maintenance in a cement plant - asm machinery applications... · 3 • m & r seminar seneffe,...
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voestalpine Böhler Welding
www.voestalpine.com/welding
voestalpine Böhler Welding
Maintenance in aCement Plant
Processes & Solutions
March 2016Dipl.-Ing. Jürgen Tuchtfeld
voestalpine Böhler Welding2 • M & R seminar Seneffe, March 2016 • Maintenance in a cement plant • J Tuchtfeld
� Stick electrodes
� Solid wires and rods
� Flux-cored wires
� Wires for submergedarc welding
� SAW powder
� Autogenous rods
� Metal powder
UTP Maintenance Product Range
voestalpine Böhler Welding3 • M & R seminar Seneffe, March 2016 • Maintenance in a cement plant • J Tuchtfeld
Product designations� indicating the welding process
Designation Type Welding process
UTP (S) DUR 350 Coated electrode SMAW
UTP A DUR 350 Solid wire or rod GMAW
UTP AF 068 HH Cored wire – gas shielded FCAW
SK AP - O Cored wire – open arc FCAW
SK AP - S Cored wire – sub arc SAW
SK 350 - G Cored wire – gas shielded FCAW
voestalpine Böhler Welding4 • M & R seminar Seneffe, March 2016 • Maintenance in a cement plant • J Tuchtfeld
Maintenance in a cement plantProcesses & Solutions
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Wear processes in a cement plant
Cement plants are amongst the most aggressive environments in terms of wear
Reasons for wear:
� High temperatures� Thermal stresses� 24/7 h of operation� Handling of hard
raw materials
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Cement production process
Rotary kiln
Clinker cooler
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Quarrying and crushing
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Excavator bucket
Abrasion zones
UTP LEDURIT 61UTP S LEDURIT 61UTP SK 255-O
Impact zones
UTP DUR 600UTP S DUR 600UTP SK 258TiC-O
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Weld metal analysis in %
C 0.5 %
Si 2.3 %
Mn 0.4 %
Cr 9.0 %
Goals
Structure martensitic with carbidesMagnification = 100:1
UTP DUR 600, 4.0 x 350 mm
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Weld metal analysis in %
C 3.5 %
Si 1.0 %
Cr 35 %
Structure austeniticwith carbides
Magnification = 500:1
UTP Ledurit 61, 4.0 x 450 mm
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Earth moving: Hydraulic excavators
Idler
Upper rollsTrack pads
Drive tumbler
Lower rolls
Bucket & Teeth
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Cost savings potential by increase of lifetimeTrack pads, Idlers, Drive Tumbler
Current welding solution: build-up with mild steel electrode and FCWImprovement:
� UTP DUR 350; UTP S DUR 350 as stick electrode� SK 350-G as flux-cored hardfacing wire
Weld metal of UTP DUR 350; UTP S DUR 350 is twice as hard as a standard mild steel electrode, but still easily machinable.
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Carrier rollers
Worn out carrier rollers Welded carrier rollers
UTP DUR 350; SK 350-G
Excavator: carrier rolls
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Cement production process
Rotary kiln
Clinker cooler
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Crushing equipment
Giratory Crusher Cone Crusher Jaw Crusher
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Giratory crusher
Lining with wear platesSee “wear plate section”
Mantel• Buffer layer UTP SK AP-O
• Hardfacing layerUTP SK 866-OUTP SK A 43-O
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Cone crusher
Buffer layer UTP SK AP-O
Hardfacing layerUTP SK 866-OUTP SK A 43-O
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Jaw crusher
UTP BMC, UTP S BMCUTP SK AP-O
Armoured plate
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Source: FAM Magdeburg
Example:Hammer Crusher
Hammers
Rotor
Screen
Rotor
Hammers
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2 possibilities: austenitic manganese steels or casted iron base material
Example:Hammer Crusher
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Hammer crusher
• Buffer & Build-up layersUTP BMC; UTP S BMCUTP SK AP-O
Hammers – 14% Mn steel
• Hardfacing layerUTP DUR 600, UTP S DUR 600UTP SK 255-O
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Weld metal as welded (200:1) Weld metal work hardened (200:1)
Dendritic, fully austenitic structure of the weld metal.
