Market requirements as a driver of innovation

REPORT Applied wear protection solutions from Kalenborn 33rd Issue Strong armour: KALMETALL protects bucket-wheel excavators Insights into cement ...
Author: Oswald Burns
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REPORT

Applied wear protection solutions from Kalenborn 33rd Issue

Strong armour:

KALMETALL protects bucket-wheel excavators

Insights into cement production

KALCRET-lining at Canadian cement works

Our deployment in shale oil production

EDITORIAL

Market requirements as a driver of innovation Dear Readers, In cement production, large quantities of bulk material are transported in all areas of materials handling and storage technology. This is why we are dedicating this issue of the Kalenborn Report to focusing on the linings used in cement works. Read how Kalenborn develops wear protection systems for mill lining and sifter systems in the form of the KALCRET hard compound and the KALMETALL-W hard overlay welded plates and in so doing meets customer demands for longer service lives. Our case studies report on applications in a wide range of different areas. The wide variety of our materials enables us to offer an appropriate solution for different levels of wear and plant components. Applications such as protecting coke warves with KALCERAM hard ceramics or coke silos with ABRESIST fused basalt show how important it is to have a wide range of materials which, beside offering abrasion resis­ tance, also have excellent sliding characteristics and high resistance to sudden changes in temperature. What else is there to report? With the website and brochures having been given a new layout, we now have also reissued and revised our former customer magazine KALREPORT. We hope you like the new look and wish you an enjoyable read.

Dr. Conrad Mauritz

Markus Buscher

WHY KALENBORN?

Effective wear protection from a single source From the development and production of our materials to the lining of the plant components, Kalenborn can be relied on to take care of every aspect. Close links to customers and the quality and durability of our products are the most impor­ tant things. Kalenborn’s experts work with the customer to develop individual and sustainable solutions that save costs and guarantee process reliability – both for optimising existing plants and for new constructions. In addition, we develop further solutions that enhance the level of production efficiency and profitability in the plants. The components that need to be lined are either provided by the customer or made by our experts in their own production facilities. We will also fit the wear protection lining on site at the customer’s premises.

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Kalenborn offers the crucial benefit that our materials undergo constant quality checks to ensure that the quality features which we promise are delivered at all times. The quality of our materials and user solutions set the bench­mark. Installing the wear protection lining on site at the customer’s premises

KALENBORN FRANCE

Wear protection for port cranes

Ports are important facilities that handle all kinds of goods and products. In the north of France, the main products that are shipped are foodstuffs and oil products as well as ore and coal. Several cranes operate every single day and transport the goods from ships to land. Because this causes particularly great wear on the ship unloaders, the port commissioned the com­ pany Kalenborn France to provide wear-­proof lining for its cranes. The challenge: to protect chutes and filling shafts as well as channels and pipes. A suitable form of wear protection had to be found for all elements. Kalenborn decided on a combination of three materials: KERAFLEX, KALMETALL and KALOCER. The transfer chute, whose impact surface has to withstand a material throughput volume of 4,000 tons an hour, was reinforced with KERA­ FLEX. The ceramic plates vulcanised into rubber mats have an extremely hard and wear-proof surface. Impact resistance is provided by the 10-mm-thick rubber layer and optimal vulcanisation of the components. The unloading surfaces of the conveyor belts were also fitted with KERAFLEX. Because the conveyor belts work at a speed of between 3.6 and 5 metres a second, high wear protection is particularly important here. Feeding chutes and filling shafts were lined with KALMETALL-W and KALOCER. The combination

of the KALMETALL-W hard overlay-welded plates and the KALOCER high alumina ceramics unites optimal wear protection with outstanding gliding properties. A consignment warehouse has meanwhile also been constructed on site: here the employees in charge of facility maintenance can independen­tly remove and process the required materials.

An external view of the ship unloader’s filling shaft lined with KALMETALL-W and KALOCER wear protection.

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KALENBORN FRANCE

Good protection is half the battle won The south of France not only boasts olive plantations and fields of lavender. The region is also home to cement works which present Kalenborn with new challenges.

