Applications for ARC Composites in the Cement Industry Composite/Ceme… · Applications for ARC...

Applications for ARC Composites in the Cement Industry

Case HistoryApplication ARC Product Reference #

Elbows and laterals on blower system ARC MX1 3153Pneumatic transport pipes ARC 897 4282, 4333Transport chutes ARC 890, 858, 855 4068Chimney stack liner ARC 982 4027Dust extraction fan ARC 897 4262Fan blade ARC 855, 897 4143Discharge chute to separator ARC 890 4284Clinker chute to separator ARC 890 4285Raw material silos ARC 855 or S2Clinker silos ARC 855 or S2Feed chute to raw mill ARC 890Feed chute to finish grinding mill ARC 890 3160Ball mill feeder ARC 890 4336Air circulation fans ARC 855Wear plates ARC 890, MX1ID Fans ARC 897Classifier fan blade ARC 858, 855 3187Cyclone ARC 890 and 897Lime mud chute ARC S2 3161Exhaust stack from kiln ARC 982 3162Cement separator (OEM) ARC 890, 897, and 855 4281, 4274

4335Transport pipe/duct above slag drier ARC 897 4283Diffuser ARC 897Clinker grinding ball mill ARC 890 4286Coal feed screw to kiln burner ARC 890 3180Ventilator vanes ARC 897 4334

111

Industry: Cement Manufacturer

Location: Bulk storage silos in the bag filling area.

Equipment: Elbows and laterals on blower system

Summary: Cement Plant solves recurring abrasion problem by using ARC MX1.

Problem: Wearing of elbows and laterals on blower system. Customer has triednumerous repair methods, including ARC 890 and none have workedsuccessfully. The abrasive agricultural lime and cement wear a hole inelbows and laterals in less than 24 hours. The elbows are hardenedsteel and very expensive. Another attempted rebuild method involvedbuilding a steel box ,welding it together around the elbow and filling itwith cement. This lasted 20 - 30 days. This is definitely animprovement, but is also very costly and time consuming.

Solution: ARC MX1 was applied to an elbow and has exceeded eight weeks ofservice. Based on this success the customer coated severaladditional elbows and laterals which are performing very well.

Results: The customer was very impressed and this has lead to other ARCapplications in the plant.

AC3153E

ARC© Copyright 1998 A.W. Chesterton, All rights Reserved

Laterals and ellbows in operation.Chesterton® DOC. NO. AC3153E, 6/98


Worn hole in steel elbow after just hours of operation.AC3153E


Welded box on lateraland elbow.

AC3153E


Worn hole in elbow protected by welded cement box.AC3153E


Elbow protected with ARC MX1.AC3153E

111

Industry: Cement

Location: Czech Republic

Equipment: Pipes and laterals of pneumatic transport line.

Problem: The very abrasive cement quickly wears out elbows andlaterals in pneumatic transport line. Frequentreplacement of these parts is required.

Solution: After proper surface preparation, ARC 897 is applied tothese parts.

Results: After two years in service only minor touch is required andpart replacement is not needed.

Savings: Part replacement cost and downtime.

AC4282E


Worn pipe elbows and laterals.

Chesterton® DOC. NO. AC4282E, 10/98


Pipe elbow after abrasive blasting.AC4282E


Chutes and pipe sections coated with ARC 897.

Chesterton® DOC. NO. ACXXXXE, X/98

3


Chute used to transport bags of cement. Repaired bywelding every 14 days. Chesterton® DOC. NO. AC4068E

Industry: Cement

Location: Norway

Equipment: Transport Chute

Problem: The chute is used to transport bags of cement after theyare filled. Normally the chute is repaired every 14 days bywelding and replacement of stainless steel which requirestwo men for a full day.

Solution: ARC 890, 858 and 855 were applied to create an ultrasmooth ceramic composite surface.

Results: After 40 days, the composite showed little wear. Morethan 140,000 bags of cement had passed over the composite.

Savings: Savings in the three months exceeded $7,000 USD.

