Transcript Cement Applications - Stanvac Superon Group

“World Class Products’’
ILL effects of Welding
Heat input, while welding leads to
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Creation of HAZ besides the Welded Zone
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HAZ is the vulnerable area- for the welded joints
to fail
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HAZ is hard and brittle – hence Cracks
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Sudden/ Dynamic loads make the welded area
crack from the HAZ
Superon’s Technology basis for
component life enhancement
- Lowest in class HAZ
How Superon Achieves lowest in
Class HAZ
• Lowest in class input amperes
• Lowest in class arc gap
We can Demonstrate our
technologies via comparitive
Demonstrations
• Lowest Input Amps
• Lowest Arc Gap
• Bead Finish
Superon’s Applications in Process
Industries
• Cement
• Power
• Sugar
• Steel
• Paper
• Forging…
Our Solutions- Cement Industry
Superon
in Cement
Stanvac
in Cement
Features Applications Demo Free
trials Outcome - FADFO
• Total application
– Payment after successful completion of the trial
period
– Pro-Rata payments for longer trial periods.
– Full job on FOC basis to prove the superiority
One of the above depending on the application and your
requirements
Thank You
Superon in Cement
Blow bar of Impactor Crusher
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Application Requirements
– Abrasion Resistance
– Impact Resistance
– Slight Erosion Resistance
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Base Material
– 14% Manganese Steel
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Superon Recommendation
– Base Layer with Super Stanhard FW 74 ( to
be used for building up worn out ones)
– Hardfacing with Super Stanhard CC 78
(only this for new blow bars)
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Product USP’s
– FW 74 is rapid work hardening nickel
fortified – Hence better impact and bond
strength – Does not chunk out – 50 HRc
(WH)
– CC 78 – High hardness best suited for
Abrasion resistance- High wear Factor –
63-67 HRc
• Very Fine stress relief checks
• No chunking
• Good erosion resistance
Impactor Arm
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Application Requirements
– Impact Resistance
– Abrasion Resistance
– Slight Erosion Resistance
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Base Material
– 14% Manganese Steel Casting
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Superon Recommendation
– Base Layer with Super Stanhard NA 75
(max 2 layers)
– Hardfacing with Super Stanhard CC 84
(Build up totally)
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Product USP’s
– NA 75 has good Bonding to Mn Steels with
high Bond strength of 1 L Psi
– CC 84 – High Hardness coupled with high
Impact resistance- 55- 57 HRc
• No stress relief Checks
• Can take very high Impact
• Good Abrasion & erosion resistance
Clinker Crushers – Rotors & Hammers
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Application Requirements
– Heat Resistance
– Impact Resistance
– Erosion Resistance
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Base Material
– High Chrome
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Superon Recommendation
– Base Layer with Super Stanhard NA
75 ( max 2 layers)
– Hardfacing with Super Stanhard CC
84 (Build up totally)
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Product USP’s
– NA 75 has good Bonding to Mn Steels
with high Bond strength of 1 L Psi
– CC 84 – High Hardness coupled with
high Impact resistance. 55- 57 HRc
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No stress relief Checks
Can take very high Impact
Good Abrasion & erosion resistance
Heat resistance – Doesn’t loose hardness at
high temperatures
VRM Table Liners & Rollers ( Sintered)
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Application Requirements
– Good Bond Strength in CI
– High Abrasion Resistance
– Impact Resistance
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Base Material
– Special Cast Iron with Sinter Suspended
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Superon Recommendation
– Buttoning done with a special
process using Super Stanhard UL 81
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Product USP’s
– UL 81 has high bond strength with
Cast Irons
– Can Take good impact – Roller impact
on tyres
– Very Fine stress relief checks
– High Hardness of 68-70 HRc
– High temperature hardness retention
Fans
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Application Requirements
– High Erosion Resistance
– Low build ups
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Base Material
– Structural Steel – Depends on the
application
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Superon Recommendation
– Super Stanhard AC 76
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Product USP’s
– AC 76 Gives a single layer hardness of
over 60 HRc
– Erosion resistance beads- Minimal
Ripple content in the bead
– Very fine stress relief checks –
Enhanced erosion resistance
– A chromium carbide rich deposits,
resists Abrasion, Fine particle Erosion
and heat
Earthmoving Buckets
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Application Requirements
– Joining of Mn steel to Mn steel or dissimilar
– High Tensile strength with Ductility
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Base Material
– Manganese steel & Cast steels
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Superon Recommendation
– Super alloy EM 35
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Product USP’s
– EM 35 gives a good bonding with
Manganese steel castings and Steels
– High Tensile strength of 1,00,000 Psi
– Deposits have high elongation -40 %
– Uniform Chemistry through the
length of the Alloy
– No red Hotness during welding
through the length
– Full Length Welding.