As welded: 330HV Work hardened: 550HV
UTP BMC
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� hard surface, soft core
� self-renewing effect� work hardening alloys:
512479
395
356
330
324
hardness [HV]
0
1
2
3
4
surface distance [mm]
new surface
580
490
466
438
438
330
350
hardness [HV]
worn surface
UTP (S) BMC UTP 7200 UTP SK AP-O UTP SK 218-O
Hard and hardenable alloys
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Buffer layerUTP 630
Hammers(casted –iron-base)
HardfacingUTP DUR 600UTP S DUR 600
Build-up layerUTP DUR 350UTP S DUR 350
Crusher hammer
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UTP DUR 600UTP S DUR 600UTP SK 255-O
Higher abrasionUTP LEDURIT 61UTP S LEDURIT 61SK 258TiC-O
RotorMild steel
Hammer crusher
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Cement production process
Rotary kiln
Clinker cooler
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Raw material grinding
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VRM working principle
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Fine grinding
Coarse grinding
Typical wear profile
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Vertical millsTypical wear profile
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Goals
Wear depends on several factors
Base material: • Crystalline structure• Grain size• Hardness• Shape• Humidity
Material used for the wear components
Mill operation
Vertical mill design:not always the same wear profile
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www.loesche.comRaw materialCoal
Coal mill
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• 2, 3, 4 and 6 conical rollers
• 1 flat table
• 4 sizes of roller module available
LM typenew generation
Raw materialCement clinkerSlag
www.loesche.com
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POLYSIUS
QUADROPOL typeNew generation
Segmented or one piece rollers and table
4 separate rolls
www.polysius.com
raw material mill
Vertical mills OEM‘s
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MPS mill
3 stationnary grinding rollers on a slowly rotating table
Raw materialCoalCement clinkerBlast furnace slag
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CoalRaw material
• Simple flat geometry of rollers and table
• Rollers with large diameter
www.flsmidth.com
ATOX mill
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OK type
Unique design
Three or four segmented rollers
Cement clinkerBlast furnace slag
www.flsmidth.com
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Grinding components design
Base metal of castings:
High Cr (16-20%Cr, 3%C)Ni-Hard 1 to 4 (4-6%Ni, 2-8%Cr, 3%C)
Roller shapes:
Conical, spheroidal, cylindrical or toroidal
Monobloc or segmented parts
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Hardfacing philosophy
Maintaining the original profile in order to guarantee optimum
production conditions.
Parts are always rebuilt to the design profile but not always to the original diameter for efficiency or
economical reason
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Hardfacing alloy with chromium carbides
to resist abrasion
and moderate pressure
Flux cored wires
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Repair shop or on site?
One or multiple welding heads to weld several parts at the same time
• No need to disassemble and reassemble the components
• Saving spare parts
Reduction of production down-time!
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Advantages of hardfacing(compared to new components)
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Advantages of hardfacing
Production (t/h) With Hardfacing
Without HardfacingExtra production
Time
• Longer service life
• Higher production output
� A hardfaced component will resist up to 2 times longercompared to a traditional cast component
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Advantages of hardfacing
0
2
4
6
8
10
12
14
16
18
20
01-Nov-98 09-Feb-99 20-May-99 28-Aug-99 06-Dec-99 15-Mar-00 23-Jun-00 01-Oct-00 09-Jan-01
Operational Days
Before Hardfacing
After hardfacing
www.flsmidth.com
Working days
Before hardfacing
after hardfacing
• Saving energy
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Advantages of hardfacing
Reduction of vibration
� Smoother operation
� Preserves the equipment
Saving spare parts
� No need to have a full set of spare parts
� Less dead capital
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Grinding equipment
Ball Mill
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Vertical roller mill: crack repair
Ni base electrode UTP 068HH
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Nickel base material Mechanical properties
Relation between base material & consumable
mechanical properties Base material UTP 068 HH
Tensile strength [N/mm2] >620 >620
Yield strength [N/mm2] 370 >380
Elongation [%] 13 >35
Hardness [HB] <217 180-350
Impact value at RT [J] 35 >80
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High ductility vs. cold cracking
Advantages of Nickel-base welding consumables!E.g. UTP 068HH
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Ball mill: crack repair
Ni base electrode UTP 068HH
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Ball mill: repair of gear ring
Ni base electrode UTP 068HH
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Cement production process
Rotary kiln
Clinker cooler
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Rotary kiln
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Rotary kiln
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Rotary kiln: repair of ring
