Reduce Costs and Avoid Downtime Large quantities of bulk material are handled in the conveying and storing systems of cement plants. Unless they are suitably protected these systems will experience fre- quent failure requiring repair or re- placement. Kalenborn offer the complete array of wear protection materials including not only cera- mic and metallic materials but also plastics and rubber. In addition, Kalenborn have extensive experience in the field of slide promotion. Interruptions of material flow inside of bunkers and silos must be avoided and Kalenborn cover the entire ma- terial range with plastics as well as metallic and ceramic materials. In any case we can supply a tailor-made solution for your particular problem. Our experts are prepared to be of assistance. Service by Kalenborn: rebuilding of a grinding roll with KALMETALL-W 100 Cooler waste gas pipe lined with KALCRET-BNY hard compound
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Reduce Costsand Avoid Downtime
Large quantities of bulk materialare handled in the conveying andstoring systems of cement plants.Unless they are suitably protectedthese systems will experience fre-quent failure requiring repair or re-placement. Kalenborn offer thecomplete array of wear protectionmaterials including not only cera-mic and metallic materials butalso plastics and rubber.
In addition, Kalenborn haveextensive experience in the fieldof slide promotion. Interruptionsof material flow inside of bunkersand silos must be avoided andKalenborn cover the entire ma-terial range with plastics as wellas metallic and ceramic materials.
In any case we can supply atailor-made solution for yourparticular problem. Our expertsare prepared to be of assistance.
Service by Kalenborn:rebuilding of a grinding rollwith KALMETALL-W 100
Cooler waste gas pipe lined withKALCRET-BNY hard compound
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1 Bunkers ABRESIST, KALEN*, KALCERAM*, KALINOX*
2 Silos ABRESIST, KALEN*
3 Transport Chutes ABRESIST, KALCOR, KALOCER
Transfer chutes ABRESIST, KALCOR, KALOCER
Chain conveyors ABRESIST
Raw Mill Ball mill(grinding/drying) - feeding KALMETALL-W, KALMETALL-C, KALCOR
All sections of cement plants are at risk withregard to wear. This covers the raw materialstorage and raw material processing. It includescoal pulverizing and injection into the rotary kiln.Furthermore, clinker handling and clinker grindingas well as handling of additives and cement arecharacterized by the same problems.
Service lifetimes of many years are oftenachieved with the following materials:
� ABRESIST fused cast basalt
� KALCOR zirconium corundum
� KALCOR-S sintered zirconium corundum
� KALOCER high-alumina ceramics
� KALCRET hard compound
� KALSICA silicon carbide ceramics
� KALMETALL-C hard casting
� KALMETALL-W hard overlay welding
� KALINOX slide promotion steel
� KALEN slide promotion plastics
In addition, material combinations have been verysuccessful in practice. They enable both technicallyand economically optimal solutions.
Reliable protection of raw mill and pipe systemwith KALCRET-BNX hard compound
ABRESIST used for the centerdischarge chute of a ball mill
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Grinding tablesegments ofa roller mill
of 5,000 mmdiametermade of
KALMETALL-C;smaller
diameters arecast in one
piece
KALMETALL-C 153 hard cast
tiles for theprotection ofgrinding roll
yokes
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ABRESIST fused cast basalt is a time-testedprotective material for cement separators
Precise fitting of KALOCER high alumina ceramics,12 and 25 mm thick
Separator cones for cement made of KALMETALL-W100 6+4, 3,000 mm Ø
Lining the separator used for cement grinding withKALCRET-BNX, up to 3,200 mm Ø
Protecting an impactplate of a cementseparator withKALCRET-CNY
Kalenborn supplies grinding rolls, grinding tablesand mill linings for grinding plant used for rawmaterial, coal and clinker. Top: regeneration ofa grinding roll with KALMETALL-W 100, bottom:newly cast component made of KALMETALL-C 151hard casting, each 1,500 mm Ø.
All sections of cement plants are at risk withregard to wear. This covers the raw materialstorage and raw material processing. It includescoal pulverizing and injection into the rotary kiln.Furthermore, clinker handling and clinker grindingas well as handling of additives and cement arecharacterized by the same problems.
