Cement Industry

In Indian Cement Industry, the more than full capacity utilization of rated capacity is quite normal in the last one decade which has been driven by the need of the Indian Cement Manufacturers to become cost competitive and bring economy of scale.  In the process, the wear rates of various equipments used in the cement manufacturing has increased due to the high velocities or by increased raw material intake over the same surface area. Additionally, the raw materials used for cement like limestone, coal, lignite, quartz, slag, gypsum, fly-ash etc.  are quite abrasive due to high Silica content . 

The Cement plant being a continuous process plant has to run continuously at least for an year  for a modern cement plant to be a profitable plant year after year due to the price sensitiveness of the product. To do so all the equipment has to be reliable and should give a life of one year to match annual shutdown or multiples thereof. This could be possible through metallurgical upgradation of various wear prone areas. Many of these upgrades have been possible through the use of latest welding technology. WEARRESIST TECHNOLOGIES PVT. LTD., INDIA (WRTPL) has been the pioneer of X’TRALIFE treatment to wear prone parts through surface engineering solutions like X’TRALIFE Wear Plates, X’TRASLIDE Wear Plates, XL-70 Chromium Boride Paste, XL welding alloys, Cladding of Complex Chromium Carbide on Ni-hard and Hi-chrome base materials and Crack Free High-Strength hard surfacing (for Roller Press). X’TRALIFE technology has significant improvement in Life compared to other reconditioning welding due to the following factors:

1. Low Dilution and High Concentration of Secondary and Primary Carbides for high-stress abrasion applications. Unique to this technology, is the fact that the hardness and wear resistance improves on the hard layer mm by mm as the material wears the thickness. 
2. High Dilution and Toughness with special Carbides for applications like Roller Presses due to which Roller Presses build up with more than 100 mm have also performed extremely well without dechunking and wear.
3. Techno-commercially viable solutions 
4. Versatile solutions to combat various wear problems as per process requirement.
5. High resistances to erosion applications through Chromium Boride weld metal devoid of soft matrix and hence the Borides are able to play their role without being lost from the matrix. 
6. Deposition of Noble Alloys with high Carbide concentration for Vertical Mills which out-perform Hi-chromeor Ni-hard by two to three times.

The prime application areas in Cement industries are :

• Raw Lime Stone, Bunker, Lining Plates & Side Plates
• Push Feeder, Sole Plate, Side Plates
• Lining Plates for Feeder
• Crusher Jaws
• Chutes Lining Plate
• Main Crusher Casing Lining Plates
• Blow Bars
• Impactor Arm
• Cone Crusher
• Impactor
• Cone & Connecting parts

Stacker Reclaimer Lime Stone region :

• All the transfer point chute
• Lining plates mainly bottoms & side plates
• Stacker & Reclaimer Boggie wheels
• Lining plates for Pen connecting in Reclaimer section.

Raw Material Handling region :

• All the transfer point chute
• Bottom & side lining plates
• Raw Material hopper discharge cones
• Feed tables, table plates, side lining and discharge chute lining, etc.

Raw Mill region :

Mill lining, rollers (wear segments), grinding table (wear segments), grinding louvre ring, rocker arms, joint head assembly, rotary… etc.

Raw Material Transportation region :

• Screw flap ring & ENDC over’s for FK Pump and PS Pump
• Air Nozzles
• Transport pipe line
• Wear bend

Pre-Heater region :

• All the transfer point chute
• Lining plates mainly bottoms & side plates
• Stacker & Reclaimer Boggie wheels
• Lining plates for Pen connecting in Reclaimer section.

Rotary Kiln region :

Inlet tip casting, outlet tip casting, supporting roller, guide roller, burner pipe.

Clinker Cooler region :

Cooler grate plates, Side plates, Main frame beam roller, Guide roller sole plate for roller, Grizzly bars, Wearplate in side cooler.

Cement Grinding region :

• Feed tables for Clinker, Pozzolona, Gypsum
• From start point Chute Liners
• Mill Inlet Cone
• Mill Lining & Diaphram scope arrangement
• Mill outlet cone arrangement
• Roller press rolls & Liners, etc.
• Vertical Mills