AC4068E


ARC 890, 858 and 855 were applied to create anultra smooth ceramic composite surface. AC4068E


After 40 days, the composite showed little wear. Morethan 140,000 bags had passed over the composite.

AC4068E

11

Industry: Cement

Location: South Africa

Equipment: Chimney stack liner of coal burning cement factory.

Problem: The carbon steel chimney stack liner is 4.5m (15 ft.) indiameter and 132m (345 ft.) tall. Flue gas enters thechimney as high as 155oC (311oF) and cools to 128oC(262oF) before it exits the top. The flue gas condensesforming sulfuric acid on the metal surfaces. After threeyears of operation, corrosion had reduced the wallthickness by one-third its original thickness. Corrosionresistant paints were tested, but all cracked and failedwithin two months.

Solution: The chimney stack liner was prepared by abrasiveblasting to white metal cleanliness with a 75-125 micron(3-5 mil) profile. Two coats of ARC 982 were applied tothe liner to a total thickness of 700 microns (28 mils).

Results: After two years in service, the application is in perfectcondition. Based on this success, the customer choseARC 982 to protect a chimney at their other plant.

AC4027E


Chimney stack liner is made of carbon steel. Flue gasenters chimney at 155oC(311oF) and cools to 128oC(262oF) by the time it reaches the top.



Flue gas condenses forming sulfuric acid on metalsurfaces, reducing wall thickness by one-third itsoriginal thickness after only three years. AC4027E


Two coats of ARC 982 were applied to a totalthickness of 700 microns (28 mils). AC4027E


The entire chimney stack was coated to a smoothglossy finish. AC4027E


Inspection after two years in service shows theapplication in perfect condition. AC4027E


© Copyright 1998 A.W. Chesterton. All rights reserved.

Industry: Cement

Equipment: Dust Extraction Fan

Problem: Fine cement particles cause abrasion to the fans and they needto be replaced frequently.

Solution: ARC 897 applied to properly prepared surface of the fan.

Results: After 4-5 years in operation, a couple of fan blades neededminor touch up.

Industry: Cement Manufacturing Plant

Equipment: Fan Blade with a diameter of 1.8 m (5’) operates at speed 965rpm. Production output is 500 tons/day. Cost of new fan blade is$47,696 USD.

Problem: The fan blade was severely worn out every 2 to 4 months due tohigh abrasion of cement ash. The damage was so bad that afterthe 4th month of operation, the fan blade could no longer performits duty. Previous repair used hard facing welding which did notlast longer than 2 months.

Solution: Surface profile was prepared and cleaned accordingly. AppliedARC® 855 at 500 microns (20 mils), then top-coated with ARC 897at 4 mm (3/16”) thickness. Material cost was only $5,495 USD.

Result: Inspection was done after 7 1/2 months of operation and onlyslight wearing on the ARC 897 was noticed. Overall, 85% of thefan blade was still in good condition. Currently, spot repair iscarried out on worn areas only.

Savings: For each fan blade, customer is saving $42,201 USD as comparedto buying a new fan blade. The customer is very satisfied and hasmade ARC 855 and ARC 897 the Standard Quality RepairProcedure for all three fan blades.

Total savings of $126,603, per year

AC4143E


Fan blade at cement factory. New fan lasts 2-4 months.Weld overlay repair required every 2 months. Chesterton® DOC. NO. AC4143E, 11/96


AC4143E

New blade after four months of wear.


AC4143E

Fan blade with ARC® 855as primer and rebuilt withARC 897.

Follow up after 7 1/2 months.85% still in tact. Savings of$126,603 per year.

111

Industry: Cement

Location: South America

Equipment: Clinker and Limestone Discharge chutes from elevator toseparator.

Summary: ARC 890 molded to provide a smooth and abrasion resistantsurface for transporting clinker and limestone.

