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Sintercast Vs Hardfacing

This document compares the process of hardfacing versus using sintercast wear-resistant material for cement mill rollers. Some key disadvantages of hardfacing listed include increased risk of cracking, bearing failures, loss of production during downtime, and health risks from fumes. Sintercast is presented as a safer alternative with benefits like consistent performance, reduced maintenance costs, higher wear life, and no risk of breakage. A cost comparison using actual mill data shows that sintercast rollers provide significant savings over multiple hardfacing cycles due to less downtime and extended lifetime.

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anrulo
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2K views

Sintercast Vs Hardfacing

This document compares the process of hardfacing versus using sintercast wear-resistant material for cement mill rollers. Some key disadvantages of hardfacing listed include increased risk of cracking, bearing failures, loss of production during downtime, and health risks from fumes. Sintercast is presented as a safer alternative with benefits like consistent performance, reduced maintenance costs, higher wear life, and no risk of breakage. A cost comparison using actual mill data shows that sintercast rollers provide significant savings over multiple hardfacing cycles due to less downtime and extended lifetime.

Uploaded by

anrulo
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Sintercast vs Hardfacing

Comparison

VEGA Industries LTD.

to

Welcome

HARD FACING

IN THE WORKSHOP
IN SITU

WAYS OF HARD FACING

 No specific technique is required. Cheap labor available in the market.

 Availability of many suppliers and variety of electrodes in the market.

 In situ hard facing helps in keeping original profile.

 Possibility of re-use of base material more number of times.

 It has short delivery time as compared to new set .

WHAT CUSTOMER BELIEVES


ABOUT HARD FACING

and reduces mill

 Hard facing at in situ condition may cause bearing failures.

situ hard facing.

 Direct Loss of production and revenue generation during stoppage for in

availability

 In case of in situ hard facing , down time increases

 Generation of surface crack is inevitable and always risk of failure.

 Fumes generate during hard facing is health hazardous for human being.

 Unable to maintain the same profile due to expansion and shrinkage.

facing.

 Difficult to maintain same performance even with identical layer of hard

 Multiple time hard facing results in cracking of casting.

 Limited Layer of hard facing due to safety reason.

 Very high risk of casting breakage during operation.

WHAT IS THE RISK IN HARD FACING

INITIALLY START WITH SMALLER


CRACK

AND TRANSFORM INTO PIECES

Shaping
a world of
Performance
CRACK ON
HARD
FACED
LAYER

Shaping a world of Performance


ROUGH
SURFACE
,

VIZAG SLAG LM 46.2+2

CRACK ON HARD FACED LAYER

ULTRATECH TADIPATRI
LM 53.3+3

CRACK ON HARD FACED LAYER

ULTRATECH GINIGERA
53.3+3

LM

CRACK ON HARD FACED LAYER

DALMIA

LM 46.2+2

CRACK ON HARD FACED LAYER

ORIGINAL MATERIAL HI-CHROME. WELDING AFTER 800


HRS. BREAKAGE IN FEW DAYS AFTER HARD FACING

ACC BARGARH - MPS 5600 BC

CRACK ON HARD FACED LAYER

Shaping a world of Performance


SPALLING
ON
HARD
FACED LAYER
,

facing on the wear resistant casting.

 We have observed that some of the customer is hard facing on the roller
tire after wear of hardened sinter layer. We are not in a favor of hard

 Mills can operate at higher operating pressure and improves the


operating and performance parameters.

higher wear life.


 Reduces the maintenance and operating cost .

production loss and direct revenue generation.


 Much lesser wear rate as compared to hard facing and gives much

wear on the casting. It reduces the power consumption.


 Reduce the stoppage for in situ hard facing and minimize the risk of

which performance will be consistent.


 Sinter layer will be more harder than hard facing layer and create uniform

 No risk of casting breakage during operation.


 Original profile can be maintained for much longer time and due to

 Reduces the maintenance cost

ADVANTAGES OF SINTER CAST OVER


HARD FACING

- These solutions help customers reduce their total cost of production.

