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Engineering Specialties Used:
Finite Element
Remediation Design
Stress Analysis

Finite Element Model of Rotary Cooler

The equipment had progressive wear and high temperature deterioration which were believed to be the cause of repeated refractory failures and shell fatigue cracks during operation. Several unscheduled shut downs were required to inspect and repair the shell and refractory, interrupting plant production and causing undesirable plant shut down/start up cycles. The cause of the wear and high temperature deterioration on the equipment was known. What was needed was confirmation that the observed wear and high temperature deterioration resulted in the refractory failures and shell fatigue cracks. Ultimately, a remediation design was needed to prevent the unscheduled shut downs from occurring in the future.

A three-dimensional stress finite element model (FEM) was built for the original equipment design. This FEM was used to determine original shell deflections and stresses which were known to be acceptable. The model was then modified to account for the deteriorated condition to understand how deflections and stresses changed over time and to confirm that theses changes were the cause of the observed failures. External stiffening rings were added to the FEM to achieve deflection and stress values equal to or lower than the original design. A remediation design fix was prepared for installation in the field.

Stiffening Ring Installation

The facility was able to eliminate unscheduled shut downs and start ups from component failure. This result reduced maintenance costs and improved safety. It also allowed the facility to come online faster after each scheduled maintenance cycle since fewer repairs were required. Argos Engineers is ready to partner with your plant personnel to extend the life of critical equipment. After the design remediation was installed, the equipment has not had another unscheduled shut down.

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