Problem: Severe abrasion from limestone at 60ºC (140ºF) and clinker at90ºC (194ºF) wears the metal surface of discharge chutes.Ceramic tile has not proven to be a reliable method of repair.The chutes are located in an area difficult to access andmaintenance can only be performed on scheduled shutdowns.

Solution: The area to be coated is abrasive blasted to a white metalcleanliness and solvent rinsed. ARC S2 is applied as a primerand topcoated with 10 to 45 mm (~0.5 to 2 inch) of ARC 890.The area is molded by plastic sheet for a very smooth surface.Two clinker chutes and one limestone chute were rebuilt.

Results: After seven months in operation, ARC 890 continues toprovide abrasion resistance and a smooth surface.

AC4284E


ARC S2 applied as primer for ARC 890.



ARC 890 applied to the chute, one-half of thethickness applied to base metal. AC4284E


The remaining half of the thickness is appliedto a plastic sheet.

AC4284E


Molding the sheet to the ARC 890 on the chute.AC4284E


Completed job prior to removal of the plastic sheet.

AC4284E

11

Industry: Cement

Location: South America

Equipment: Multi-section clinker discharge chute from elevator to separator.

Summary: ARC 890 solves recurring abrasion problem in clinker dischargechute.

Problem: Heavy abrasion from the clinker wears through the dischargechute quickly. The present method of repair (rubber conveyorbelts) wears out quickly leaving holes in the chute that must berepaired by welding.

Solution: Expanded metal is spot welded to specific areas on the chute.The area to be coated is abrasive blasted to a white metalcleanliness and solvent rinsed. ARC S2 is applied as a primerand topcoated with a minimum of 6 mm (1/4 inch) of ARC 890.Five sections of the chute were coated.

Results: After 45 days of operation, only very slight wear of the ARC 890is present (no touch-up required). Previous methods of repairwould completely fail in the same period of operation.

Savings: Replacement costs, welding costs and downtime.AC4285E


Total view of installeddischarge chute.


Discharge Box from clinker elevator

Upper impact Box

Lower Impact Box

Straight section of chute

Inlet elbow to separator


Expanded metal is spot welded to the bottomand side wall of discharge chute. AC4285E


Straight section of discharge chute.AC4285E


AC4285E

ARC S2 applied as a primer.


Impact box at top of discharge chute.AC4285E


Applying ARC 890 to inlet elbow of chute.

AC4285E


AC4285E

Smoothing of ARC 890 with plastic sheet.


Completed straight section of discharge chute.AC4285E


AC4285E

ARC 890 applied to discharge box.

11

Industry: Cement

Location: Northeast USA

Equipment: Finish Grinding Mill Feed Chute

Summary: Cement plant solves recurring abrasion problem byusing ARC 890.

Problem: Feed chute in finish mill which had a 0.5 inch (12 mm)thick special alloy wear plate would wear through in fourto six months. Clinker from the kiln flows through thechute. Previous repair methods involved welding asteel box on the outside of the chute and filling it withcement. After one or two repairs using this method, thechute could no longer be repaired and was replaced.

Solution: ARC 890 was applied to chute and after five months ofwear, it is in perfect condition and does not need evenminor touch up.

Results: This feed chute is critical to plant operation, lost timedue to breakdown is in excess of $10,000 USD/hour.Customer is extremely pleased with the results andplans to coat the Raw Mill Feed Chute in the same way.

Savings: Reduced downtime and replacement costs.AC3160E


Coated chute before assembly.



© Copyright 1998 A.W. Chesterton. All rights reserved.

Industry: Cement

Location: Northeast, USA

Equipment: Lime Mud Chute

Summary: Cement Plant solves flow of Lime Mud problem by usingARC S2.

Problem: A gravity feed Lime Mud Chute would plug as lime mud stuck tobottom and sides. Chute would have to be manually unplugged,which was both expensive and a safety hazard.

Solution: After proper surface preparation, ARC S2 was applied to chutemaking it too slippery for lime mud to adhere.

Results: ARC S2 improved flow dramatically. Customer now wants tocoat several other lime mud transportation areas with ARCComposites.

