Tipper Jaw crushers Hammer crushers Chutes amp Hoppers Raw Mills Cyclones Clinker Crushers Screw Conveyor Ball Mills Conveyors Bulker Truck Elevator buckets Conveyors Hopper INDUSTRY OVERVIEW ID: 999143
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1. APPLICATIONS IN CEMENT
2. Loaders & TipperJaw crushersHammer crushersChutes & HoppersRaw MillsCyclonesClinker CrushersScrew ConveyorBall MillsConveyorsBulker TruckElevator bucketsConveyorsHopperINDUSTRY OVERVIEWOpen pitLoader + TipperElevator – dump trackHopperConveyors belt steel/Agron feederJaw crusherConveyor belt rubberCrsher-screenCone-crusherChuteConveyor belt rubberLiner platesElevator bucketsHopperConveyor belt rubberRaw millPreheading in cyclonesRotary klmClinker rockerConveyor belt rubberHammer crusherHopperScrew conveyorsSilos (Gypsum, Minerals and Clinker)Ball millHopperSiloLoading on bulk/beat or bagged
3. 4 HOPPER
4. Hoppers and drain chutes. HARDOX 400HOPPER AND DRAIN CHUTES
5. HARDOX 450 – 6mmHOPPER AND DRAIN CHUTES
6. 5 CONVEYOR BELT/APRON FEEDER
7. General DescriptionThe deflector plates are fixed at the end of the conveyor belts. The limestone continuously hits the deflector plates and falls down on the hopper. The previous deflector plates were manufactured with ar 400 and could not perform. A dead bead solution was made by the help of welding round bars on the plate. The used material in the round bars were made by high crome material, but hardox 400 round bars would be a great solution.REFERENS CASEDeflector Plate 5 Conveyor Belt/Apron Feeder5 CONVEYOR BELT/APRON FEEDER
8. REFERENS CASE5 CONVEYOR BELT/APRON FEEDER
9. Wear in conveyors and scrappersSTACKER/RECLAIMER
10. Bucket elevatorHardox 400, 450RAW MEAL CONVEYORS
11. REFERENS CASESprockets in HARDOX 500Reinforced chain parts in HARDOX 400 & 450Wear protection on elevator housingSPROCKET WHEELSRAW MEAL CONVEYORS
12. Drag chain HARDOX 400 or HARDOX 500Dimensions:Length 30 metersFloor width 400 mm in 15 mmSide walls height 300 mm in 10Scraper 20 x 300 x 400 mmWeights:Floor: 1440 kgWalls: 1440 kgScraper: 1152 kgDRAG CHAIN
13. Other type of chain conveyor or Screw conveyor HARDOX 400/450CONVEYORS
14. 6 PRIMARY CRUSHING: Impact + Jaw crusher
15. Depending on crushing stage and requested outcome, there are different crushers to fragmentize and form rocks: Impact crusherJaw crusherCone crusherCRUSHERS – Large share of castings in most crusher types
16. Steel grid screensRubber grid screensThe wear on crusher wearparts primarily depends on rock hardness and abrasiveness, and degree of impact. This will effect the type of wear material used.After each crushing stage there are a number of screen levels to sort aggregates by size:CRUSHERS – Large share of castings in most crusher types
17. Jaw crusherCRUSHERS – Large share of castings in most crusher types (cont’d)
18. Impact crusherCRUSHERS – Large share of castings in most crusher types (cont’d)Horizontal Shaft Impactor (“HSI”)Vertical Shaft Impactor (“VSI”)
19. LINERS HARDOX 500 50MMIMPACT CRUSHERS
20. Weld-on Lining Plates/Bolt-on Lining Plates for Cheek PlatesJAW CRUSHERS
21. Side wedge in Stone Crusher (liner)HARDOX 550 Thickness: 30 to 60 mm DescriptionWedge-shaped plates for stone crushers made from Hardox550, 35 mm thick.Manufacturing stepsCutting method – Gas cutting; DrillingBusiness Benefit2 x Liftime compared to the plates made from 12% Mn-steel
22. Secondary crusher-cone crusherPRIMARY CRUSHER – Jaw crusher
23. Linear plates in HARDOX 550 or HARDOX 600PRIMARY CRUSHER – Jaw crusher
24. PRIMARY CRUSHER – Impact crusherGRIZZLY BARS/SCREENS
25. Breakage is common in both segments and wear bars, both usually made out of 12 %Mn-steels. With the HARDOX 500, breakage is reduced to zero and wear life increased. Segments for the grate basket and the perpendicular wear bars are made of HARDOX 500. The wear bars are 75 mm. Success with Hardox 500(76mm) bars lasted 1380 hrsAverage service life for Mn-castings was 700 hrsCRUSHER at a limestone quarry/cement plant
26. 7 CONVEYOR BELT – Rubber
27. Clinker conveyor sprocket – Made out of HARDOX 500 (56 mm)CONVEYOR SPROCKET
28. 8 CRUSHER SCREENS
29. General DescriptionThe quarried limestone is normally in the form of big boulders, ranging from a few cm to meters in size. After passing the jaw crusher the limestone is processed in the secondary hammer crusher. Breakage caused by contamination is common in both segments and wear bars, both usually made out of 12 % mn-steels. With the hardox 500 in the grizzly bars and hardox 450 in the segments, breakage is reduced to zero and wear life increased more than double.REFERENS CASEGrizzly Bars 8 Crusher Screens8 CRUSHER SCREENSBusiness PotentialThe application have been successful in the Middle East and several other places around the world. In a country like Turkey with more than 70 cement plants would the potential be 1000 tons only for the grizzly bars.
