Hatch Overview

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 Furnaces Projects

Over 100 new & retrofit

furnaces world-wide
Electric arc furnaces
Rectangular 6 in-line
Round AC 3-in-delta
Round DC
Flash furnaces
Shaft furnaces
Reverb furnaces
TSL furnaces

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Furnaces Innovation
First Prototype First Commercial Application
Technology Feature
Client Year Client Year
High Voltage Shielded Arc Smelting Practice Falcondo 1967 Falcondo 1971
Copper Coolers for Furnace Sidewall Protection Falcondo 1973 Falcondo 1973
Waffle-Type Copper Coolers Sidbec 1975 Kidd Creek 1985
Copper Metal/Matte Tapping Modules (externally cooled) Falconbridge 1979 Falconbridge 1979
Copper Slag Tapblocks Falconbridge 1979 Falconbridge 1979
Plate-type Copper Coolers Chino Mines 1981 Asarco Hayden 1983
Copper Metal/Matte Tapping Modules (internally cooled) Inco 1991 Impala 1991
Vertical Wall Hold Down System Impala 1991 Impala 1991
Tongue and Groove Wall Refractory Inco 1993 Inco 1993
Copper Plate - Hung Roof Kidd Creek 1995 Kidd Creek 1995
High Intensity Waffle Coolers - Rectangular furnaces Kennecott 1996 Kennecott 1996
Forced Air - Copper Fin Cooling for Sidewalls BHP Hartley 1997 BHP Hartley 1997
Circular Furnace Flexible Bindings Gulf Chemical 1999 Gulf Chemical 1999
High Intensity Waffle Coolers - Circular furnaces Cerro Matoso 2000 Cerro Matoso 2000
AU-E Refractory Thickness Measurement Vale Copper Cliff 1998 BHP Kalgoorle Nickle 1999
Fully Automated Hot Calcine Transfer Cerro Matoso 2000 Cerro Matoso 2000
Graphite-Copper Cooling Panel Anglo Polokwane 2005 Anglo Polokwane 2006
Taphole Acoustic Monitoring System (TAM) Kennecott 2007 Kennecott 2008
Composite coolers Anglo Polokwane 2006 Anglo Mortimer 2014
Fibre Optic Temperature Measurement System Lonmin 2009 Lonmin 2009
Radar Feed Level Measurement Anglo Polokwane 2010 Anglo Polokwane 2010
Stave On-Line Thickness Measurement (LFPU) ArcelorMittal Dofasco 2011 ArcelorMittal Indiana Harbour 2012
High-Intensity In-Wall Air-Cooling Confidential 2013 Confidential 2014
Flash Furnace Swirl Disperser Olympic Dam 2014 Olympic Dam 2014
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Hatch Upgrades and Rebuilds (partial listing)

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Hatch Upgrades and Rebuilds (partial listing)

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Selected Project References
Anglo converting Process (South Africa)
Freeport Miami (USA)
Platinum Industry (Southern Africa)
Middleburg Ferrochrome (South Africa)
Once Puma (Brazil)
Barro Alto (Brazil)

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ACP Converting Furnace
Requirements and challenges:
Process conditions
High matte and slag temperatures, High heat
loads, and High matte superheat
Accretion management
Thermal cycles
Semi batch process
Project Scope: Support
structure
Refractory
lining
Slag zone waffle
coolers
Matte and slag
tapholes
Converter steel
Spring
binding
system
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ACP Converting Furnace
Key achievements:
Stable slag zone freeze lining at high heat
loads
Controlled expansion and contraction
through thermal cycles
Process temperature flexibility through
robust crucible design
24 month campaign life driven by uptake
and boiler tube
Copper coolers never replaced

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Miami Smelter TSL Furnace
Requirements and challenges:
Production increase
Higher O2 enrichment
50% to 65%
Campaign life
Target 36 months
Multiple suspected refractory erosion
mechanisms

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Design Considerations
Cooling element design
Layout determined based on heat fluxes

Freeboard/Kettle Zone
Copper with cast-in Monel pipes
Kettle Plate Coolers
1 x thermowell per cooler
Staggered arrangement to improve load Splash Blocks
distribution through lining