In order to optimise the process of grinding cement, a European cement manufacturer decided to procure a new vertical roller mill. However, as the facility only produces special cement con­ taining a high fraction of granulated slag, the mill is subjected to heavy loading. This places great demands on the wear protection and on extending the lifespan of the facility. The customer commissioned the experts from Kalenborn to line the vertical roller mill and its systems. They impressed the customer with the wide range of materials produced within the company that make it possible to protect components that are subject to different levels of loading in the best way possible. Kalenborn worked with the mill supplier to come up with an integrated solution in which three proven materials are used. In order to protect the sifter housing from the high temperatures which are generated, the installation team laid 280 m2 of

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KALOCER alumina ceramics in the upper section. Due to the vibrations that are to be expected in the area of the sifter, the KALOCER tiles were securely fixed in place with holes and weld-on sleeves. In the bottom and top section of the sifter and in the bottom section of the return cone, the decision was made to use KALMETALL-W hard overlay welded plates, which guarantee both high wear resistance and impact strength. A total of 55 m2 was lined using this material. The Kalenborn experts protected the dust line behind the mill over an area of lining of around 124 m2 with the hard compound KALCRET, which can be trowelled on. KALCRET is suitable for creating a quick and seamless lining and also ensures very good wear resistance and compressive strength – even at high application temperatures. The installation team installed all of the lining on site at the cement works within the specified schedule. Kalen­born was thus able to complete the assign­ ment to the customer’s complete satisfaction.

KALOCER alumina ceramic tiles as protection from the high stresses caused by fluctuating temperatures

AREAS OF USE AT CEMENT WORKS

Versatile applications In cement works, large quantities of bulk materials are transported across all stages of the production process. Kalenborn has many years of experience in lining the various components in cement works so that they become wear-­ resistant and promote sliding. The large range of metallic

and ceramic materials as well as plastic-based materials are all produced in house. It is the combination of different materials that makes it possible to produce a particularly effective lining that is adapted to the particular application.

Limestone quarry

Blending bed Crusher

Clay

Raw material Raw meal sifter

Dedusting filter

Preheater

Fuel preparation

Tertiary air duct Raw meal mill

Clinker silos

Rotary furnace Raw meal silo Clinker cooler

Aggregates

Cement sifter Dedusting filter

Cement silos Cement mill

Solid material flow Exhaust air/heat

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KALENBORN MATERIAL KALCRET

KALCRET – wear protection that can be trowelled, cast or sprayed on

Linings with KALCRET protect plant components and pipes. There are already many successful applications throughout the raw materials industry, for example in mining, in power plants, in the steel and cement industries, and in waste incineration plants. In power plants, KALCRET protects the pipe bends of pulverised coal pipes. One typical application in steelworks is providing wear protection for the agi­ ­tator for extracting the dust from the blast furnace gases and the windboxes below the sinter belt. In cement works, the pipes in clinker dust pipelines are lined with KALCRET and in cement grinding KALCRET is used to protect the sifter lining. KALCRET is easy to apply in lots of versatile ways. As a casting compound, flat surfaces can be lined quick­ ly and efficiently and with the Kalenborn spray technology for KALCRET large surface areas can be coated quickly and securely so that the plant availability is restored in a short period of time. KALCRET is hard, wear-resistant and can be used flexibly As a cement-bonded hard compound, KALCRET combines excellent wear protection properties with easy handling. Its particular advantage is its flexibility. Linings over large surface areas and repairs, even to complex geometries, can be carried out with simple tools. It can also be processed overhead. The surface which is lined can be subjected to loads again after just 24 hours.

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KALCRET can be supplied for temperatures of up to 1200°C and is also capable of being combined with other materials from the Kalenborn wear protection range. Kalenborn individually matches the requirements for the material which is spe­ cially produced with the customer, in accordance with the particular intended uses. For more information and to view an application film, scan the QR code or go to www.kalcret.com The Kalenborn spray technology enables large surface areas to be coated quickly and safely.

KALENBORN DO BRASIL

ABRESIST used to protect coke silos In late 2012, a major steel producer from Brazil approached the Kalenborn do Brasil branch office: at a plant near to Rio de Janeiro there were problems with wear on two coke silos.

Shortly after the plant was constructed, in August 2011 the silos were each half lined with har­ dened plates and Kalenborn’s ABRESIST material. One year later, the plates were already beginning to show fairly substantial signs of wear, while ABRESIST was still in good condition. The company then requested that the silos should be fully lined with ABRESIST. Closer examination revealed that the friction from the coke had already resulted in wear and corrosion to the hardened plates. Moreover, the gaps between the individual plates meant that the structure of the silo was not completely protected, as is the case with ABRESIST. In March 2013, the larger silo was therefore completely protected with ABRESIST over the course of 18 working days, with the smaller one requiring 15 working days to be completed. A total surface area of more than 600 m2 was laid in the hoppers. Eight workers were involved in carrying out the work.

that, under the given conditions and in relation to the thickness of the material, ABRESIST is five times more abrasion-resistant than the rival product.