HEMM Structures
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Application Requirements
– Joining of Structural Steel
– High Resistance to Contaminations
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Base Material
– Structural Steel
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Superon Recommendation
– Super Stan Alloy ST 22
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Product USP’s
– ST 22 Gives a tensile strength of
88,000 Psi.
– High resistance to contaminations
– Self Lifting slag
– Non hygroscopic in Nature- NO HIC
or Delayed Cracking
– High arc force leading to purging of
the impurities
High Alloy Joining – Kiln Tyre and
Girth Gears
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Application Requirements
– High Strength Joints
– NO PWHT possible
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Base Material
– Forged Steel- High Alloys
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Superon Recommendation
– Super Stan Alloy TC 41
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Product USP’s
– TC 41 has a tensile strength of 88,000
Psi
– Deposits can be thermally Cycled
– Deposits has high elongation – 40 %
– Deposits doesn’t undergoes any Heat
treatments- makes it an ideal alloy
for High strength joining
– All positional welding alloy – Ideal for
all Heavy machinery
High Strength Dissimilar Steel Joining
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Application Requirements
– High Strength joints
– Dissimilar steel composition
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Base Material
– High Alloy Steels
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Superon Recommendation
– Super Stan Alloy DS 34
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Product USP’s
– DS 34 has a highest tensile strength of
1,35,000 Psi
– High tensile strength coupled with
highest elongation due to a ideal ferrite
balance
– Low temperature arcing – even at 40
Ampheres
– Contact or touch type welding
– Good arc force, resists contaminations
on the components to be welded
Anchor Joining
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Application Requirements
– Thermal Cycling
– Joining Dissimilar steels
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Base Material
– High Alloy Steels
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Superon Recommendation
– Super Stan Alloy CN 54
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Product USP’s
– CN 54 has a Tensile strength of 84,000 Psi
– Full length burning and no red hotness
during welding in the alloy
– Uniform Chemical composition through
the deposit
– No moisture pickup.
– High Alloyed core wire.
Tip Casting Plate /Clinker Breaker
Hammer /Inlet Sectors
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Application Requirements
– Harness At High temperatures
– Abrasion/ Erosion/ Impact Resistance
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Base Material
– High Alloy Steels
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Superon Recommendation
– Super Stanhard (T) 93
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Product USP’s
– Can work at high temperatures
– Hardness of 64-67 HRc
– No red Hotness till the end of the
electrode
– No flux dropping
– Seamless Steel tube construction
– Easy Strike & Re strike
– Low work at lower ampherages
Thank You
Cement Applications
Machine
Stacker Reclaimer
Component
Alkyde Enamel
Structures
Base Metal
Fabricated
structure
Stanvac
Solution
Polyhyb 2050
(1040+725)
Customer
Benefits
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Self Priming , Fast curing & Easy Recoatability
Cross linked polymers
Provides cathodic Protection
Barrier Permeability
Higher Salt Spray resistance & UV – Both Indoor/ Outdoor
5 % ( Mild)Acid/ Alkali Resistance
Self extinguising
Cement Applications
Machine
Stacker Reclaimer
Component
Conveyor Belts
Base Metal
Rubber with
Cotton/ Nylon Ply
Stanvac
Solution
717 Polyurethane
Kote- Black
Customer
Benefits
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Better than Hot/ Cold Vulcanising
Fast curing- Lower down time
Excellent elongation > 600 %
Good adheshion on rubber- Brushable & Putty grades
Cement Applications
Machine
Grate Cooler
Component
Structures
Base Metal
St.Steel
Stanvac
Solution
HHC 300 with ST3
Customer Benefits
• Temperature resistance up to 3000C
• Fast drying – Dry to handle on application
• Bright colors to dissipate heat as required by the
application.