Freeboard Plate Coolers

Top Waffle Coolers

Bath Zone
Middle Waffle Coolers

Bottom Breast Coolers

Tapblocks

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 Platinum Furnace Upgrade - Southern Africa
Anglo American
Three 6IL EAF upgraded to include sidewall copper
cooling
Project completed between 1992 to 2008
Impala
Two 6IL EAF upgraded to include sidewall copper
cooling
Project completed in 1991
Zimplats
One circular AC EAF upgraded to include sidewall
copper cooling
Project completed in 1998

Upgrades resulted in crucible life extension

Before: 6 -24 months campaign
After: 4-5 years campaign
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 Middleburg Ferrochrome DC EAF M3
Requirements and challenges:
High freeboard temperature in DC
furnace resulted in excessive
refractory wear
H o ld - D o w n S y s te m F o r c e
( T h r u th e W a ll)

Project scope:
Crucible upgrade
Freeboard adapted to accommodate
copper coolers
Shell structural modifications S k e w B r ic k
S la g , M e ta l,
an d F ee d F o rce s
R e a c tio n F o r c e s

Wall hold-down system incorporated S h e ll R e a c tio n

F o rce
H e a r th
F o rce

Project completed in 2003

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 Onca Puma Cooling Implementation - 2013
Requirements and challenges:
Furnace design limitation causing
premature failure
Direct water cooling: steam explosion
and hydration from water infiltration
High copper cooler temperature
Partially Hydrated lower hearth
Unstable upper wall
Project scope:
Complete crucible re-design
Fabrication QA/QC
Construction technical support
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 Project Implementation - Barro Alto - 2014
2 Electric Arc Furnaces (EAF) Retrofitted with Hatch Technology
Key Responsibilities Innovative Approach Project Data integrated with 3D Model
- Engineering of EAFs
Schedule optimization and safety benefits
- Construction management including;
Facilitates constructability discussions with all stake holders
Contracting Strategy
Detailed Construction Planning Safe management of
concurrent tasks
Materials Management
Commissioning strategy
QUANTITIES
DEMOLITION INSTALLATION
/EAF
3300T REFRACTORY 2990T Results
332T STEEL 1145T
2 Furnaces delivered 27 days ahead of schedule and under
145T MECHANICAL 335T
budget
1260T SLAG
1500T SALAMANDER Resulted in early production ramp up for the client
1272m PIPING 12800dia-in
ELECTRICAL CABLES 8180m Managed contractor extras to within 2% of contract value
1060 INSTRUMENTS 868
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Fibre-optic temperature sensors

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 Fiber Optic Lining
Monitoring Background
Optical sensing elements - installed in a protective
sleeve in the area of interest
Capability to provide fine spatial resolution with
tens of sensors on a single fibre optic strand
Small size allows the sensors to be positioned for Protective Sleeve
superior sensitivity to changes in condition.
Immunity to electrical interference Refractory
The system can be customized for different
applications and integrated into the existing plant
control system to provide seamless integration for
operators
Ramming
Fiber Optic temperature sensor selected according Shell Plate
to expected temperature range
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Crucible NDT

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 Non-Destructive Testing
Extending campaign life with non-
destructive testing and condition monitoring
Thickness measurements and continuous
monitoring of refractory

Refractory monitoring program

- Acousto-Ultrasonic-Echo (AU-E) Technique
- Critical areas to be measured
- Calibration and baseline measurements
- Follow-up measurements

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Laser Scanning

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Laser Scanning (3rd party)
Verify position and orientation of equipment that cannot be accessed while operating
Laser scanning, reduces design unknowns & number of field inspections in brownfields
projects
Point cloud data imported into CAD tools Autodesk Recap file for 3D navigation

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Computational Modelling
Specialized Engineering, Analysis and Design Group (SEAD)

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CFD Modelling Electric Furnace Bath Flow
Can be used to perform numerical experiments that provide insight into likely
behaviour when certain process parameters are varied (Lonmin 2009)

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FEA - Refractory Analysis 3D Slice
3D Slice modelling captures all the effects of 2D model, along with
effects of expansion papering, brick course movement, frictional
contacts with expansion gaps, nonlinearities, crushing, etc.
Slice Model with
Individual Bricks,
Frictional Contact &
Expansion Papers

Gaps Opening Around Cooler Exaggerated

(Similar to 2D Results)
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