Wear Resistant Systems for the Steel industry
Maintain plant efficiency and integrity with Kingfisher Industrial
Degradation of plant equipment – we understand the pain
As with most commodities, steel manufacturers compete with other producers throughout the world for supply of raw materials and likewise, its customer base. As the open market invariably dictates the purchase price of traditional finished product, quality, efficiency and an innovative product range are the fundamentals to a successful operation. Despite the large number of people employed within an integrated steel works, it is the efficiency of the process that makes the real difference in the cost of tonne produced. From sourcing superior grades of ores and minerals to the blending process of both iron and steel making and finally the casting and rolling of finished product, the right choices made here will determine the quality and market demand of the finished product.
Increase plant longevity
Albeit new innovative technologies are now being introduced into the iron and steel making process, traditional methods are still the dominant force in producing the capacity needed to supply both the developed and emerging markets. As ever, the vast amount of both capital and maintenance expenditure is an ongoing circumstance of the industry due to the nature of processing millions of tonnes of abrasive bulk solid materials. From the reception point of unloading panamax and capsize bulk carriers, the wear experienced through impact, friction and sliding induced abrasion is eating away the infrastructure of the equipment. Plant protection is not a choice in the steel industry, it is a must.
The Solution Providers
Many operations buy into traditional methods of protection such as QT steel plate and thick rubber protective panels, however, forward thinking engineers push the boundaries on what methods of protection can be incorporated into the design of their plant that will cater for the effects of the different materials handled. Due to the nature of some extremely abrasive ores and minerals, no protective lining system will be unaffected by their characteristics, however Kingfisher, having worked within the industry for over twenty years have had achieved many successes in exceeded expectations.
Despite many lining producers claims that the variation in performance of materials such as high alumina ceramic or chromium carbide deposit plate are similar due to the purity of aluminium oxide percentage being the same or the Vickers hardness of comparable clad plates being equal, it is working with chosen manufacturers of materials that Kingfisher have achieved unparallel performance criteria. Leading the market in identifying what works and what doesn’t based on proven experience of cost v performance ratio’s is what sets us apart from the followers.
Protection over replacement
See below an example how Kingfisher Industrial can help with Wear Protection within the Steel industry
Problem
An engineer from a UK steel plant approached Kingfisher with a problem he was having to address on a yearly basis. Having inherited the mechanical maintenance of the sinter strand on the OPP works, he was having to either replace or re-plate the sinter strand wind boxes on a regular basis due to effects of the abrasive dusts and fines being drawn through the gas main feeding the waste gas fan… (Read full case study for more info)
Solution
Having undertaken some trials using different ceramic lining systems, we opted to fully line the internal surfaces using our 30mm thick K-CAST BKR ceramic lining system with it being applied onto a 20mm deep honeycomb mesh. As the lining system was now protecting the working surfaces, the structure was manufactured from traditional S275 mild steel. In order to protect the steel surfaces from corrosion caused by the gas composition, all surfaces were shot blasted and coated with a high temperature epoxy resin system tolerant of the gas analysis.
Benefit
Along with the cost of the fabrication being much cheaper, the lining system has been in service for over 10 years and we have yet to undertake any lining repairs or replacement of any of the structure
Key Benefits
Improved Wear Resistance
Lining System can be replaced
Increased Operational Uptime
Reduction in Maintenance Costs
more examples
K-Cast Lined Windbox
K-Alox Lined Vibrofeeder
K-ZAS Lined Pipework
K-Alox Lined Blast Furnace Skip Car
K-Alox Lined Head Chute & Trash Grid
K-ALOX Lined Sinter Discharge Chute
K-Alox Lined Slag Granulation Slow Down Box
K-Alox Lined Sinter Strand Roll Feed
K-ZAS Crash Deck Blocks
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 Steel industry, please register your interest and we will 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