Service lifetimes of many years are oftenachieved with the following materials:
� ABRESIST fused cast basalt
� KALCOR zirconium corundum
� KALCOR-S sintered zirconium corundum
� KALOCER high-alumina ceramics
� KALCRET hard compound
� KALSICA silicon carbide ceramics
� KALMETALL-C hard casting
� KALMETALL-W hard overlay welding
� KALINOX slide promotion steel
� KALEN slide promotion plastics
In addition, material combinations have been verysuccessful in practice. They enable both technicallyand economically optimal solutions.
Reliable protection of raw mill and pipe systemwith KALCRET-BNX hard compound
ABRESIST used for the centerdischarge chute of a ball mill
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Grinding tablesegments ofa roller mill
of 5,000 mmdiametermade of
KALMETALL-C;smaller
diameters arecast in one
piece
KALMETALL-C 153 hard cast
tiles for theprotection ofgrinding roll
yokes
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ABRESIST fused cast basalt is a time-testedprotective material for cement separators
Precise fitting of KALOCER high alumina ceramics,12 and 25 mm thick
Separator cones for cement made of KALMETALL-W100 6+4, 3,000 mm Ø
Lining the separator used for cement grinding withKALCRET-BNX, up to 3,200 mm Ø
Protecting an impactplate of a cementseparator withKALCRET-CNY
Kalenborn supplies grinding rolls, grinding tablesand mill linings for grinding plant used for rawmaterial, coal and clinker. Top: regeneration ofa grinding roll with KALMETALL-W 100, bottom:newly cast component made of KALMETALL-C 151hard casting, each 1,500 mm Ø.
All sections of cement plants are at risk withregard to wear. This covers the raw materialstorage and raw material processing. It includescoal pulverizing and injection into the rotary kiln.Furthermore, clinker handling and clinker grindingas well as handling of additives and cement arecharacterized by the same problems.
Service lifetimes of many years are oftenachieved with the following materials:
� ABRESIST fused cast basalt
� KALCOR zirconium corundum
� KALCOR-S sintered zirconium corundum
� KALOCER high-alumina ceramics
� KALCRET hard compound
� KALSICA silicon carbide ceramics
� KALMETALL-C hard casting
� KALMETALL-W hard overlay welding
� KALINOX slide promotion steel
� KALEN slide promotion plastics
In addition, material combinations have been verysuccessful in practice. They enable both technicallyand economically optimal solutions.
Reliable protection of raw mill and pipe systemwith KALCRET-BNX hard compound
ABRESIST used for the centerdischarge chute of a ball mill
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Grinding tablesegments ofa roller mill
of 5,000 mmdiametermade of
KALMETALL-C;smaller
diameters arecast in one
piece
KALMETALL-C 153 hard cast
tiles for theprotection ofgrinding roll
yokes
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ABRESIST fused cast basalt is a time-testedprotective material for cement separators
Precise fitting of KALOCER high alumina ceramics,12 and 25 mm thick
Separator cones for cement made of KALMETALL-W100 6+4, 3,000 mm Ø
Lining the separator used for cement grinding withKALCRET-BNX, up to 3,200 mm Ø
Protecting an impactplate of a cementseparator withKALCRET-CNY
Kalenborn supplies grinding rolls, grinding tablesand mill linings for grinding plant used for rawmaterial, coal and clinker. Top: regeneration ofa grinding roll with KALMETALL-W 100, bottom:newly cast component made of KALMETALL-C 151hard casting, each 1,500 mm Ø.
Wear Protected Components
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Raw meal bunker with slide promoting liningmade of KALEN-1006
Housing made of KALMETAL-W for a raw meal fan –2,000 mm Ø – as self-supporting structure
Raw meal transport to the preheater –reliably protected with KALCRET
Pipe diverter in pneumatic pipe lined with KALCOR
Protectionof a raw
meal mill:KALCRET for
the piping,KALMETALL-W 100 for the
mill lining
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Lining of Preheater Cyclones
Solution offered by Kalenborn:prefabricated KALCRET shapeswith insulation and mechanicalfixing to the steel structure.
