Metguard Application in Kalinganagar Steel Plant: Addressing Corrosion in Slag Handling Areas

Location: Kalinganagar, Odisha (100 km from Bhubaneswar and the coastline)

Industry: Steel Manufacturing (Hot-Rolled Products)

The Kalinganagar steel plant, a major hub for hot-rolled products, operates in an environment that subjects its infrastructure to severe corrosion. This is especially true in the slag handling areas, which experience some of the highest levels of corrosive exposure in the plant. The presence of aggressive gases and materials, such as hydrogen sulphide (H2S), makes it crucial to implement advanced anti-corrosion technologies.

Corrosion Challenges in Slag Handling

An integrated steel plant exposes its structural components to a wide range of corrosive materials throughout processes like steel purification and by-product recovery. In particular, slag handling processes release hydrogen sulphide, a major contributor to sulfidic corrosion, which severely degrades steel infrastructure. This corrosion is further exacerbated by the presence of moisture, sulfur oxides, and other industrial pollutants.

Key areas where Metguard was applied include:

• Slag Transporting Conveyor: Continuously subjected to corrosive gases like H2S.
• Conveyor Gallery for Slag Handling Unit: Affected by the combined corrosive action of sulfur compounds and environmental moisture.
• Blower Systems: Exposed to corrosive pollutants during the slag removal process.
• Utility Pipe Lines: Vital for the movement of gases and liquids, these lines face constant corrosion pressure.

Metguard's Advanced Corrosion Protection

To combat the intense corrosion in these critical areas, Metguard was applied, offering a robust solution for long-term protection. Here's how Metguard addressed the corrosion issues:

• No Metal Loss & Extended Lifespan: Metguard’s patented metal passivation technology ensures that structural components in the slag handling areas experience no metal loss, significantly extending their lifespan, where traditional coatings fail.
• Environmentally Friendly: Metguard is free from harmful chemicals like lead, chromates, and isocyanates, making it a sustainable choice in this industrial setting.
• Easy Application: The coating can be applied without abrasive blasting, using brushes, rollers, or airless sprays, directly onto metal surfaces, making it a quick and efficient solution.
• Sulfidic Corrosion Resistance: Metguard’s formulation provides strong protection against sulfidic corrosion, which is particularly destructive due to hydrogen sulphide emissions in the slag handling process.
• Cost-Efficiency: With low maintenance requirements and no need for frequent reapplications, Metguard has significantly reduced the plant's lifecycle costs.

Conclusion

The application of Metguard in Kalinganagar’s steel plant, particularly in the most corrosive environments like the slag handling areas, has proven to be a highly effective solution. By offering long-term protection, ease of application, and significant cost savings, Metguard has safeguarded vital infrastructure, reduced maintenance needs, and contributed to a more environmentally sustainable operation.