Non-Destructive Testing

Challenges

Keeping mechanical and structural assets in good working order is a constant challenge in metallurgical, energy, and infrastructure industries. Assets eventually deteriorate or become damaged during operations. So they must be retrofitted or replaced to ensure continuous and safe production and maximum productivity. Comprehensive inspection and monitoring techniques are needed to extend the service life of mechanical and structural assets, and optimize maintenance schedules and productivity.

There is a solution. Non-destructive testing (NDT) techniques inspect or monitor the condition and deterioration of mechanical and structural assets without damaging the assets themselves. In many cases, NDT techniques can also be applied without disrupting normal operations.

NDT has a wide range of benefits, including accident prevention, facilitation of maintenance planning, and optimization of efficiency and profitability. Used regularly, NDT contributes to safer, more reliable assets, and greater profits for the companies that own them.

Capabilities

Acousto Ultrasonic-Echo (AU-E)

This Hatch-patented technique measures the thickness and condition of refractory linings in operational metallurgical process vessels. AU-E provides valuable information about the vessel’s condition without disrupting the production schedule. It can detect refractory thickness and deterioration-build-up thickness, metal impregnation, metal penetration, and refractory hydration and oxidation.

Low-frequency pulsed ultrasonic (LFPU)

This system measures the wear and deterioration of cooling staves in blast furnaces. LFPU can determine the remaining stave thickness from the cold face of the furnace shell while the furnace is fully operational. It's a more advantageous solution to destructive core drilling and conventional ultrasonic rod-thickness measurements.

Furnace-integrity monitoring system (FIMS)

Our patented technique prevents and provides early warning of structural failures and run-outs in metallurgical furnaces. A system of sensors, it detects and maps acoustic emissions that can be caused by refractory movement and changes in the vessel integrity.

Radar feed-level measurement

This automatic feed-level measurement system was developed by our experts based on radar. The provisionally patented system can accurately and continuously measure the top level of the concentrate or feed bank in metallurgical furnaces. Real-time feed-level measurement allows furnace operators to optimize the smelting process, reduce energy consumption, and increase profitability.

ElectroDAR

This patent-pending system determines the tip position of electrodes in electric arc furnaces. It works by using radar to continuously measure the electrode length during furnace operation. The real-time electrode-tip-position measurement allows operators to maintain the desired power input, increase furnace efficiency and produce a lower-cost, higher-quality product.

Taphole acoustic monitoring (TAM)

This Hatch-patented system monitors drilling, lancing, and tapping operations in metallurgical furnaces. TAM works by detecting and mapping the acoustic emission locations during these operations. Operators are able to avoid directional lancing, and uneven wear of the taphole refractory lining is prevented. The result? Increased life of the lining and reduced furnace downtime.

Related services & technologies

Corrosion, Materials & Coatings

Copper

Coal

Technical papers

Progressing towards furnace modernization by utilizing comparitive analysis of acousto ultrasonic-echo (AU-E) monitoring: Case studies

Author(s): M. Henstock, A. Sadri, W.L. Ying, P. Szyplinski

Extraction 2018, August 26–29, 2018 • Ottawa, Ontario, Canada

Development of electrode tip position measurement technology for electric furnaces

Author(s): T. Gerritsen, A. Sadri, D. Chataway, M. Cramer

Infacon XV: International Ferro-Alloys Congress, Edited by R.T. Jones, P. den Hoed, & M.W. Erwee, Southern African Institute of Mining and Metallurgy, Cape Town, 25–28 February 2018