Savings: Reduced downtime and improved plant efficiency.

11

Industry: Cement

Location: Northeast USA

Equipment: Exhaust stack from kiln

Summary: ARC 982 used to solve severe corrosion problem in 28m(93 ft.) stack.

Problem: Stack had severe corrosion occurring in bottom 4.5m (15ft.) because of temperature fluctuation and sulfuric acidcondensation on steel. Over 30% of original steelthickness had corroded and had to be removed.

Solution: The surface was prepared by abrasive blasting to whitemetal cleanliness with a 75-125 micron (3-5 mil) profile.Two coats of ARC 982 were applied.

Results: ARC 982 prevents corrosion of remaining metal. Thecustomer is planning on coating the rest of the stack andduct work from the bag house with ARC Composites.

Savings: The savings is huge with product and application of ARC982 being about $10,000 USD, whereas the replacementcost for stack is well over $500,000 USD. By not havingto replace the stack, the customer saved over $500,000USD.

AC3162E


Outside of stack and duct work from kiln.



Severely corroded inside of stack.AC3162E


First coat of ARC 982 applied to white metal.AC3162E


Second coat of ARC 982 applied up to 4.5m (15 ft.) height on inside of stack.

AC3162E

111

Industry: Cement

Location: Eastern Europe

Equipment: Cement Seperator (Type VTP 2400).

Problem: Abrasive wear of rotating equipment required replacingequipment after only 1 year of operation. Areas of highwear were the end plate and vanes on the rotor and theinternal parts of the upper stator area.

Solution: After proper surface preparation, ARC 897and 890 wereapplied to the high wear areas. ARC 855 also applied tofeed duct and low wear areas.

Results: ARC Composites provide abrasion protection for over 3years in operation. Design engineers from OEM observeapplication and perform internal testing to evaluate ARCComposites. OEM specifies ARC Composites be appliedto critical wear areas. Many ceramic separators arecoated with ARC Composites at the OEM each year.

AC4281E


Rotor of cement separator.



End plate of cement separator coated with ARC 890.AC4281E


Seperator vanes prior to abrasive blasting.AC4281E


Duct feeding separator. Also coated with ARCComposites. AC4281E

11

Industry: Cement

Location: Czech Republic

Equipment: Cement separator

Summary: ARC 897 and 890 extend equipment life. Based ondemonstrated success the original equipmentmanufacturer (OEM) of cement separators specifies ARCComposites to protect critical areas on new equipment.

Problem: Abrasive wear of rotating equipment required replacingequipment after only 1 year of operation. Areas of highwear were the end plate and vanes on the rotor and theinternal parts of the upper stator area.

Solution: After proper surface preparation, ARC 897and 890 wereapplied to the high wear areas.

Results: ARC Composites provide abrasion protection for over 3years in operation. Design engineers from OEM observeapplication and perform internal testing to evaluate ARCComposites. OEM specifies ARC Composites be appliedto critical wear areas. Many ceramic separators arecoated with ARC Composites at the OEM each year.

AC4274E


Rotor of cement separator. ARC 890 is applied on the topplate and ARC 897 to the ring on the bottom.

Chesterton® DOC. NO. AC4274E ,9/98


Vanes of cement separator.AC4274E


Complete view of separator showing the stator.AC4274E

111

Industry: Cement


Equipment: Transport pipe/duct above slag drier.

Problem: Abrasive wear of pipe and duct section from the slag.

Solution: Area to be coated was abrasive blasted to a near-white/white metal cleanliness and 75-125 micron (3-5 mil)profile. ARC 897 was applied at a 3mm (1/8 inch)thickness to all wear areas.

Results: After five years in operation ARC 897 is still providingabrasion and corrosion protection.

AC4283E


Pipe above slag drier.



Pipe partially coated with ARC 897.AC4283E


Duct section coated with ARC 897.AC4283E

11

Industry: Cement


Equipment: Clinker grinding ball mill

Problem: Ball mill designed with basalt tiles for abrasion resistance.Repairing the basalt tiles of the spiral cone is very difficultand expensive. The customer was looking for anabrasion resistant material that could be repaired.

