Cement Plant Wear Case Study - Improved Performance Using Trimay Wear Plate Solutions

All machinery parts used in cement and concrete manufacture are subjected to continuous abrasion, which is a hazard to their functioning and cripples their service life. Trimay has come up with wear solutions for machinery parts in various stages of cement and concrete manufacture. The overlay plates from Trimay find applications virtually everywhere in the manufacture machinery such as chutes, buckets, pipes, fan blades and housing and conveyors. The most recommended solutions are the T157 and T171* overlay plates.

The T157 Overlay

The T157 overlay is made of iron-based steel and is designed for operation in heavy wear environments with direct impact probability ranging from mild to moderate. The chrome overlay is characterized by a smooth surface and additional chromium and manganese enhances the wear resistance of the T157. The Rockwell hardness test rating of T157 ranges between 56 and 58 HRc and loses only 0.13 g (+/-0.03) on ASTM G65-04 Procedure A mass loss test. The slick drag coefficient of the T157 overlay, which represents its ability to impede material buildup, is 0.185

The T171 Overlay

The T171* overlay is made up of iron-based steel and has excellent glass forming chemistry that permits high levels of undercooling during welding. It has a hardness test rating of 68 - 71 HRc and unique wear resistance to severe sliding abrasion in harsh service environments. The T171* also has high impact resistance and toughness equivalent to 400 Brinell Q&T plate. This is due to formation of complex borocarbide phases, which are fully wetted by the matrix and avoid delamination, premature pull-out, and crack nucleation. They also reduce stress concentration sites and the ductile matrix provides good crack blunting and bridging, thus resulting in better impact resistance.

Case Study: Cement Plant in The Great Lakes Region

Problems Encountered

The clinker chute in the clinker stacker was exposed to abrasion despite the ceramic lining provided. The service life of the stacker therefore was only 3 months. Similarly the raw mill separator hub post liners which were coated with Ni-hard also survived only for 4 months. The service life of the fan housings also was minimised due to abrasion from cement and silica dust.

Recommended Solutions

Trimay’s T157 overlays were chosen as they provide a tight carbide matrix structure. The T157 12mm, 14mm and 9mm overlays were suggested for clinker chute, raw mill separator and the fan housings, respectively. For applications in which maximum extension in the life of the equipment is desired, Trimay suggests use of the boron-based T171* overlay plate with a dense matrix. This structure reduces the exposed surface area to the minimum, thereby minimising the abrasion level.

Achieved Results

The Trimay solutions to the abrasion problems gave an appreciable increase in the service life of the machinery parts. The life of clinker stacker was found to be more than 18 months, which is six times that provided by ceramic liners. In case of the raw mill separator hub post they lasted for more than 19 months, which was five times that of the service life provided by the Ni-Co plates. The fan housings lasted for more than 36 months, with the shape air fan housing, which is constantly exposed to coal dust and air, lasting for over 3 years.

Conclusions

The results of the above case study show the improvement in service life of the machine parts achieved by using Trimay’s wear plate solutions. Trimay provides turn-key wear protection solutions for all the various machinery parts used in cement and concrete manufacture.

About Trimay

Trimay develops and manufactures the highest quality wear overlays for customers seeking to maximize efficiency by extending the life of equipment, parts and pipelines exposed to severe wear conditions. Trimay achieves its high-quality standard through research and development, partner companies and exclusive suppliers, as well as through in-house experimentation and process optimization.

* Developed by Trimay Wearplate Ltd. using NanoSteel® Technology under license from The NanoSteel® Company, Inc.

This information has been sourced, reviewed and adapted from materials provided by Trimay Wear Plate Ltd

For more information on this source please visit Trimay Wear Plate.

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