UTP 068HH - UTP AF 068HH
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Application details
� Application: Crack repair / rotary ring kiln tyre
� Welding process: automatic and semi-automatic
� Duration of work: 18 days
� Main product: UTP AF 068HH, Ø 1.2 / 1.6 mm (FCAW)
� Quantity used: 950 kgs
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Crack welded withUTP 068HH; UTP AF 068HH
Buffer Technique
Welding procedure
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Profile grinding
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Rotary kiln: crack repair on supporting roll
UTP 068HH
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Cement production process
Rotary kiln
Clinker cooler
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Hammer crusher / clinker
Hammers14% Mn steel
Rotor Mild steel
• Buffer layerUTP BMC; UTP S BMC –
UTP SK AP-O
• Hardfacing layerUTP LEDURIT 65 – UTP SK A43-O
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UTP Ledurit 65, 4.0 x 450 mm
V 1.5 %
Weld metal analysis in %
C 4.5 %
Cr 23.5 %
Mo 6.5 %
Nb 5.5 %
W 2.2 %Structure
austenitic with carbidesMagnification = 100:1
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64
UTP Ledurit 65
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Cement production process
Rotary kiln
Clinker cooler
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Transport and separation
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Conveyor screws: feeding and mixing
UTP 75UTP A 7550UTP SK 900Ni RTC-G
Edges of wings
Shaft and wings
UTP LEDURIT 61UTP LEDURIT S 61
UTP SK 255-OUTP SK 866-O
Higher abrasionUTP LEDURIT 65
UTP SK A43-O
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Ventilators
Blades
UTP LEDURIT 65SK ABRAMAX-OUTP SK A 43-O
Higher abrasionUTP SK A 45-O
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Conveyor chains
UTP 711 BUTP SK 255-OHigher abrasionUTP LEDURIT 65UTP SK A 43-O
Upper zone
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Wear plates
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Components and parts made of SK ABRAGUARD can be delivered tailor made:Cut, bent, rolled, slotted, fabricated, bored, sieves, assembled, pieces according drawing, Constructed and assembled in our partner service center or in situ acc. drawing
vaBW wear plate service
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Welding of wear plates
Joining of wear plates
UTP 63; UTP S 63UTP BMC; UTP S BMCUTP SK AP-OUTP SK 402-O
1
2
1
2 Protection of the joints against wear
For wear resistant plates (example Hardox®)UTP DUR 600, UTP S DUR 600UTP SK AP-O
For composite wear plates (or hardfaced plates)UTP LEDURIT 61, UTP LEDURIT S 61UTP SK 255-O
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Wear plates: applications in a vertical roller mill
Wall lining of grinding chamber
Feeding chute
Air port ring
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Wear plates:material transport and storage
Raw meal
Clinker / cement
Additives
Solid fuels
Ducts and pipes
Hoppers
Packing equipment
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Hardfacing of pipes
• ElectrodesUTP Ledurit 61, Ledurit S 61
• Flux-cored wireUTP SK A 43-O
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Wear plates:ball mill
Lining of chamber
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Wear plates:Classifyer
Feed chute
Lining of reject cone
Rotary blades
Lining of classifying chamber
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Wear plates:Other applications
Fan blades
Cyclone
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Repair & Maintenance:Other applications
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Repair & Maintenance:Other applications
Joining of construction steelsUTP 614Kb
Welding of cast iron
UTP 86FNUTP SK FNMS-G
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Repair & Maintenance:Other applications
Rebuilding of components:
UTP DUR 300; UTP DUR 350UTP DUR 300; UTP A DUR 350
UTP SK BU-OUTP SK 242-O UTP SK 258(L)-O/S UTP SK AP-O/S
Depending on hardness
Crane wheels / idler
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Repair & Maintenance:Other applications
Gouging
UTP 82 AS
SK CUTARC (Rotating parts – automated process)
With gasWith
cored wire
Torch positioning
Cylinder surface
to be gouged
Independent welding
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What exactly is UTPperform?
Decades of experience and innovate products provide
the longest life cycle for your applications.
High Performance
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Independent weldingis becoming reality
Forestry
Agriculture and Food
Earth Moving
Sugar & Ethanol
Ship repairing
Oil & Gas
Present with 11 manufacturing plants, hundreds of distributers
in 153 countries where your M&R needs us.
Cement industry
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Fast and easy fixes!Independent power supply!
Passionate about solving your M&R challenges every day
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Welding for the independent will become reality
Independence in their perfection
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Independence in their perfection
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Beschreibung des Inhaltes
Artikelnummer etc.
CurrentClamp
StickElectrode Holder
Protectivegloves
16 mm², 3 m 200A, 60% 16 mm², 4m 200A
Protectiveshield
Slag hammer witha steel brush
The SYSTEM TROLLEY Set
ELECTRODES
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Thank youJürgen Tuchtfeld
Phone: +49 7633 409 154