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HARD FACING
IN THE WORKSHOP
facing.
Fumes generate during hard facing is health hazardous for human being.
Generation of surface crack is inevitable and always risk of failure. and reduces mill
availability
LM
DALMIA
LM 46.2+2
ORIGINAL MATERIAL HI-CHROME. WELDING AFTER 800 HRS. BREAKAGE IN FEW DAYS AFTER HARD FACING
No risk of casting breakage during operation. Original profile can be maintained for much longer time and due to
which performance will be consistent. Sinter layer will be more harder than hard facing layer and create uniform
wear on the casting. It reduces the power consumption. Reduce the stoppage for in situ hard facing and minimize the risk of
production loss and direct revenue generation. Much lesser wear rate as compared to hard facing and gives much
Mills can operate at higher operating pressure and improves the operating and performance parameters.
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
Life time is increased by 1.5 2.5 times depending on the characteristics of the raw material ground. Total safety against breakage
The hard inserts are embedded in the core of nodular iron. The nodular iron is highly ductile and capable of withstanding severe shocks.
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 construction results in biting action on the raw material thereby reducing the slippage. Reduced slippage results in better grinding efficiency. Reduction in Mill down time:
COST COMPARISON
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.
Contd--
COST COMPARISON
Mill Type
Type
Conventional
14
10.8
Total Cost of original set plus hard facing / Hour for original set
COST COMPARISON
Cost Comparison of Hard Facing roller with Sinter Cast Cement Mill 8400 Kg Ni Hard IV with Hard Facing Sinter cast 40 10000 20.0 87360 8.7 11.9 3.1 ADDITIONAL in 10000 Hrs 96628.0 11015592.0 1101.6 USD/hr By saving min 14 stoppage of 29 hrs each for hard facing USD / hr. 4.29 mm Life achieved Without Hard Facing IN 7000 HRS and still in operation In case of Sinter cast max wear of 30 mm was observed after 5400 hrs operation USD USD / hr. 40 Units No Of Roller 2 Plant MCL Jayantipuram
Mill Type
Alloy
Maximum wear
Run hrs
Wear Speed
Cost of set
Cost / hrs
Indirect advantages
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)