End-User Feedback

A mill’s acquisition price is only a portion of the total cost to remove and replace large-bore furnace hoses, and here are the related costs.

• The time required to move these large assemblies from storeroom to melt shop
• Stage the necessary lifting equipment
• Schedule the mechanical teams for the change out
• Review proper safety procedures, i.e. lock-out, tag-out, fall protection
• Ensure that all personnel have proper safety clothing and equipment
• Limit production downtime to a minimum
• Hose change time can range from ½ to 6 hours
• Unscheduled downtime at the EAF due to premature failure will far exceed the acquisition cost of a GSM Hose

Facts

• Efficient movement of cooling water around an Electric Arc Furnace (EAF) is critical to the continuous steel making process. These crucibles often pour liquid steel every 40-50 minutes.
• The typical life of large bore metal and/or rubber furnace hoses utilized in this service can range from as little as 10 months to as long as 3 years.
• Root causes of premature hose failures in a typical mini-mill:
  • Stress cracks in the metal hose liner caused by frequent flexing and movement when the furnace roof opens for charging, melting, and tapping.
  • Metal hose liners rupture from impulse cycles created by vacuum pumps when pulling spent water throughout the cooling system.
  • Hot scrap, slag, and ‘skulls’ landing on water supply hoses during the charging process often burn through the metal braid and/or heat resistant hose coverings.
  • When using metal hose or thin-wall rubber hose with swivel joints, severe hose twists can occur, restricting water and eventually causing shut- down to an EAF.
• Acquisition prices for EAF roof and crucible water hoses range from $3K to $15K each, depending on bore size (ID) and length.

Dixon Solution

Dixon has been fabricating and supplying ball-joint armored hose assemblies for water cooling transfer applications in steel mills for over 50 years. The unique half-round design not only prevents hose kinks, but also keeps the hose round for continuous and consistent flow of water around the furnace crucible and roof panels. Ball-joint armor can be applied to hose sizes ¼” through 12“ ID.

Durable, efficient and safe, Dixon armored assemblies outperform and outlasts alternatives. Most mills experience 3-5 times the hose life, and some hose assemblies are performing as much as 10 years of service!