Cooling screw

Renewable Power • Niigata City, Niigata Prefecture, JP

APPLICATION (+1 pts)
APPROVED

Basic Information

Overview

The cooling screw in bottom ash handling equipment is used under high-temperature and severe wear conditions, and therefore requires regular replacement and repair.

Industry

Renewable Power

Location

Niigata City, Niigata Prefecture, JP

Component/Workpiece

Cooling screw

Business Type

Integra - Workshop

Job Type

New

OEM

Sumitomo Heavy industries (Raumaster)

Type of Wear

Abrasion

Tags

cooling screw
hardfacing techniques
renewable energy applications

Base Metal

Carbon steel, SUS304 stainless steel

General Dimensions (mm)

Φ250㎜×5,300㎜

Problem Description

The challenge the customer was facing

When the cooling screw wears, the processing capacity decreases, so regular replacement and repair are carried out; however, this creates issues such as securing sufficient maintenance time and the high associated costs.

Previous Service Life

1y

Welding Alloys Solution

How WA solved the challenge

We manufactured a cooling screw with a specification in which CNV-O was hardfaced on the flights and HC-O on the casing.

Product Category

Integra Services

Product Description

HARDFACE CNV-O ＆ HARDFACE HC-O Wires

Job Duration

4mo

Technical Advantages

By adopting the hardfacing design recommended by Welding Alloys Japan (WAJ), the service life can be significantly improved, maintenance-related downtime reduced, and overall productivity enhanced.

Images (2)

Photos and visuals for this case study

Case study image 1Case study image 2

Financial Impact

Solution Revenue

¥4,157,700

Cost Reduction Analysis

Annual Cost Before

¥9.00

Annual Cost After

¥-0.38

Annual Savings

¥9.38

104.0% reduction

Annual Cost Comparison
Previous Solution¥9.00
WA Solution¥-0.38

Cost Breakdown

Part Information
Cost of Part (A):¥3.00
Cost of WA Solution (B):¥-1.00
Parts Used/Year (E):3
Solution Lifetime Comparison
Previous Solution:3.0 months
WA Solution:2.0 years
WA solution lasts 8.0x 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

Submission Details

Contributor

Yuuki Shimizu

yuuki.shimizu@waj.co.jp

Created

April 10, 2026

Submitted

April 15, 2026

Approved By

Bastien Gerard

April 15, 2026