• Silicone Based – Hence suited for High Temp.
• Better Corrosion protection combined with Temp.
Cement Applications
Machine
VRM
Component
Pipe Bends
Base Metal
St. Steel
Stanvac
Solution
731Stangard ER
Xtreme/1180*
Customer Benefits
• Zirconium Carbide based- High abrasion/ erosion
resistant.
• Lower down time.
• Insitu application.
• Enhanced life > 7 times MS
Cement Applications
Machine
VRM
Component
Roller Hub
Base Metal
Cast/ Forged
Stanvac
Solution
731Stangard ER
Xtreme/1180 For
better Bonding
Customer Benefits
• Zirconium Ceramic based- High abrasion/
erosion resistant.
• Lower down time.
• Insitu application.
• Enhanced life > 7 times MS
Cement Applications
Machine
LRS Tanks
Component
Tank
Base Metal
Struc Steel
Stanvac
Solution
712 CRS
Customer Benefits
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Excellent Chemical Resistance at Elevated temp.
With Stands up to 2400C Max
Resistance to Mild Acids. Alakalies
Di electric Insualtion coating combined with Temp.
Cement Applications
Machine
Electrical panel
Areas
Component
Die Electric
Flooring
Base Metal
Concrete/ Tiles/
marbles
Stanvac
Solution
1311 Insulkote A /
B
Customer Benefits
• Meets requirement of 15652-2006
• BDV of more than 34/ 45 KV in air medium
• Abrasion resistant & No tracking due to non
accumulation of dust.
• Non Inflammable
• Repairable
Cement Applications
Machine
Pumps- utilities
Component
Casing &
Impellors
Base Metal
Grey Cast Iron
Stanvac
Solution
1170/1180 or
731/1180
Customer Benefits
• Improves the efficiency- lower energy consumption
• Higher Abrasion/ Erosion resistance- Higher life.
• Zirconium Ceramic based Putty
Cement Applications
Machine
Work Shop
Component
Shafts/Emergency
Leak Reapairs
Base Metal
Forged Steel / bar
stock
Stanvac
Solution
815 Stangard
Steel Putty
Customer Benefits
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Ultra High Compressive strength
Fast curing
Repeated no of applications
Machinability. Good Shore hardness
Temperature range -100C to +2000C
Cement Applications
Machine
Cement Silo
Component
Silo
Base Metal
Concrete
Stanvac
Solution
754 ( Inner)
754+ 725 ( Outer)
Customer Benefits
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Non sticking of Cement – Easy Flow
Protects moisture and Vapour Migration- Rebar Protection
Stops carbonation of the concrete
Improved Aesthetics- Prevents lichen, moss and fungus growth
Cement Applications
Machine
Cooling Towers
Component
Cooling Tower
Base Metal
Concrete
Stanvac
Solution
1311 MVT System
Customer Benefits
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Stops carbonation of the concrete
Improved Aesthetics
Enhances Life.
