Wear Resistant Systems for Cement Production
Maintain plant efficiency and integrity with Kingfisher Industrial
Equipment Abasement – we understand the pain
Having to manage the process of cement manufacture from the quarry to the bag involves a multitude of activities with each operation depending on the success of the previous stage. As with a chain, its operation is achieved by the strength of each link and each one contributes to the success of the collective parts. Having plant and equipment, designed, manufactured and serviced to achieve continual operation when handling various bulk solids in harsh environmental conditions is of utmost importance. As with most of today’s manufacturing plants, they have evolved into an efficient lean process that with the correct investment in protecting the capital equipment can give security of service.
Increase equipment service life
As with your engineering and maintenance teams, Kingfisher follow the process from the quarry to the bagging plant. We have many years experience in solving the problems experienced with mineral excavation through to the blending of clay and chalk to the cooling and storage of clinker and finally to the milling and conveying of cement. Equipment such as front loading buckets, crushing equipment and reception hoppers have seen extended service life through the use of protection systems such as chromium carbide clad plate or manganese steel castings.
The Solution Providers
A wide range of ceramic materials such as high alumina or cast basalts have been used extensively in applications where pneumatic conveyance of either clinker or cement has taken place in cyclones, separators or conveying pipework. The use of polymers to protect equipment where extreme impact prior to crushing is evident benefit from being lined with hard rubber liners and likewise the difficulties associated with the storage of coal and cement are eliminated due to the low coefficient of friction that polyethylene liners offer in assisting discharge.
In all of these cases and in many more, the cement industry can achieve significant benefits when working alongside Kingfisher. By utilising our experience to design, manufacture, protect and install process plant and equipment we are able to work alongside your engineers in being able to implement best practice throughout your plant giving you that confidence in the integrity of your fixed assets.
Protection over replacement
See below an example how Kingfisher Industrial can help with Wear Protection within the Cement industry
Problem
Solid recovered fuels (SRF) have become a crucial alternative to fossil fuels in the cement industry, offering both environmental and economic benefits. However, while direct maintenance costs are often considered, associated expenses related to material buildup, blockages, and equipment degradation are sometimes overlooked. Protecting equipment such as silos, feeders, and pipelines is essential to maintain system performance and prevent costly plant shutdowns.
Solution
Integrating proven technologies that offer corrosion and wear resistance, along with enhanced material transfer capabilities, is crucial to safeguard equipment and prevent costly disruptions. A UK cement producer embarked on a project to install an alternative fuel system (AFS) at its 1.5 million tpa plant, aiming to replace a significant portion of coal usage with SRF. Kingfisher, known for its expertise in providing solutions for handling abrasive materials, was enlisted to assist with the technical design, manufacture, and supply of pneumatic conveying injection pipelines for the project.
Benefit
Kingfishers’ extensive experience in handling SRF and understanding its characteristics has enabled them to offer tailored solutions that provide significant plant protection. Their K-BAS ceramic lining pipe work system, for instance, outperforms unlined equipment by a factor of 6 to 1, offering an unparalleled level of protection within budget constraints. Kingfisher supports the need for ongoing customer service, recognising the evolving nature of environmental legislation, fuel prices, and process requirements.
Key Benefits
Improved Wear Resistance
Lining Sysem can be replaced
Increased Operational Uptime
Reduction in Maintenance Costs
more examples
K-BAS Lined PFA Silo Diversion Line
K-BAS Lined Calciner Coal Pipework
K-BAS Cement Transfer Pipework
K-ALOX Lined Cakestore Flights
View more case studies
If you’d like to see more case studies showing how we Kingfisher help solve problems and find solutions within the Cement industry, please register your interest and we will get in touch.
Asset integrity experts
In identifying all relevant wear criteria and referencing a huge portfolio of wear protection materials and techniques, Kingfisher is able to make sound recommendations supported by firm performance guarantees. This option reduces the inherent risk of uneconomic investment as the costs of replacement can sometimes outweigh the initial CAPEX cost.
For more information about how Kingfisher Industrial assists the global cement production industry, have a read through our industry specific brochure and get in touch.
Wear Protection
Kingfisher offer a full range of ceramic, metallic and polymer lining systems. With our experience protecting process plant and equipment in many industrial applications and the performance knowledge of the materials we provide we offer a totally unbiased solution for each individual application.
Ceramic
Metallic
Polymer