Solution: ARC 890 was applied to the press face of the spiral conescrew inside the ball mill to provide an abrasion resistantsurface.

Results: ARC 890 has provided the same abrasion resistance asbasalt tiles with the ability to be easily repaired. Thecustomer performs minor touch up to the ARC 890 on ascheduled maintenance basis.

Savings: Repair and maintenance costs of ARC 890 are a fractionof those for basalt tiles.

AC4286E


Clinker Grinding Ball Mill


1


Damaged spiral cone from inside ball mill.AC4286E


Spiral coneafter abrasiveblasting.

AC4286E

2


ARC 890 applied to press face of spiral cone.AC4286E


Inspection of ARC 890 in ball mill.AC4286E

Industry: Cement Plant

Equipment: Coal feed screws

Media: Raw coal

Location: New England

Summary: Abrasive coal was wearing out flights of screw leading toinsufficient coal feed to crusher mills.

Process: Coal is fed from the silo to the kiln burners. If coal is nottransported at sufficient rate of flow due to worn flights, crusherscannot feed kiln burners and cement production rates drop off.

Problem: Abrasion of coal had worn flights leading to reduced flow rates.Cost to weld repair was $2,400 USD/year per screw

Solution: After proper surface preparation ARC 890 was applied to theflight faces (push side and slave side) and the cylinder. Finalsmoothing coat of ARC 855 is applied to ensure minimalroughness and allow for maximum flow.

Results: Coated screw last over 18 months (>3 times that of uncoatedscrew). Coating of coal feed screws with ARC Composites isnow plant standard operating procedure.

Savings: Plant realizes savings of over $3,000 USD per year per screw.AC3180E


Coal feed screw after abrasive blasting. Note thehardface welding on the leading edge of the flights.



Coal feed screw after abrasive blasting. Note thehardface welding on the leading edge of the flights.



AC3180E

ARC 855 used as a prime coat for ARC 890.


AC3180E

Surface finish of ARC 890 after application by trowel,


AC3180E

Brush application of ARC 855 as a smoothing topcoatover the ARC 890.

1


Classifier fan blades.Chesterton® DOC. NO. AC3187E, 6/99

Industry: Cement

Equipment: Classifier Fan Blades

Problem: Excessive wear on the lower sections of the blades.

Solution: After abrasive blasting, rebuild the leading edges of thelower blade section using ARC 858 and ARC 855. ARC897 and 890 have been used in similar applications wheremore severe abrasive wear is present.

AC3187E

1


Classifier fan blades.Chesterton® DOC. NO. AC3187E, 6/99


ARC 858 and 855applied to anindividual classifierfan blade.

AC3187E

Industry: Cement

Equipment: Pneumatic transport pipe

Location: Portugal

Problem: Severe abrasion to pneumatic transport system requiring a one weekmaintenance shutdown every six months. The most severe wearoccurred on the sleeve separators. The regular repair procedure ofwelding abrasion resistant steel plates on holes was not acceptable.

Solution: After proper surface preparation, ARC 897 and 890 were applied tothe sleeve separator area as a test.

Results: At the 6 month inspection, the test areas were in excellent conditionand no touch up was needed. Based on these results, the customerdecided to rebuild all worn areas with ARC 897.

Savings: The repair time with ARC 897 is dramatically less than welding andthis is significant maintenance savings for the plant.

AC4333E



Entrance to the pneumatictransport system prior torebuilding with ARC 897.



Entrance to the pneumatictransport system prior torebuilding with ARC 897.


AC4333E

Condition of sleeve separatorafter 6 months in service.The abrasion resistant steelplates used here were 6 mm(1/4 inch) thick.


AC4333E

ARC 897 and ARC 890 wereapplied as a test to the sleeveseparator area.Inspection would be possibleonly after six months.According to the customer, thefaster application time andreduced overall repair time ofARC Composites would be a bigadvantage.


