Successful wear protection depends not only on selecting the correct wear protection product but also on installation by specialists with plenty of know-how. Moreover, it pays to monitor the newly installed wear protection.
Specialist installation is a key factor in the successful performance of cement-bound wear resistance materials.
In most cement plant applications, erosion is the predominant wear parameter. To protect against wear, cement producers and their wear protection suppliers need to understand the in situ conditions. To help achieve this, there are different test methods to rate the performance of the materials under standardised conditions with international standards such as ASTM C704-15 providing key guidance. Known for similar types of refractory materials, this standard compares the resistance to particle erosion in the best way.
In combination with other methods, such as the Boehme test according to DIN 52108 and the rubber wheel abrasion test according to ASTM G65, Germany-based wear protection company Kalenborn can closely relate the test to the actual kind of stress happening in a cement plant. If this or a few other standards are chosen to describe the performance, it establishes a good particular user experience related to international testing standard results.
Understanding the operational conditions at the plant also enables the wear specialist to consider the maximum operational temperature and select the correct type of concrete. Regular high- performance cement is only suitable for use in temperatures of up to 400 ̊C. For high-temperature applications, special cements with a resistance of up to 1200 ̊C deliver a considerably better performance.
In addition to the selection of a suitable wear production product, an important factor for the performance of a cement- bound material, such as hard compound KALCRET lining, is the installation. Factors such as proper mixing, the temperature during installation, the moisture content and the presence of moisture during the installation alongside the setting time, all define the quality of the final product. A qualified state-of-the-art and careful installation is essential to achieve all required properties. Kalenborn supports customers by sending specialist personnel to site, supervising contractors on site, and training designated contractors and partners. Testing specimens from the installation site in the Kalenborn laboratories are also available.
“Understanding the operational conditions at the plant also enables the wear specialist to consider the maximum operational temperature and select the correct type of concrete. "
Visual wear monitoring
To enable the operator to diagnose the condition of the wear lining, there are a range of monitoring tools for different applications. In addition to providing a meaningful assessment, the system contributes to sustainable action and increases process reliability, which increases the plant availability. Condition- based maintenance conserves the customer’s resources while increasing plant availability. Monitoring enables the best possible plant uptime with maximum safety and planned repairs.
For KALCRET hard-compound lining, Kalenborn has developed its own process for wear protection monitoring. Coloured indicator stones with the same properties as the base materials are used to visually determine the degree of wear. The indicator elements are fixed in the lining and provide the operator with early information on the remaining thickness by visual inspection. With increasing wear, more indicator stones become visible and provide continued information about the condition of the wear protection lining. Preventive action can be taken to avoid the premature or sudden failure of a component due to wear.
In addition to visual wear protection, Kalenborn also offers an electrical and two mechanical wear protection monitoring systems. The systems are constantly being optimised and expanded. The product range is also due to include a digital version in the near future, which provides discrete values on the condition of the wear protection lining.
“For KALCRET hard- compound lining, Kalenborn has developed its own process for wear protection monitoring. "
Case study in Vietnam
A privately owned cement producer in Vietnam wanted to protect its new 250tph vertical roller mill (VRM). The company worked together with a team from Kalenborn in Germany and the Kalenborn Vietnam office, alongside the contractor that supplied and installed the VRM, to find the most suitable wear-resistant linings.
Approximately 500m2 of linings were done. The separator, which is exposed to fine dust and impacted by high velocities, was protected using KALOCER hd high- alumina ceramic tiles, which are very abrasion-resistant. The ductwork leading to the filter received a KALCRET BTX hard- compound lining while the sections around the moving parts, which are affected by the impact stress of coarser grains, benefitted from KALMETALL w linings.
Both the KALCRET and the KALOCER hd linings were installed by trained personal on-site. Meanwhile, the KALMETALL w liners were supplied cut and shaped to site, to be welded and bolted in by the machine fabricator. The entire project was carried out on schedule. After two years of operation, the mill runs at full capacity. Not a single unplanned stop has been necessary to repair parts of the linings. Regular checks show a regular wear pattern but no actual damage or failures.
The operator is now considering the installation of a second mill, which would again use customised wear protection by Kalenborn.
Written by Kalenborn, Germany
Published in February 2022 Edition of the International Cement Review Magazine.