Maintenance in a Cement Plant - ASM Machinery applications... · 3 • M & R seminar Seneffe,...

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

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

Maintenance in a cement plantProcesses & Solutions

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

Cement production process

Rotary kiln

Clinker cooler

Quarrying and crushing

Excavator bucket

Abrasion zones

UTP LEDURIT 61UTP S LEDURIT 61UTP SK 255-O

Impact zones

UTP DUR 600UTP S DUR 600UTP SK 258TiC-O

Weld metal analysis in %

C 0.5 %

Si 2.3 %

Mn 0.4 %

Cr 9.0 %

Structure martensitic with carbidesMagnification = 100:1

UTP DUR 600, 4.0 x 350 mm

C 3.5 %

Si 1.0 %

Cr 35 %

Structure austeniticwith carbides

Magnification = 500:1

UTP Ledurit 61, 4.0 x 450 mm

Earth moving: Hydraulic excavators

Upper rollsTrack pads

Drive tumbler

Lower rolls

Bucket & Teeth

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.

Carrier rollers

Worn out carrier rollers Welded carrier rollers

UTP DUR 350; SK 350-G

Excavator: carrier rolls

Rotary kiln

Clinker cooler

Crushing equipment

Giratory Crusher Cone Crusher Jaw Crusher

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

Cone crusher

Buffer layer UTP SK AP-O

Hardfacing layerUTP SK 866-OUTP SK A 43-O

Jaw crusher

UTP BMC, UTP S BMCUTP SK AP-O

Armoured plate

Source: FAM Magdeburg

Example:Hammer Crusher

Hammers

Screen

Hammers

2 possibilities: austenitic manganese steels or casted iron base material

Example:Hammer Crusher

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

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

� hard surface, soft core

� self-renewing effect� work hardening alloys:

512479

hardness [HV]

surface distance [mm]

new surface

hardness [HV]

worn surface

UTP (S) BMC UTP 7200 UTP SK AP-O UTP SK 218-O

Hard and hardenable alloys

Buffer layerUTP 630

Hammers(casted –iron-base)

HardfacingUTP DUR 600UTP S DUR 600

Build-up layerUTP DUR 350UTP S DUR 350

Crusher hammer

UTP DUR 600UTP S DUR 600UTP SK 255-O

Higher abrasionUTP LEDURIT 61UTP S LEDURIT 61SK 258TiC-O

RotorMild steel

Hammer crusher

Rotary kiln

Clinker cooler

Raw material grinding

VRM working principle

Fine grinding

Coarse grinding

Typical wear profile

Vertical millsTypical wear profile

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

www.loesche.comRaw materialCoal

Coal mill

voestalpine Böhler Welding34 • M & R seminar Seneffe, March 2016 • Maintenance in a cement plant • J Tuchtfeld 34

• 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

POLYSIUS

QUADROPOL typeNew generation

Segmented or one piece rollers and table

4 separate rolls

www.polysius.com

raw material mill

Vertical mills OEM‘s

MPS mill

3 stationnary grinding rollers on a slowly rotating table

Raw materialCoalCement clinkerBlast furnace slag

CoalRaw material

• Simple flat geometry of rollers and table

• Rollers with large diameter

www.flsmidth.com

ATOX mill

OK type

Unique design

Three or four segmented rollers

Cement clinkerBlast furnace slag

www.flsmidth.com

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

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

Hardfacing alloy with chromium carbides

to resist abrasion

and moderate pressure

Flux cored wires

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!

Advantages of hardfacing(compared to new components)

Advantages of hardfacing

Production (t/h) With Hardfacing

Without HardfacingExtra production

• Longer service life

• Higher production output

� A hardfaced component will resist up to 2 times longercompared to a traditional cast component

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

Reduction of vibration

� Smoother operation

� Preserves the equipment

Saving spare parts

� No need to have a full set of spare parts

� Less dead capital

Grinding equipment

Ball Mill

Vertical roller mill: crack repair

Ni base electrode UTP 068HH

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

High ductility vs. cold cracking

Advantages of Nickel-base welding consumables!E.g. UTP 068HH

Ball mill: crack repair

Ball mill: repair of gear ring

Rotary kiln

Clinker cooler

Rotary kiln

Rotary kiln: repair of ring

UTP 068HH - UTP AF 068HH

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

Crack welded withUTP 068HH; UTP AF 068HH

Buffer Technique

Welding procedure

Profile grinding

Rotary kiln: crack repair on supporting roll

UTP 068HH

Rotary kiln

Clinker cooler

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

UTP Ledurit 65, 4.0 x 450 mm

V 1.5 %

C 4.5 %

Cr 23.5 %

Mo 6.5 %

Nb 5.5 %

W 2.2 %Structure

austenitic with carbidesMagnification = 100:1

UTP Ledurit 65

Rotary kiln

Clinker cooler

Transport and separation

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

Ventilators

Blades

UTP LEDURIT 65SK ABRAMAX-OUTP SK A 43-O

Higher abrasionUTP SK A 45-O

Conveyor chains

UTP 711 BUTP SK 255-OHigher abrasionUTP LEDURIT 65UTP SK A 43-O

Upper zone

Wear plates

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

Welding of wear plates

Joining of wear plates

UTP 63; UTP S 63UTP BMC; UTP S BMCUTP SK AP-OUTP SK 402-O

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

Wear plates: applications in a vertical roller mill

Wall lining of grinding chamber

Feeding chute

Air port ring

Wear plates:material transport and storage

Raw meal

Clinker / cement

Additives

Solid fuels

Ducts and pipes

Hoppers

Packing equipment

Hardfacing of pipes

• ElectrodesUTP Ledurit 61, Ledurit S 61

• Flux-cored wireUTP SK A 43-O

Wear plates:ball mill

Lining of chamber

Wear plates:Classifyer

Feed chute

Lining of reject cone

Rotary blades

Lining of classifying chamber

Wear plates:Other applications

Fan blades

Cyclone

Repair & Maintenance:Other applications

Joining of construction steelsUTP 614Kb

Welding of cast iron

UTP 86FNUTP SK FNMS-G

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

Gouging

UTP 82 AS

SK CUTARC (Rotating parts – automated process)

With gasWith

cored wire

Torch positioning

Cylinder surface

to be gouged

Independent welding

What exactly is UTPperform?

Decades of experience and innovate products provide

the longest life cycle for your applications.

High Performance

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

Fast and easy fixes!Independent power supply!

Passionate about solving your M&R challenges every day

Welding for the independent will become reality

Independence in their perfection

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

Thank youJürgen Tuchtfeld

Phone: +49 7633 409 154

juergen.tuchtfeld@voestalpine.com

Maintenance in a Cement Plant - ASM Machinery applications... · 3 • M & R seminar Seneffe,...

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