AC4333E

After six months, the test area showed no wear. Based on theseresults, all of the worn areas are now coated with ARC 897.

Industry: Cement

Equipment: Rotor vanes of air ventilator

Location: Portugal

Problem: Severe abrasion to rotor vanes from the cement in the air and the highrpm of the rotor. In extreme areas the vanes of the rotor actually splitfrom wearing so thin and create a unsafe working environment

Solution: The vanes were rebuilt by first tack welding expanded metal to thevane and then coating with ARC Composites. Four vanes wereinitially rebuilt in this manner as a test.

Results: After the test period was complete, the vanes rebuilt with ARCComposites were found to be in excellent condition and this techniqueis now the standard repair method to all fans working in theseconditions.

Savings: The repair time with ARC Composites is dramatically less thanwelding and this is significant maintenance savings for the plant.

AC4334E



Rotor to a ventilator in acement plant. These rotorsare used to “pull” air throughthe pipes and ducting,making it possible totransport cement to thecyclones and sleeveseparators.They are subjected to highwear due to cementabrasion at high r.p.m.



Rotor to a ventilator in acement plant. These rotorsare used to “pull” air throughthe pipes and ducting,making it possible totransport cement to thecyclones and sleeveseparators.They are subjected to highwear due to cementabrasion at high r.p.m.


AC4334E

At extreme abrasionsituations, the fansplits into two parts,making it a big safetyhazard to workers andalso nearby equipment


AC4334E

Expanded metal wasspot welded to rebuildthe vanes of the rotor.Only four vanes wererebuilt during the initialtest.


AC4334E

After the test period wascomplete the vaneswere inspected.Arc 897 is now thestandard repair methodto all of the fans workingin these conditions.

An additional advantage:to using ARC is thatthese repairs can bedone in place (beingbalanced afterwardsalso in place)dramatically reducingdowntime.

Industry: Cement

Equipment: Blades of cement separator

Location: Portugal

Problem: Severe abrasion to edges of cement separator blades requiring costlyreplacement.

Solution: After proper surface preparation, ARC 897 was applied to theseparator blades.

Results: The customer is very pleased with the performance of the ARC 897and its ability to rebuild the separator blades in place.

Savings: The repair time with ARC Composites is dramatically less than partreplacement and this is significant maintenance savings for the plant.

AC4335E



These blades suffer intensiveabrasion . This is a static separatorand cement is forced through theblades intervals.This makes the blades lifetime veryshort.Using ARC 897 on the blades (repairin place) makes it unnecessary toreplace them, reducing downtime.

Industry: Cement

Equipment: Ball mill feeders

Location: Portugal

Problem: Severe abrasion and impact damage to ball mill feeder. The previousmethod of repair, welding, was not acceptable because of the internalstress developed in the metal during welding accelerated the failurerate and lead to frequent part replacement.

Solution: The feeders were first spot welded and then abrasive blasted. ARC890 was used to rebuild the ball mill feeder.

Results: ARC 890 has dramatically extended the service life of the ball millfeeder and this technique is now the standard repair method to all ballmill feeders in the cement plant.

Savings: Touch up repairs to the ARC 890 can be done in place savingsubstantial downtime. Part replacement costs have been virtuallyeliminated.

AC4336E



Ball Mill feeders. These parts are subjected to very high wear andconstant impact. The previous repair method, welding, induced stressin the metal which accelerated the failure rate.


AC4336E

Ball mill feeder in place in the ball mill. This component is verydifficult to replace requiring substantial downtime.


AC4336E

Ball mill feeder after service. This plant could not find a reliablerepair that allowed for the same part to go back into service.


AC4336E

After proper structural inspection, expanded metal spotwelding was done on the areas to be coated.


AC4336E

Ball Mill feeder rebuilt with ARC Composites. This repairmethod is now a standard procedure in this cement plant.

Applications for ARC Composites in the Cement Industry Composite/Ceme… · Applications for ARC...

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