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X’tralife treatment to increase Roller Press Roll profile life

Success story about the increase Roller Press Roll profile life

Problem :

  • The profiling life on a slag roller press at a cement plant in eastern India was only 1250 hours and the tonnage use to drop after 1000 hours.
  • The plant was required to stop for 3-4 days for profiling and thereby maintain roller health. This was observed due to combination of both wet and dry slag and wet slag was causing excessive damage.
  • The plant was subjected to this problem for decades and it has generated challenge for WR team.

Challenge :

  • For Wearresist, challenge was to increase the service life in order to aid assistance to fight the war against wear and tear as this has affected productivity and profitability.

Resolution of the identified challenge :

  • Wearresist has analyzed the root cause of identified challenge through in depth characterizations. Considering wide range of products, WR team has offered the revolutionary XL – CC870 alloy which has capability to produce uniform grain distribution and formation of micro constituents.

Key characteristics :

  • XL-CC-870 revolutionary flux cored wire provides exceptional wear resistance while comparing to most chrome carbides and complex carbide alloys through excellent elemental distribution.  This product has been developed particularly for roller press roll profiling.
  • Gives exceptionally 67-70 HRC with single layer of deposition.
  • A multi component steel alloy with unique uniform melt chemistry which allows higher solidification ratio (G/R) to be achieved during welding. This results into uniformly distributed microstructure having lower dilution value.
  • An iron (Fe) based alloy with exceptional abrasion and erosion wear resistance with high toughness. The micro structure consists of chromium carbide phases along with Fe based solid solution which is why it provides resistance to wear.

Feedback :

  • After 1000 hours in 1st inspection, the roller profiling bead has been observed with negligible reduction in the height of bead which indicates very less wear loss.

 

  • Hence, problem has been solved with appropriate application of metallurgical revolution through XL – CC870. The conditions of the roller @ 1000 hours are shown in the picture.

 

  • Later, there was a new challenge which can be called as acid test. The magnetic drum has stopped working thereby resulting into some small chip outs.

 

  • But that has turned out to be blessing in disguise. Due to excellent wear properties of XL – CC870. The roller was still going ahead without any drop in output.

Achievement :

WRTPL offered a commitment of 2500 hours working but the roller worked for more than 3500 hrs in first trial .the same performance is repeated regularly since then.

Key benefits due to increased life of Roller Press Roll :

  • Above case study addresses the concern of top management about reclamation of key spares rather then buying new. This approach is economical and technically superior for the society.
  • The solution in terms of repair and reclamation aware society to adapt better metallurgical upgrades and innovative processes to improve the availability of the plant and machinery.
  • Overall, this thereby reduces the downtime losses and operational costs resulting into absolute improvement of the bottom line for the organization.
Condition of roller before Xtralife profiling
The XL – CC870 profiled roller ready for use
The XL – CC870 profiled roller ready for use
Conditions of the roller after @ 1000 hours
This meant that the profiling could even sustain foreign material ingress and still go strong
The conditions of roller after 3500 hours. The best part is that unlike past no drop in tonnage until the last tonnage.