ABRESIST: The mineral wear protection made from cast basalt offers high wear resistance, a smooth surface that lasts, and no corrosion

Over 600 m²

of surface area was installed within the silos.

The project was implemented to the client’s complete satisfaction. Investigations also showed

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KALENBORN KALPROTECT

KALCERAM – in Europe’s largest heavy-plate works Europe’s leading manufacturer of heavy plates is a long-standing customer of Kalenborn. From steel bridges and skyscrapers to oil and gas pipelines, the company’s plates are used in numerous projects all around the world. The company’s headquarters is also the site of the coking plant, which produces coke for the two blast furnaces at the heavy plate plant. In the course of refurbishing the coke ramp, this long-standing customer approached Kalenborn because we had previously refurbished coke ramps here. During the expansion of the coke works in 2006 and 2009, one ramp was wear-protected with materials from Kalenborn. During the present-day refur­ bishment, this experience was to be taken into account. A coke ramp is a chute onto which quenched coke is tipped. The coke slides over a ledge and down to a clearing table, from where it is transported on a conveyor belt. Along with heavy-duty wear protection, the customer also emphasised the need for the coke to slide well on the ramp. The material would also need to withstand the temperature changes arising from the quenching of the inevitable ember clusters in the

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coke. Around two wagon-loads of coke are placed on the ramp every hour. Due to the extreme conditions caused by the changes in temperature, Kalenborn‘s wear protection experts line the chutes of the coke ramps with KALCERAM-K. This material features good gliding properties and high thermal shock resistance. Kalenborn was able to distinguish itself particularly well with the overall package of engineering, material procurement and installation services on site. Customers value the excellent and reliable working relationship.

KALENBORN MATERIAL KALMETALL-W

KALMETALL-W – tough, impact-­ resistant and indestructible The metallic materials from Kalenborn are suitable for a wide range of industrial applications – and KALMETALL-W is one of them. The armour plates with different thicknesses and quality grades are noted for their excellent wear resistance and impact strength. The reinforced plates are made up of a steel base plate and a hard metal overlay which is welded on, in some cases in several layers. The base plate ensures the static strength of the component whereas the wear resistance and impact strength comes from chromium carbides that are embedded in the metal structure. By varying the base plate and the hard metal alloy, applications at high temperatures of up to 750°C or aggressive process conditions can also be carried out. Modern processing techniques and metallurgical know-how allow us to manufacture highly complex and precise components, housings and plant parts in line with the customer’s specifications.

For example, fans, cyclones, sifters, chutes and mixers can all be fabricated as a self-supporting structure made from KALMETALL-W. The material is also suitable for use in regenerating grinding rollers and grinding tables in vertical roller mills. The original geometry of the components is restored, which means they can continue to operate effectively for many thousands of hours. This solution is not only cheaper, it is also more flexible than procuring new components and makes it possible to get the vertical roller mill back into operation again quickly. Our company Kalenborn Delma has many years of experience in deposit welding – on site or alternatively in our plant in Poland.

For more information and to view an application film, scan the QR code

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KALENBORN KALPROTECT

Protect what keeps us warm Kalenborn’s wear protection solutions are also needed in Northern regions. At the plant of Estonia’s leading producer of shale oil, oil shale is separated to produce shale oil and shale gas.

The raw materials which are obtained are required to produce fuel for households. Shale oil is also a popular fuel used by ships sailing in the Atlantic Ocean and the Arctic Ocean. The company produces more than 250,000 tonnes of shale oil per year. More than two million tonnes of oil shale are processed to produce this quantity of oil. This is a complicated process – resulting in challenges for wear protection. The plant grinds wet oil shale around the clock and guides the rock via conveyor belts into a flash dryer where it predries. The fine-grained, dried oil shale is then blown at high speed and in air at a temperature of 800 degrees through a riser pipe up into laterally adjacent cyclones. At this level, the moist air escapes while the dry oil shale is discharged downwards in the cyclone. The issue of wear protection in the flash dryer had hitherto largely been ignored. As a result, the plant components were sensitive and only had short service lives. Already in 2013, the company asked Kalenborn to develop specific wear protec­tion solutions for the plant parts with a wide range of different

