CRITICAL WELDING OF SS ANCHORS IN KILN, PRE-HEATER AND COOLER AREA
AREA OF CONCERN
Kiln is a freely floating tube made out of boiler quality steel plate lined with refractory bricks used in the pyro-processing (Klinkerisation) stage of manufacture of cement. The temperature varies from 600 OC to 1300 OC. Inside the kiln is lined with refractory castables, these refractory castables are
anchored to kiln plates by using SS 310 grade –anchors. This anchor needs to be joined with kiln shell-this acts as a re-enforcement to hold the castables together. Further, these anchors are used in pre-heater/kiln burner nozzle area where castables are used as well. If the anchor welding fails the castables also fall and that particular portion gets heated up and in due course, it forms red spot & cracks. So it’s extremely critical that anchor welding requires utmost reliability.
So after replacement or repair in kiln shell or preheater, SS 310 anchors are welded on to the kiln shell inner portion, the best solution for this welding is LH 126 our unique alloy ideal for joining SS to any type of steel, in this case, joining of SS 310 with boiler quality steel. Also, this specially formulated Ni-Cr alloy is the most ideal alloy for continuous high temperature working up to 1200OC approx. with very high tensile strength & elongation giving highest reliability in this application.
ALTERNATIVE FUEL & RAW MATERIAL (AFR) SHREDDERS ROLL
SPECIALLY FORMULATED NANO BASED SOLUTION FOR AFR SHREDDER COMPONENTS
AREA OF CONCERN
Today in many cement units across India, alternate fuels of different waste materials like municipal waste, plastics, wood, tyre & sludge are used for firing the kiln. This alternative fuel materials are crushed in an AFR shredder crusher rolls, hence the rolls and hammers in the crusher unit get worn out by severe abrasion, erosion combined with high corrosion and this requires immediate replacement or wear facing with welding due to frequent stoppages.
ADFL has a couple of solutions for this high wearprone application. Wear protection of new shredder rolls and hammers with a combination of LH TUF TECH 58, our titanium carbide electrode designed for high impact & abrasion. The final wear protection with our unique Nano-based Electrode LH ULTRATHERM 70N to give extended life. For worn-out ARF shredder rolls, we build the fatigued shredder roll and hammer to the required profile using our low hydrogen electrode LH 104 & the final wear protection again with LH TUF TECH 58 & Nano electrode LH ULTRATHERM 70N.