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In 2018, KazChrome's Furnace No. 4-3 at Workshop No. 4 in Aktobe, Kazakhstan, exhibited unusually high temperatures in the hearth region of the furnace liningLining. To investigate the cause, pyrometallurgical experts conducted a comprehensive assessment, including physical measurements, thermal modeling, and Acousto Ultrasonic-Echo (AU-E) non-destructive testingTesting (NDT) of the hearth and sidewalls. AU-E inspection results provided direct thickness measurements, revealing that only 40% of the original refractoryRefractory thickness remained in the hearth. NDT findings indicated severe compromise of the working liningLining layer, with signs of delamination and potential floatationFlotation. Based on these results, a full hearth relining was deemed necessary to restore furnace integrity. This paper presents the detailed investigation conducted by KazChrome and Hatch furnace specialists, outlining the assessment methodologies, key findings, and the decision-making process that led to the reline of Furnace No. 4-3.

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Detection of a DC Furnace Hearth Delamination and Floatation by Thermal Analysis and Non-destructive Testing Methods

  • 会议论文

  • 发表日期：

    2025年

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  • Afshin Sadri,
  • Zhanibek Nurmukhanbetov,
  • Erzhan Abdulabekov,
  • Mike Mosnier,
  • Anastasiya Mitsui,
  • Wai Lai Ying,
  • Frans Hannemann,
  • Allison Irvine

摘要

In 2018, KazChrome's Furnace No. 4-3 at Workshop No. 4 in Aktobe, Kazakhstan, exhibited unusually high temperatures in the hearth region of the furnace liningLining. To investigate the cause, pyrometallurgical experts conducted a comprehensive assessment, including physical measurements, thermal modeling, and Acousto Ultrasonic-Echo (AU-E) non-destructive testingTesting (NDT) of the hearth and sidewalls. AU-E inspection results provided direct thickness measurements, revealing that only 40% of the original refractoryRefractory thickness remained in the hearth. NDT findings indicated severe compromise of the working liningLining layer, with signs of delamination and potential floatationFlotation. Based on these results, a full hearth relining was deemed necessary to restore furnace integrity. This paper presents the detailed investigation conducted by KazChrome and Hatch furnace specialists, outlining the assessment methodologies, key findings, and the decision-making process that led to the reline of Furnace No. 4-3.