High Tolerance to Salt & Chloride
Wet Tolerance capability – best suited for Cooling towers
Cement Applications
Machine
Machine Beds
Component
Machine Beds
Base Metal
Concrete
Stanvac
Solution
751 Stanfloor
Customer Benefits
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Quick Setting
No Shrinkage- 100 % Solids
Chemical Resistant
Can be made self levelling
Longer Life
Cement Applications
Machine
VRM
Component
Reject Cone Outer
Base Metal
ST 55
Stanvac
Solution
731Stangard ER
Xtreme/1190
Customer Benefits
• Zirconium Ceramics based- High
abrasion/ erosion resistant.
• Lower down time.
• In-situ application.
• Enhanced life > 7 times MS
Cement Applications
Machine
VRM
Component
Cage Mill stator
Base Metal
Structural Steel
Stanvac
Solution
1180/731Stangard
ER Xtreme
Customer Benefits
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Abrasion Resistant
Erosion Resistant
Ease of Dynamic Balancing
Insitu applications- No down time
Cement Applications
Machine
VRM
Component
Water sprinkler
Base Metal
Pipe Steel
Stanvac
Solution
731 xtreme
Customer Benefits
• Abrasion Resistant
• Erosion Resistant
• Insitu applications- No down time
Cement Applications
Machine
VRM
Component
Outlet Elbow
Base Metal
St Steel+ Ceramic
Tiling
Stanvac
Solution
731Stangard ER
Xtreme
Customer Benefits
• Abrasion Resistant
• Erosion Resistant
• Insitu applications- No down time
Cement Applications
Machine
VRM
Component
Nozzle Ring
Base Metal
Fabricated/ Cast
Stanvac
Solution
731Stangard ER
Xtreme
Customer
Benefits
• Abrasion Resistant
• Erosion Resistant
• Insitu applications- No down
time
Cement Applications
Machine
Kiln
Component
Coal Burner nozzle
Pipe
Base Metal
St. Steel- y Piece
Stanvac
Solution
731Stangard ER
Xtreme
Customer Benefits
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Abrasion Resistant
Erosion Resistant
Insitu applications- No down time
High cost benefit
Cement Applications
Machine
Rotary Packer
Component
Packing Spout
Base Metal
St. Steel
Stanvac
Solution
731Stangard ER
Xtreme
Customer Benefits
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Abrasion Resistant
Erosion Resistant
Insitu applications- No down time
High cost benefit
Cement Applications
Machine
Battery room
Component
Flooring
Base Metal
Concrete Floor
Stanvac
Solution
4029 System
Customer Benefits
• 98% H2SO4 33% HCL resistance
• 100 % Volume Solids
• High Build
Cement Applications
Machine
GCT
Component
Scrubber
Structure/ Flooring
Base Metal
Steel/ Concrete
Stanvac
Solution
1040/756+
718EGF-NV+
727*- System
Customer Benefits
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98% H2SO4 33% HCL resistance
100 % Volume Solids
High Build
Resists thermal Shocks and temp up to
1000C & 1400C intermittent
Cement Applications
Machine
Kiln
Component
Kiln Shell
Corrosion
Base Metal
St Steel
Stanvac
Solution
HHC 600
Customer Benefits
• Heat Resistance
• Stops Corrosion due to sweating
• No reduction of shell thickness
Cement Applications
Machine
GCT
Component
Flue Gas Ducts
Base Metal
St Steel With
Insulation
Stanvac
Solution
Aluclad 710/ 706
Stangard
Customer Benefits
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Heat Resistance- upto1600C
Stops Corrosion due to sweating
No reduction of shell thickness
710- Stop Moisture Entry into the Ducts
Cement Applications
Machine
Reverse Air Bag
House & LRS
Tanks
Component
Structures
Base Metal
St Steel With
Insulation
Stanvac
Solution
Z712 Quicksteel
CRS
Customer Benefits
• Heat Resistance- upto2800C
• Stops Corrosion due to S02,So3
Condensation
• No reduction of shell thickness
• Resists Acid/ Alkali Attacks
Thank you