Wear-protection for industrial plant

In order to protect plant components used in production of energy and raw materials, as well as in primary industries, Kalenborn provides tried-and-tested solutions for effective protection against wear. No two problems of wearing are alike. There is frictional wear on plant components which are in continuous use (such as cyclones) or impact wear on components which are not used continuously (such as transfer chutes). The optimum wear-protection system often involves a combination of multiple materials. Those materials are then matched to the different loadings. The selection of a suitable means of installation is also important. Various determining factors such as temperature, vibration or accessibility within the plant make a variety of attachment methods for wear-protection components necessary.

Example application from the steel industry

Sheet metal from Europe’s leading heavy plate manufacturer are used in numerous projects, from steel bridges and skyscrapers to oil and gas pipelines. The company headquarters also includes a coking plant which makes coke for the two blast furnaces at the heavy plate plant.

Background to the story

The coke ramps onto the chutes of which quenched coke is tipped suffer very serious wear due to friction and impact. The impact walls opposite the ramp and the coke removal points also get badly worn by hot abrasives.

The job in hand

  • Wear-resistant lining of the chutes, making sure that coke can still slide smoothly down the ramp. The wear-resistance solution should be able to withstand the temperature fluctuations which occur due to repeatedly occurring clusters of coke embers.
  • The impact walls and side walls are to be protected against hot abrasives. The lower parts of the walls suffer particularly bad abrasion.
  • At the end of the chutes there should be some edge protection capable of withstanding mechanical loads.

The solution

  • Due to the extreme temperature fluctuations, Kalenborn lined the coke ramp chutes with KALCERAM-K hard ceramic. This material has good low-friction properties for the coke to slide along it, and it also possesses a high resistance to temperature fluctuations.
  • The impact and side walls were lined with KALSICA silicon carbide ceramic, which is very highly resistant to hot abrasives. The KALSICA plates with their claw fittings were mechanically attached and also back-filled with temperature-resistant adhesive.
  • The side walls were lined at the bottom using KALCOR-S plates with claw fittings, which, like KALCERAM-K, have a high resistance to temperature fluctuations, but also exhibit the higher resistance to abrasion needed here.

At the end of the chutes, angle pieces made of the hard cast material KALCAST were used to protect the edges against the heavy mechanical forces. These were attached by means of a substructure which was screwed into place.

KALCERAM KALSICA KALCOR KALCAST

The result

  • The longer lifespan of the system enables the customer to continue economic and safe production.

Kalenborn was able to make a particularly distinctive impression with its full service package including engineering, delivery of materials and installation on site. The customer was very happy with the commissioning of the work to plan which resulted from the rapid installation and reliable cooperation.