Table of Contents

• Protective maintenance
• Maintenance & repair of worn-out components
• Breakdown Repair or Maintenance

Opportunities in the Cement Industry

The cement industry is a vital part of the core sector that supports the world of infrastructure. One of the basic fulcrums which drives this process industry is maintenance and repair of cement Industry components.

Cement is manufactured from the raw material ore of limestone. The entire process starts from the mines and ends up as a final product in the Cement plant. This makes wear the underlying theme in the manufacturing of cement –primarily it is abrasive wear caused by hard limestone combined with impact, heat & erosion in the process

The modes of repair by welding can be divided into three types:

1. Protective maintenance of wearing components
2. Maintenance & repair of worn-out components
3. Breakdown repairs with highly reliable components

Now let us see the three types of repairs in detail to understand more about the welding of cement Industry components

• Protective maintenance:

Manufacturing of cement involves handling hard limestone in very high abrasive conditions, with impact, heat, and erosion. In many cases, components making up the base material need protection. This can be as simple as wear protective welding of new components like earth moving buckets or rotary airlock valves with tailor made, ready-to-use wear solutions designed to give long life before they get worn out again, like Endurafon & Hardox ready-to-use wear plates.

• Maintenance & repair of worn-out components:

As the name itself suggests, this involves repair of the worn-out components with low heat input LH welding alloys to ensure prolonged life or improved life of the worn-out components. Repair & maintenance can also be defined in two parts.

1. Repair applications for joining components:
   

Typical applications include joining of anchor in Kiln, Pre-heater and cooler. This is an important application which supports castables in high temperature applications, as any damage or failure of castables will mean stoppage of plant, hence it is a critical application in any cement plant. ADFL’s LH 126 is widely used for this application across cement plants in India.

2. Application for Wear Protection:

The second one is built up & wear protection of wear prone components in the cement plant; Typical example is Buttoning of Sinter Cast rolls in VRM rollers and Roller Press Roll (RPR) pattern welding build up with Custom designed products to enhance life. LH WearTherm 65 is a product developed for this application & well appreciated for its longer life.

• Breakdown Repair or Maintenance

Cement industry is a process industry hence certain components fail due to heavy loads, heat, material fatigue and it is difficult to carry an inventory for these components hence these components need in –situ repair ensuring maximum reliability and performance, some critical examples are kiln tyre or kiln girth gear repaired at site.

It is a matter of pride for Ador Fontech Limited that we are the first re-call for all Cement Industry customers when faced with breakdown of the plant in such applications. We have tailor-made solutions with specially manufactured Low Heat Input (LH) welding electrodes which provide the highest reliability and life enhancement. Our LH Gold 555 & LH 521 are key products which signify our capabilities.

ADFL brings its 4 decades of experience in all types of applications in the Cement industry like joining, hard facing & cutting solutions required at customer premises. One of the key advantages with Ador is also our repair facility – our Life Enhancement Services facility in Nagpur. It is dedicated to the repair of all cement industry components, and also boasts a dedicated team to serve customers at their sites for all maintenance and welding repair solutions.

One of the key jobs we carry out through our LE services team at site is Kiln shell welding or kiln shell replacement. We carry out the Kiln shell welding process with a custom-built Automatic SAW welding process. This process gives highest reliability and productivity to customers and this process is 3 times faster than conventional repairs in the industry.

This is why the name Ador Fontech Limited is synonymous with total solutions for any Repair & Maintenance problems in the cement industry.

Reclaim. Do not Replace.