Case Study Library

L'impact de l'enclume sur le processus de fabrication est déterminé par les caractéristiques de la matière première, spécifiquement le calcaire. Les variations dans la composition et la qualité du calcaire peuvent affecter la performance de l'enclume, entraînant des problèmes tels que des défauts dans le produit final ou une usure prématurée de l'équipement. Pour atténuer ces problèmes, il est essentiel d'analyser et de sélectionner soigneusement le calcaire utilisé, ainsi que d'adapter les paramètres opérationnels de l'enclume en fonction des propriétés spécifiques du matériau afin d'optimiser le rendement et la durabilité du processus.

The material (hardfacing) used by OEM was not a quality material and procedure was not used correctly causing issues with material chipping and breaking off. OEM used a large oscillated bead to protect the edge causing heat input issues.

The problem was the competitor overbuilt all 4 tables by 25mm. Learning how to automated gouge not only a table but a radiused one in-situ was a steep task given this was a process the crew was new to.

There are two sinter lines with equal production on each line. Each line produces approximately 3.5 Mt per year. The hourly production is 600 t, with 30% recirculation. The client wanted to reduce the total cost of ownership by increasing service life (limiting the number of shutdowns for replacement and reducing the number of spare parts). Previously, they used steel beams—either cast or cast with 2D hardfacing. The service life of a beam, depending on its position in the sinter breaker line, was about 6 months (including its rotation).

WA Integra originally started welding these segments on a fabricated jig. Once welding was complete, the roll segments had to be cut apart using gouging rods and then cleaned up with a grinder. This work caused the segment joints to become brittle. This resulted in premature breakouts/wear.

Original OEM crusher teeth wore out fast. These only lasted about 2 months. The alternative that the OEM was proposing the plant was replacing these rollers with new ones.

The customer was using OEM recommended AR plate for the application. The wear was excessively high and the customer had to replace these louvres (blades) 4-6 months.

The rollers worn out by abrasion.

The connectors were worn due the transport of materials.

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.