Jun

Enriched service life of ceramic embedded rolls with weld buttoning

Salient features of X’tralife treatment at one of the cement plants in slag

Challenge was to increase the wear life and it should run up to 2000 hrs. The buttoning of ceramic rollers as also rebuilding of VRM table with flux core wires was to be done parallel in total time of 37 hrs which was very challenging.
Maximum wear was observed up to 45 mm depth and width was observed around 45 mm on the periphery of rollers in the grinding zone.
X’tralife treatment was introduced consisting of unique technology electrodes which are extremely successful on VRM application and high UTS dissimilar steel joining electrodes for buffer layers.
Besides, Complex Chromium Carbide tubular electrodes were utilized for build up and final layers other than critical 45 mm.
After inspection of the rollers it was observed that maximum wear on MR1 & MR3 rollers is 3 mm and on MR2 roller is 5 mm. Besides, after running 611 hours of the VRM, the rollers performance is improved in terms of getting smooth wear and minimum wear on VRM table, increased in TPH, and minimized vibration level.