30. REFERENS CASE8 CRUSHER SCREENS
31. DescriptionThe grizzly bars is the screening unit in a hammer mill which is used mainly in the cement industry. The grain size is determined by the gap.Technical dataThe velocity of the hammer mill is 600 rpm and it runs for 16 hours a dayUsageImpact bar: 80 x 130 x 2230mm, HARDOX500 Bars: 60/30 x 80 x 2230mm, HARDOX500 Side plates: 50 x 350 x 2100mm, HARDOX450GRIZZLY BARS to secondary crusherHARDOX 500HARDOX 450
32. Life timeThe life of the grizzly bars is 6-12 months depending on the material impact. The side panels have a lifespan of 3-4 years. The total demand of the grizzly bars is several 1000 units per year.GRIZZLY BARS to secondary crusherHARDOX 500HARDOX 450
33. HARDOX – 450 Crusher ScreenCRUSHER SCREENS
34. HARDOX 400 – 10 mm Screen MeshSCREEN MESH
35. 9 CONE CRUSHER
36. Con crusherCRUSHERS – Large share of castings in most crusher types (cont’d)
37. Cone Crusher Top Cone Liner HARDOX 400 – 25mmCRUSHERS – Large share of castings in most crusher types (cont’d)
38. Protector ring for cone Crusher HARDOX 500 – 15 mm CRUSHERS – Large share of castings in most crusher types (cont’d)
39. 10 CHUTES AND FEEDERS
40. Recomended Materials10 CHUTES AND FEEDERS
41. 10 CHUTES AND FEEDERSGeneral DescriptionEntrance to conveyor after primary crushing. Success. Increased wear life. Minimizing service brakes. REFERENS CASELimestone Feeder 10 Chutes and Feeders
42. 10 CHUTES AND FEEDERSREFERENS CASE
43. CRUSHER FEEDER AND CHUTE Feeder and Hopper to the primary crusher Liner plates in HARDOX 400-600
44. 12 LINER PLATE STORAGE BIN
45. 13 ELEVATOR BUCKET
46. Bucket elevatorHardox 400, 450RAW MEAL CONVEYORS
47. Elevator bucket in Hx 400/450Possible enforcement in Hx 500 on outer edgeThicknessMS: 6 to 8 mm Hx 4 mmELEVATOR BUCKET
48. Elevator buckets. Body HARDOX 400. Front edge in HARDOX 500Weight 5 x 800 x 400 x 60 buckets = 768ELEVATOR BUCKET
49. Possible applications for HARDOXSprockets in HARDOX 500Reinforced chain parts in HARDOX 400 och 450Wear protection on elevator housingSPROCKET WHEELSRAW MEAL CONVEYORS
50. RAW MEAL CONVEYORSGeneral DescriptionDrag chain element, raw mill feeding. SSAB improved not only the quality but offered shorter lead times than OEM spare parts.REFERENS CASEDrag Chain Element 15 Conveyor EquipmentBusiness PotentialAny raw mill feeding system.
