 1300
Cooling Water
(t/h)
160 275
Event
Period
(days)
01 .Aug,2001 Sep. Oct.
Salamander Tapping
1
Cooling
4
Remove Coke
8
Dismantle Shell
10
Erection
38
Commissioning
7
Heat-up & Start-up
11
Install Shell
(8, Oct)
Install Stave/Refractory
Shut Down (7, Aug)
Start-Up
(30, Aug)
Relining Schedule
(25, Oct)
(14, Oct)
Wear Profile
J
K
L
M
N
O
P
H I
L
M
N
O
P
H
Dome
Calming
Zone
Stave 8
Stave 7
Stave 6
Stave 5
Stave 4
Stave 3
Stave 2
Stave 1
Tap Hole
Tuyere
I
H
Schematic diagram of wear profile
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
O
N
M
L
P

S-3
G
A
B
920
300

300
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
T/H B (90) T/H A (270)
330
30
150 210
Adhesive Material
Investigation of wear profile
5
5
1
1

1
0
8
8
.
2

9
3
9
1

2284.5
6
1
2

330.5 330.5 330.5 290.5 290.5 367 367
MS5 (Al2O3 67%)
10572
10111.25
9484
7031
Carbon block
260
CORANIT (Al2O3 83%)
MS5 (Al2O3 67%)
Sampling of bored specimen (1)
CORANIT(Al2O3 83%)
Carbon Stamping Mass
8
2
0

9
4
0

1
1
8
0

367 367 330.5 330.5 330.5
4
2
0

4
6
0

2
0
0

3
0
0

4
0
0

Carbon Block
Stave Cooler
Pumping Castable
MS5(Al2O3 67%)
270.5 270.5
2284.5
544
7
1
6

260
Sampling of bored specimen (2)
100 200 300
100 200 300
Insulating castable
Set bricks for tapping hole (MS5, Al
2
O
3
67%)
Mud (Al
2
O
3
59%, SiC 8%, C 11%)
Fixing mud (Al
2
O
3
8%, SiC 56%, C 16%)
0 220 440 640 790 1150 1450
1800
1800
627 994 1324 1654 1800
Appearance of the bored specimen
5
5
1
1

1
0
8
8
.
2

9
3
9
1

2284.5
6
1
2

330.5 330.5 330.5 290.5 290.5 367 367
MS5 (Al
2
O
3
67%)
10572
10111.25
9484
7031
Carbon block
260
CORANIT (Al
2
O
3
83%)
MS5 (Al
2
O
3
67%)
L
I
Mixture of mud,
char, slag, &
molten iron
Hot metal
Hot metal
Wear profile of tapping hole (1)
CORANIT(Al
2
O
3
83%)
Carbon Stamping Mass
8
2
0

9
4
0

1
1
8
0

367 367 330.5 330.5 330.5
4
2
0

4
6
0

2
0
0

3
0
0

4
0
0

Carbon Block
Stave Cooler
Pumping Castable
MS5(Al
2
O
3
67%)
270.5 270.5
2284.5
544
7
1
6

260
Mixture of mud,
char, slag, &
molten iron
J
J
Hot metal
Hot metal
Wear profile of tapping hole (2)
T/H A
T/H B
Char
DRI
In-Liner
T/H A
T/H B
Wear profile of Dome & Calming zone
Cracking
area

Stave
damaged

Cooling line
exposed





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STAVE4
STAVE5
STAVE6
STAVE7
STAVE8







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180
o
270
o
0
o
90
o
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Wear profile of char bed zone
Gunning
bonded area

Fine coal calcinated
coating area

injection refractories
sticking area







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STAVE4
STAVE5
STAVE6
STAVE7
STAVE8
180
o
270
o
0
o
90
o
25 26 24 22 23 21 19 20 18 16 17 15 14 13 13 12 10 11 9 7 8 6 4 5 3 2 1
Sticking profile of char bed zone
T/H B
T/H A
T/H A
T/H B
Wear profile of K, J Row
T/H A
T/H B
T/H A
T/H B
Wear profile of I, H Row
Analysis of
Charging Material
Hole
Melter-gasifier
Stave 7
65cm
Collection of specimen
0
20
40
60
80
100
0.0 0.1 1.0 10.0 100.0
S ize(m m )
A
c
c
u
m
u
l
a
t
e
d
(
w
t
%
)
0-10cm
10-20cm
20-30cm
30-40cm
40-50cm
50-60cm
+60cm
total
Size distribution of specimen
0
20
40
60
80
100
0 10 20 30 40 50 60 70
D epth from M G surface(cm )
C
(
w
t
%
)
0
10
20
30
40
50
60
70
80
A
s
h
(
w
t
%
)
-0.125
1
4.75
-0.125
1
4.75
Carbon & Ash of specimen
0%
20%
40%
60%
80%
100%
1-1 2-1 3-1 4-1 5-1 6-1 7-1 1-2 2-2 3-2 4-2 5-2 6-2 7-2 1-3 2-3 3-3 4-3 5-3 6-3 7-3
D epth from M G surface(cm )
C
o
n
t
e
n
t
(
w
t
%
)
Fe2O 3
K2O
N a2O
Al2O 3
SiO 2
M gO
C aO
FeO
C
- 0.125m m 1.02.0m m + 4.75m m
Content distribution of specimen
Refractory lining for dome of the melter- gasifier were partly fallen.
It was inferred to be caused by restricted thermal expansion of the lining.

Refractory lining upon stave cooler had been totally removed.
It was thought for the lining to be damaged by not only friction between coal and
the lining but also collapse of the bottom lining.

Carbon block lining around the melter-gasifier was perfectly protected from
attack of molten steel and slag by skull, formed near the carbon block.

The skull consists of mixture of coal ash, molten steel, and dolomite stone.

Tapping holes were seriously damaged by mechanical and chemical wears.
Almost all of the mullite and alumina bricks for tapping hole is thought to
be worn during operation.
Mixture of tapping mix, char, and slag sustained structure of the tapping hole.
Summary
Layout of FINEX construction work
Pre-pond
Pump
Room
Cooling
Tower
Electrical
Room
Reactor Tower
Pipe Rack
HCI Tower
Clarifier
Filter Room
COREX
Construction : Jan.2001 ~ May.2003
Start-up : 31.May.2003