This equally ensures:
� high wear protection
� high thermal insulation
� short installation times
Discharge chute lined withKALMETALL-C, 25 mm thick;fastened with countersunk screws
Pulverized coal pipe with ABRESIST and burner tubes made ofKALMETALL-W 100; depending on the operating conditions pipesare protected with ABRESIST, KALCOR, KALCRET or KALOCER
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Plate of a reciprocating grateclinker cooler armored withKALMETALL-W 145
Conveyor for clinker transportlined with KALMETALL-W 100;800 mm Ø
Pneumatic transport componentswith efficient ABRESIST wearprotection
Dust collecting pipe for clinker fitted with 6 mm thickKALOCER mosaics set in KALFIX epoxy adhesive
Pipe for clinker transport made of KALMETALL-W 100, 300 mm Ø
Impact hammer of a clinkercrusher made of KALMETALL-C
Clinker dust pipe protected with KALCRET hardcompound
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Transport pipe to the cement silos; the bends areprotected by ABRESIST just like the straightextensions
Jointless lining with KALCRET,even for asymmetric crosssections
KALCOR-S allows long dutycycles and high temperaturestress
Kalenborn deviation pots installedin case of narrow space
KALCERAM hard ceramics lining for a chute of acement bag loading system
ABRESIST +++ 350 662 ++++ Good material flow in case offused cast basalt hard, abrasive conveyed material
(1) The Mohs scale is applicable only to ceramic materials - no more than comparison values for other materials (values given in brackets)(2) The Vickers HV values are only valid for metallic materials - no more than comparison values for other materials (values given in brackets)(3) The specified temperatures refer to standard applications; other temperatures must be agreed upon with the technical departments of Kalenborn
ABRESISTfused cast basaltMineral protection made ofcast basalt to protectagainst abrasive wear.
Advantages: high wearresistance, permanent smoothsurface, no corrosion.
KALCORzirconium corundumCast or sintered material madeof alumina and zirconia oxide.
Advantages: high wearresistance, resistant againsthigh temperatures, corrosionresistant.
KALOCERhigh alumina ceramicsSpecial oxide ceramics for plantcomponents subject to extremewear.
Advantages: high wear resistance,permanent smooth surface,no corrosion.
KALSICA siliconcarbide ceramicsSuitable for plant componentsthat are exposed to extreme wearand/or high temperatures.
Advantages: highly wear resistant,resistant against thermal shocksand producible with narrowdimensional tolerances.
KALEN slidepromotion plasticsRange of different polyethylene(PE) and polyurethane (PU)materials.
Advantages: good durability,free of corrosion, smooth surface.
KALMETALL-W hardoverlay weldingTough basic body and hardoverlay welding with primarychromium carbides.
Advantages: highly wear resistant,good resistance against impactwear, self-supporting structures.
KALMETALL-Chard castingDifferent materials characterizedby corresponding resistanceagainst abrasion and impactwear.
Advantages: alloy matched to thespecific application, of advantagein case of larger quantities.
KALCREThard compoundCement bonded compound forjointless protection to be trowelled,cast or sprayed-on.
Advantages: high wear resistanceand compressive strength,jointless, temperature resistant.
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Ceramic wear protection
� very good abrasion resistance� tile, cylindrical or jointless lining� temperatures up to 1,000 °C / 1,832 °F
Metallic wear protection
� good resistance against sliding and impact wear� thin walls, self-supporting structures� good thermal shock resistance
Plastic lining
� excellent slide promotion� good resistance against impact wear� low weight
Material combinations
� optimal wear protection for every application� optimized lining cost� optimized weight
Advantages of Lining Materials
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Pipes used by the cementindustry are reliably protectedwith ABRESIST, KALCRETKALCOR or – in case ofextreme wear – withKALOCER.
Immersion pipe of a cyclone forseparation of granulated slag.The pipe inside has been linedwith KALCRET, the cover armoredwith KALMETALL-W.
Kalenborn supply wearprotected plant components.
In addition we provide forregeneration of worncomponents - here a
grinding table of acoal pulverizer.
KALENBORN, ABRESIST, KALCOR, KALOCER, KALSICA, KALCRET, KALMETALL, KALINOX and KALEN are trademarks of Kalenborn.This brochure and other technical information are general only. They do not cover any guarantee with legal effect. Technical changes and errors are reserved.