Technical Assistance For 3 Quick Critical CGL Issues
Giirtec Steel provides technical assistance on following 3 quick critical CGL issues as:
1. New design heat exchanger for Jet cooler: (To prevent water leakages in the furnace)
In the old design of heat exchangers, the headers are directly brazed to the bundle tubes, which could lead to leakage at the brazing points in case of a crack or rupture, with the high risk of water entering the furnace atmosphere. Fortunately, the new design concept is the absence of any welding or brazing. The tubes of the bundles are crimped between two tubular sheet plates, with no water leakages in the furnace & advance indication of heat exchanger failure.
2. New design of water jackets for the Pyrometer cooling system: (To prevent water leakages in the furnace)
In the old design of pyrometer water jackets, a single-envelope construction was used. In the event of jacket failure, cooling water could leak directly into the furnace, causing serious operational and quality issues.
To address this problem, a new design has been developed using a double-envelope construction, where one envelope is placed inside another. With this design, even if leakage occurs in the inner envelope, the water is safely contained within the outer envelope. Due to the high furnace temperature, the leaked water is converted into steam, which is then discharged through an external vent near the inlet. This design completely prevents water from entering the furnace.
Giirtec Steel has received feedback from multiple customers stating that water leakage in the old design leads to water falling on the steel strip, resulting in white patches. These defects are not acceptable from a quality perspective and can cause up to 500 tons of material to be downgraded. Additionally, identifying the exact leakage location is extremely challenging, often requiring the production line to be shut down for approximately 20 hours for investigation and repairs.
Important Point:
GIIRTEC will supply the new design heat exchanger / pyrometer water jackets as spare parts and ensure that they are perfectly compatible and properly installed in the existing furnace system.
3. To support on investigation of rough patches appearing on sheets when processing minimize spangle & proving technology to support to fix this issue.
To support the investigation of rough patches appearing on sheets during processing under minimize spangle conditions, a detailed analysis and technology-based approach will be implemented. The objective is to identify the root cause of surface irregularities and provide effective solutions to eliminate the issue.
The investigation will focus on critical process parameters, including surface temperature control, cooling efficiency, strip movement, and interaction between the sheet and processing equipment. Special attention will be given to conditions specific to minimize spangle processing, where surface sensitivity is higher and even minor process deviations can result in roughness or surface defects.
Advanced monitoring and proven technologies will be utilized to analyze operational data, identify abnormal trends, and determine potential sources of the rough patches. Based on the findings, corrective measures and process optimizations will be recommended to stabilize sheet quality and ensure consistent surface finish.
This approach aims to reduce quality rejections, improve product consistency, and support smooth and reliable operation during minimize spangle processing.
Why Choose Our CGL Technical Assistance?
Enhance the reliability, safety, and quality performance of your Continuous Galvanizing Line (CGL) by addressing critical operational challenges with proven engineering solutions. Giirtec Steel delivers targeted technical assistance focused on preventing furnace-related failures, minimizing quality losses, and improving process stability through advanced design concepts and deep metallurgical expertise.
- Advanced Equipment Design Expertise: Strong technical knowledge in designing and upgrading critical CGL components.
- Customized Engineering Solutions: Tailored technical approaches based on plant-specific configurations and production requirements.
- Proven Industrial Experience: Successful implementation of design improvements solutions across multiple flat rolled steel plants.
- End-to-End Technical: Support Comprehensive assistance from issue investigation and root cause analysis to solution implementation.
Benefits of Our Technical Assistance
- Enhanced furnace safety by eliminating water leakage risks
- Minimized production downtime and faster fault identification
- Reduced quality downgrades and material losses
- Stable and consistent performance under minimize spangle conditions
Whether you have a question, concern, we would love to hear from you! Our dedicated customer service team is ready to assist you with any inquiries you may have.