Casing Liners

Power & EnergyEL JORFLASFAR, MA

STAR (+3 pts)
APPROVED

Basic Information

Overview

This application aims to replace the current chromium cast iron liners with Welding Alloys (WA) hardfaced plate liners, with the objective of enhancing wear resistance, extending component service life, and improving weldability.

Industry

Power & Energy

Location

EL JORFLASFAR, MA

Component/Workpiece

Casing Liners

Business Type

Integra - Workshop

Job Type

New

OEM

IHI

Type of Wear

Abrasion
Impact

Tags

casing liners
operational efficiency

Base Metal

E24+Hardfacing

General Dimensions (mm)

385x315x30mm

Problem Description

The challenge the customer was facing

The client engaged us to identify a viable alternative to the existing chromium cast iron liners installed in their vertical coal mill. The current solution faces multiple challenges, including a limited service life and the inability to perform in-situ repairs due to the non-weldable characteristics of chromium cast iron. Additionally, the prolonged lead times associated with foundry manufacturing adversely affect operational efficiency.

Previous Service Life

1y

Competitor

Mafoder

Welding Alloys Solution

How WA solved the challenge

Our proposed solution involves the application of hardfaced plates featuring a 10 mm overlay, quantity : 90 pcs, utilizing Hardface HC-O flux-cored wire. This method is designed to substantially enhance the service life of the equipment while providing robust protection for the mill casing's parent material.

Product Category

Composite Wear Plates

Product Name

Hardplate 100

Thickness

20+10

Job Duration

3w

Technical Advantages

**Extended Service Life** The optimized hardfacing solution (Hardface HC-O) delivers exceptional wear resistance, extending operational lifespan significantly beyond that of traditional chromium cast iron. **Excellent Weldability and Repairability** In contrast to chromium cast iron, hardfaced plates can be readily welded and repaired on-site, leading to decreased maintenance costs and minimized downtime. **Reduced Downtime** The capability for in-situ repairs substantially shortens shutdown periods, enhancing overall plant availability. **Shorter Delivery Lead Times** Hardfaced plates exhibit notably shorter manufacturing and delivery timelines when compared to foundry castings. **Consistent Quality** Utilizing controlled welding processes ensures uniform overlay quality, effectively mitigating defects typically associated with casting, such as porosity and cracking. **Improved Mechanical Reliability** The combination of a ductile base plate and a hardfacing layer provides enhanced impact resistance, significantly lowering the risk of sudden failure compared to brittle cast iron. **Flexibility in Design and Application** Hardfaced plates can be tailored in terms of thickness, overlay composition, and geometry to meet specific operational requirements. **Lower Total Cost of Ownership (TCO)** The extended service life, ease of repair, and reduced downtime collectively contribute to a significant reduction in overall lifecycle costs.

Service Life

2y

Images (3)

Photos and visuals for this case study

Case study image 1Case study image 2Case study image 3

Cost Reduction Analysis

Annual Cost Before

MAD400,000.00

Annual Cost After

MAD234,750.00

Annual Savings

MAD165,250.00

41.0% reduction

Annual Cost Comparison
Previous SolutionMAD400,000.00
WA SolutionMAD234,750.00

Cost Breakdown

Part Information
Cost of Part (A):MAD400,000.00
Cost of WA Solution (B):MAD313,000.00
Parts Used/Year (E):1
Solution Lifetime Comparison
Previous Solution:1.5 years
WA Solution:2.0 years
WA solution lasts 1.3x longer!
Before (Previous Solution)
Maintenance/Repair (F):-
Disassembly Cost (G):-
Downtime/Event (H):-
After (WA Solution)
Maintenance/Repair (F):-
Disassembly Cost (G):-
Downtime/Event (H):-
Formula Used

Annual Cost = (A × E) + (E − 1) × (F + G + H)

Where: A = Cost of Part, E = Parts/Year, F = Maintenance, G = Disassembly, H = Downtime

Welding Procedure Specification (WPS)

No WPS data available for this case study

Submission Details

Contributor

Amine Naciri

amine.naciri@welding-alloys.com

Created

March 25, 2026

Submitted

March 26, 2026

Approved By

Bastien Gerard

March 26, 2026