51. RAW MEAL CONVEYORSREFERENS CASE
52. 16 VETICAL RAW MILL
53. VRM – Liners in the grinding zone areaEquipment : VRM – Grinding Zone Area HARDOX 600 – 20mm thick liners rolled to 4500mm diameter Performance – 16 months still performing Expected to give better life than CCO Wear Plates (5+5)Roll bending of HARDOX 600 plates to higher diameters to be done very carefully
54. VRM – Liners in the grinding zone area
55. General DescriptionThe vertical raw mill is a very important unit in a cement industry where the lime stone is pulverised and the smaller particles are suckey up by a cyclonic action in the mill . During this operation the fine lime stone particles hit the side walls and the armour ring which gets worn out very badly dur to the high velocity along with abrasion and erosion. REFERENS CASECement Grinder 16 Vertical Raw MillVRM – Liners in the grinding zone areaBusiness PotentialThis application can be replaced in all cement plats where there are Vertical Roll Mills both for coal and lime stone.
56. REFERENS CASEVRM – Liners in the grinding zone area
57. General DescriptionThe vertical raw mill is a very important unit in a cement industry where the lime stone is pulverised and the smaller particles are suckey up by a cyclonic action in the mill . during this operation the fine lime stone particles hit the side walls and the armour ring which gets worn out very badly dur to the high velocity along with abrasion and erosion. REFERENS CASEInlet protective shell 16 Vertical Raw MillVRM – Liners in the grinding zone areaBusiness PotentialThis application can be replaced in all cement plats where there are Vertical Roll Mills both for coal and lime stone. Reduced cost and shorter lead time comparing the OEM part of Loesche.
58. REFERENS CASEVRM – Liners in the grinding zone area
59. General DescriptionHardox 600 has been used in the so called grit cone of the vertical roller mill. It has replaced the hardfaced castodur diamond plate of (8+5) which used to worn out (develop holes) within 1 month. The wear life improved from one month to three months. The demand is one plate per month. The vertical raw mill is a very important unit in a cement industry where the lime stone is pulverised and the smaller particles are sucked up by a cyclonic action in the mill.REFERENS CASEGrit Cone Liner 16 Vertical Raw MillVRM – Liners in the grinding zone areaBusiness PotentialMost likely there is at least one plant in each larger country that would be feasible. If the cone is not in sections, a plate replacement may be a challenging option.
60. REFERENS CASEVRM – Liners in the grinding zone area
61. General DescriptionRelining of the interior of the raw mill. Roll bending of Hardox 600 plates to higher diameters to be done very carefully. REFERENS CASELiner Package – Relining 16 Vertical Raw MillVRM – Liners in the grinding zone areaBusiness PotentialThis application can be replaced in all cement plats where there are Vertical Roll Mills both for coal and lime stone.
62. REFERENS CASEVRM – Liners in the grinding zone area
63. Hardox 600 in liners. The life achieved in this case is also just better or same as Castodur Diamond Plates. Much lower price however.VERTICAL RAW MILL – Repair work
64. 17 PREHEATING IN CYCLONES
65. REFERENS CASEFan blades and liners 17 Cyclones and Air Separators17 PREHEATING IN CYCLONESLINERS FAN BLADES
66. REFERENS CASE17 PREHEATING IN CYCLONES
67. Assemblage of a separatorMaterial Recommendation: Hx 400/450AIR SEPARATOR
68. Guide vanesDeflection platesWear protectionHARDOX 500HARDOX 400HARDOX 500Wear life appr. 2 years AIR SEPARATOR
69. AIR SEPARATORLiner plates on wallsErosive wearHARDOX 400, 450Fan bladesErosive wearHARDOX 500
70. Bottom part made in HARDOX 400 or HARDOX 450HOPPER
71. Materials recomendation CYCLONE
72. Liner plates in HARDOX 450 – 8MMCYCLONE
73. Raw meal conveyed to the topGas pipe from clinker cooling bedKilnPREHEATING TOWER
74. PREHEATING TOWER FEEDERRaw meal flows through the chute into the air suspended preheater cyclonesLiners made of HARDOX 400/450
75. 19 CLINKER COOLER