- By providing better solutions in abrasion resistance products.

AIAE / Vega always strive to achieve total customer


satisfaction:

WHY SINTER CAST ?

The inserts are mechanically bonded to the base metal. There is no


metallurgical bond, hence even if small cracks appear in the inserts, these
can not penetrate through the ductile core

The hard inserts are embedded in the core of nodular iron. The nodular iron is
highly ductile and capable of withstanding severe shocks.

Life time is increased by 1.5 2.5 times depending on the characteristics of


the raw material ground.
Total safety against breakage

Improved wear life

ADVANTAGES OF SINTER CAST

Replacement can be planned to match the annual shutdowns.

Mill availability increases due to less adjustments.

Higher lifetime reduces the no. of stoppages.

Reduction in Mill down time:

The construction results in biting action on the raw material thereby


reducing the slippage.
Reduced slippage results in better grinding efficiency.

Uniform wear profile results in consistently maintaining mill operating


parameters.

Tailor made solution provides uniform wear profile.

Consistency of Mill performance:

ADVANTAGES OF SINTER CAST

Madras Cement-(Alathiyur), LM56.20+2

COST
COMPARISON

Madras Cement-(Alathiyur), LM56.20+2

Contd--

COST COMPARISON BASED ON ACTUAL DATA , MAY NOT BE SAME


FOR OTHER PROJECTS. WE SUGGEST NOT TO CONSIDER THIS
PEROFMANCE AND PRACTICE OF HARD FACING AS A SOLUTION.

10.8
14-20 mm
3240
46286
118525.7
4.6
11.9

Maximum Wear at the time of


hard facing

Total Cost of Hard Facing After


every700 hrs operation

Total Cost of Hard Facing

Total Cost of original set plus hard


facing / Hour for original set

Cost / Hour for Hard Facing

Cost Per hour including Original


set with Hard Facing

72240

Cost of welding per Kg

No Of times Hard Facing

Conventional

Cost USD

8400 Kg

Weight of each Roller Tire

Type

Cement Mill

Mill Type

USD / hr.

USD / hr.

10000

10000

700 Hrs

700 Hrs

14

10000

Running
hours

Calculation

No Of Roller

Plant

Remarks

Including Hard
operation

Facing

up

After Every 700 Hrs Operation

20-30 mm per 1000 hrs operation

to

10000

Hrs

Total 300 kg electrodes consumption on two


roller tire per 700 hrs operation

After Every 700 Hrs Operation. Normally possible


hard facing in between 14 times on each roller
tire

Cost for two roller tire. Multiple hard facing up


to 10000 hrs operation.

MCL Jayantipuram

Cost Comparison of Hard Facing roller with Sinter Cast

COST COMPARISON

96628.0

Units

USD/hr

By saving min 14 stoppage of 29 hrs


each for hard facing

USD / hr.

USD / hr.

USD

In case of Sinter cast max wear of


30 mm was observed after 5400 hrs
operation

Life achieved Without Hard Facing


IN 7000 HRS and still in operation

mm

MCL Jayantipuram

1. Consistency in mill output; 2. Reduced Maintenance; 3.Consistency in Performance Parameters like Power
Consumption, Fineness etc; 4. 100 % Safety against breakage ; 5. Uniform Wear Profile ( due to insert design)

Indirect advantages

1101.6

Hrs

Extra Revenue per hrs due to Sinter Cast

10000

11015592.0

in

ADDITIONAL

3.1

Revenue due to extra grinding of cement

Extra Cement ground


Operation ( Tons)

Saving in Sinter cast in comparison to Ni


Hard IV with No of times Hard Facing

11.9

8.7

Cost / hrs

Equivalent Cost for 10000 Hrs

87360

Cost of set

4.29

Wear Speed

20.0

10000

40

Sinter cast

No Of Roller

Plant

Run hrs

40

Ni Hard IV with
Hard Facing

Alloy

Maximum wear

8400 Kg

Cement Mill

Weight of each Roller Tire

Mill Type

Cost Comparison of Hard Facing roller with Sinter Cast

COST COMPARISON

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