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geometries and operating conditions. These solutions were intended above all to guarantee long service lives for the components. With a wide range of wear protection materials manufactured internally and many years of experience in this field, Kalenborn was able to offer the right solution. Kalenborn installed a lining system comprising KALSICA-N and KALCOR-S offering outstanding resistance to abrasion at high temperatures and high thermal shock resistance in the lower heating section of the flash dryer. In the middle section, ABRESIST and KALMETALL-W were used due to the shape of the riser pipe. In order to improve the impact strength, the engineers from Kalen­­born employed a structure comprising KALMETALL-W and 100 mm thick KALSICA-N bars in the upper section of the distributor. The cyclones were also lined with KAL­METALL-W100. The plant was able to start operating the same year. The adapted wear protection solutions from Kalenborn met the customer’s expectations. Two further plants were lined in 2014 and 2015. The longer service life now enables the company to manufacture products efficiently and reliably.

KALENBORN DELMA

Strong armour

The bucket-wheel excavator transports the iron ore pellets to the steelworks via the conveyor belt

Kalenborn has been a partner to one of the largest manufacturers of steel in North Africa since 2015. The company supplies customers all over the world, handling 5.8 million tonnes of steel per year. The iron ore pellets that are processed for steel production arrive at the port by ship. A bucket-­ wheel excavator is responsible for unloading the pellets from the ship and at the same time trans­ ports them by conveyor belt to the steelworks. From time to time in the past, the pellets got caught in the wear protection on the bucket-­ wheel structure. The stray pellets caused additional weight on the bucket wheel and thus disrupted the smooth running of the machine. Here, a solution was needed. As Kalenborn was already known as the supplier of wear protection, the customer had a closer look at the range of materials on offer and was impressed. Working in close collaboration, agreements were then made on how to optimise the key aspects of the wear protection. The goal: Achieving a long lasting life and trouble-free operation for the bucket wheel.

protection were also covered with armour plates or manually reinforced with KALMETALL-W 100. The project was implemented to the customer’s complete satisfaction. The customer particularly praises the personal contact with the counterparts from Kalenborn. This close collaboration makes it possible to find the right solution to every problem. The large number of materials and options for lining that Kalenborn offers has been very helpful here. The next bucket wheel has already been ordered.

At the end of 2015, Kalenborn produced the bucket wheel as a complete welded structure including attachments. The areas which needed to be protected were made from KALMETALL-W 100. The hard overlay steel plate offers a very persuasive choice with excellent wear resistance and impact strength. Areas requiring special

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Kalenborn Phone: +49 (0)2645 18-0 www.kalenborn.com KALENBORN BRANCHES

USA: Kalenborn Abresist PO Box 38 5541 North State Road 13 Urbana, IN 46990 Phone: +1 (800) 348 0717 [email protected]

France: Kalenborn France 24, rue Maurice Ravel 28130 Maintenon Phone: +33 (0) 23727 19 89 [email protected]

Kalenborn Bazalt ul. M. Piłsudskiego 68 27-200 Starachowice Phone: +48 41 274-5351 [email protected]

Kalenborn Technologies 1000 Sequoyah Road Soddy Daisy, TN 37379 Phone: +1 (423) 531 4161 [email protected]

Germany: Kalenborn Kalprotect Asbacher Str. 50 53650 Vettelschoss Phone: +49 (0) 2645 18 0 [email protected]

Hungary: Kalenborn Refmon Bereki út 1 9246 Mosonudvar Phone: +36 96 578-578 [email protected]

Canada: Kalenborn Canada 602-755 Blvd. St Jean Pointe-Claire, PQ H9R 5M9 Phone: +1 (514) 426 0460 [email protected]

Poland: Kalenborn Delma ul. Olszowa 60 58-150 Strzegom Phone: +48 74 855 54 00 [email protected]

Singapore: Kalenborn Asia 80 Genting Lane  Singapore 349565 Phone: +65 6745 2988 [email protected]

Brasil: Kalenborn do Brasil Rua Boaventura, 1621 Belo Horizonte/MG Phone: +55 (31) 3499-4000 [email protected]

Odlewnia Świdnica ul. Kliczkowska 53 58-100 Świdnica Phone: +48 74 640 20-25 [email protected]

Philippines: Kalenborn Weartech Philippines No. 322 Marcos Highway, Bo. Mayamot, Antipolo City 1870 Phone: +63 (632) 696 9001 [email protected]

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