76. COOLING BED AND GUIDE PLATESHARDOX 500 or HARDOX HiTemp for guide plates in the clinker cooling bed
77. Clinker conveyor from cooling bed to chuteCLINKER CONVEYORPlatesMild steelHARDOX 450 +40% wear lifeClinker is loaded through tube from cooling bed
78. Clinker loaded from conveyor into chuteOften made in hard faced materialHARDOX 550HARDOX 600CLINKER CHUTE
79. Material Recommendation:Hardox 600CLINKER CHUTE
80. Chain of scrapersWear Situation: Sliding wearCLINKER CONVEYORScrapersHARDOX 400HARDOX 450 +30% wear life
81. 21 HAMMER CRUSHER AND CLINKER GRINDER
82. General DescriptionThe quarried limestone is normally in the form of big boulders, ranging from a few cm to meters in size. After passing the jaw crusher the limestone is processed in the secondary hammer crusher. With the hardox 600 in the 100kg heavy hammers, the life time is suspected to be 50-100% better. REFERENS CASEHammer Crusher 21 Hammer CrushersBusiness PotentialThis application can be replicated in all cement plants. 21 HAMMER CRUSHER AND CLINKER GRINDER
83. REFERENS CASE21 HAMMER CRUSHER AND CLINKER GRINDER
84. General DescriptionHammer crushers in limestone quarries.REFERENS CASEHammers 21 Hammer Crushers21 HAMMER CRUSHER AND CLINKER GRINDER
85. REFERENS CASE21 HAMMER CRUSHER AND CLINKER GRINDER
86. Directly after cooling bedTemperature ~100°CCLINKER CHRUSHERGratingHARDOX 450HARDOX 500Liner platesHARDOX 450HARDOX 500
87. Original hammer made by 12% Carbon-Mn steel Weight: 90kgAbrasive: Limestone in a cement plantEstimated life-time: 2 monthsA test piece (blue area) was sent to laboratoryHAMMER CHRUSHERThe SSAB hardness measurement shows that the hammer effect is reaching a hardness of maximum 500 Brinell.HV2Distance from hammer top (mm)
88. A thin hammer is usually performing the same as a thicker one and is much easier to manufacture.HAMMER CHRUSHER – Examples
89. LIMESTONE HAMMERSMaterial RecommendationHardox 500, 30 to 60 mm Previous material12% Mn steel Service lifeCa 3 months Competitive advantageAvailability of plate Volume82 pcs, 60x220x320 mm, for one set Manufacturing stepsCutting method - Gas cutting; Machining - StatusSuccess, Roughly the same lifetime as 12% Mn steel, better availibility.CommentsCutting and machining represent ca 30 % of total price
90. CEMENT HAMMERHammers in Hardox 600Limestone quarry 20 mm AWJ HARDOX 600 is now used to replace other materialHeat treatment of hammers HARDOX 600 compared to C60 20% better, Mg 15% better, Cr -10 %, Bimetal -35%, Martensitigue +-0%Hammers from Hardox and Magotteaux
91. 23 SCREW CONVEYORS
92. Steel grade: Hardox 450 & 500Description of the applicationCement Mill Inlet Scroll. Shell 12mm Hardox 400 Flights 12mm Hardox 500Manufacturing stepsCutting method - Gas cutting; Bending method - Roll bending; Bending method - Press forming; Welding method - MAGCEMENT MILL INTAKE SCROLL
93. Materials recomendation SCREW CONVEYORS
94. Use: crushed clinker/cementFlanges in drumHARDOX 400/450Result: +30% wear lifeFlanges made inHARDOX 400/450Protection plates on the centre axleSCREW CONVEYORS
95. Screw conveyor for clinker mfgRotation speed 20-30rpm. Working hours 24h per day. Made of steel S355 (the blades on the screw shaft)Thickness 4,5,6mm HARDOX 400/4504-5000 hours (before less than 2000)Wearlife: +100%SCREW CONVEYORS
96. 24 SILOS
97. Remember: size and number of silos indicate plant capacity AND opportunity for upgradinRAW MEAL SILOS FOR HOMOGENISING
98. 25 BALL MILL
99. Materials recomendationRe-lining package 25 BALL MILL – RELINING
100. General DescriptionCommon solution is based on a cast iron plate but some OEMs prefer boron steel but with reduced lifetime. The solution offered by SSAB with Hx 600 cut with AWJ has offered very good performance. REFERENS CASESlite Plate 25 Ball Mill Grinder25 BALL MILL – RELINING
101. REFERENS CASE25 BALL MILL – RELINING
102. Wear protection at inlet and outlet chutesHARDOX 500HARDOX 550BALL MILL – CONFIGURATION
103. Diaphragm platesThe counter sunk holes and slots are water jet cut.The slots are taper cut with 5 axis water jet cutting torch.BALL MILL: DIAPHRAGM PLATES (slite plate)
104.