A Case Study inCement Plant

Wear Solutions

1-888-4WEARCON1 011 816-587-1923 Cell: 586-925-0581

www.wearcon.com

• Fourth largest cement company in U.S.

• Chanute, KS is the home of Ash Grove’s first cement plant

• Plant started on July 28, 1908

•164,500 tons were produced in the first year

• Major improvements in 1911, 1920, and 1964

• Final major expansion in July 2001

• Over 1.4 Million MTPY of clinker production

Ash Grove Cement Company Chanute, KS

• Capable of grinding 340 MTPH

• Crushing 4” Limestone to a product size of 80% passing 200 mesh (74 micron)

• Raw mill equipped with high- efficiency classifier

Vertical Roller Mill FRM 48/234

Wear Issues and

Wear-Con’s Solutions

2002

• First wear developed in ductwork above vertical roller mill. Holes developed in first 6 months of operation

• Ductwork made of mild steel and patches were applied over the holes in first year

• Ductwork temp patched in 2002 with WC700 Chrome Carbide

• Raw Mill Water Spray Box protector upgraded to WC700/900 in March 2002

• Initially no protection. WC700 lasted 3 months and

WC900 lasted 6 months

Wear Issues and

Wear-Con’s Solutions

2003

Raw Mill Separator Vanes upgraded to VB96 in Jan 03

VB96 lasted 1 year vs. AR Vanes which lasted only 3 months

• Raw Mill Separator Cone upgraded to WC90 Ceramic in July 03

Wear Issues and

Wear-Con’s Solutions

2004

• Wear in the Bonnet and Transition became excessive and metal repairs were only a temporary solution

• Wear-Con’s field crew installed WC90 Ceramic in the corner

of Transition and Bonnet on site in Feb 04

Wear Issues and

Wear-Con’s Solutions

2005

• Wear in Duct, Bonnet, Transition, Splitter Box, and Classifier Cone was very severe

• Ash Grove contacted Wear-Con in Jan 05

• In only 4 weeks, Wear-Concepts submitted proposal, mobilized crews and began project on Feb 28, 2005!

Wear-Con gets another call

2005

Over 12,300 WC90 ceramic bricks were installed in only 12 days!

Ash Grove inspected the final work and could not find any discrepancies with workmanship

All work was completed safely,on time, and within budget.

• Original linings installed during 2002 thru 2005 timeframe are still providing wear protection

• Additional work is scheduled to be done in 2006

Was Customer Satisfied?

• Build Relationships

• Solve wear issues, not just ‘sell products’

• Provide ‘Turn-Key Solutions’

• Provide Peace of Mind

Wear-Con’s Keys to ensuringCustomer Satisfaction

when solving wear issues