Sieves

Sieves

ScreenCoat- Technology - Hot & Cold Sieves up to 800 °C Screencoat is designed to maintain the dimensional stability of the sieve screen perforation. As wear particles are classified according to the sieve screen size, any losses of the perforation dimension will result in larger particles passing through the predetermined hole size reducing the efficiency of the sieve screen. Castolin Eutectic’s Screencoat sieve edge wear protection extends the useful life of the sieve screen and provides repetitive reliability. Castolin’s Sieves are superior... Longer lifetime will save you money and hassle Improved performance will optimize your output (substantial savings!) Every sieve is tailor-made to your requirements. Any type of sieve can be produced: hot sieve, cold sieve, hot chute of all shapes, forms and materials. In addition, we have a wide range of related products. Holes in Castolin sieves are subject to less abrasion, which optimizes your production efficiency and constant output. All materials & production processes are scientifically researched and only the best are used. Our hardfacing and hole cutting processes ensure minimal abrasion over time. Our proprietary screencoat technology has proven to lengthen the lifetime of sieves.

Sinter Crusher

In steel plants, equipment that processes sinter at very high temperature is exposed to severe wear conditions. In particular, sinter crusher that has to ensure large throughput must be wear-protected in order to avoid expensive maintenance and frequent plant shutdowns. Maintenance Managers agree that standard solutions available on the mar-ket are not sufficient for their needs; rotors and breaker bars must regularly be replaced with new ones. The insufficient wear resistance of the standard solutions is due to three main factors: The sinter high temperature that reduces the hardfacing characteristics, The sinter abrasive nature that wears-out the parts, The high impacts that destroy brittle hardfacings. Unique E3 techology E3 is a legally protected solution specifically developed for improving steel sinter crush-er productivity and service life. This solution has been originated after 4 years of tests made in laboratory as well as on real working conditions. It is based on a unique Castolin high temperature wear resistant alloy that offer extreme resistance even when impact and abrasion are present. E3 is particularly suitable for protecting the most critical sinter crusher parts such as the rotor discs, teeth and breaker bars. In addition to increase part service life, E3 allows you: To reduce frequent sinter crusher maintenance and plant shutdowns, To keep higher crusher productivity by preserving teeth shape, To reduce the purchasing costs of new parts, To avoid using complex water cooled breaker bars.

Concrete Mixer

Today’s construction industry increasingly requires the industrial production of consistent, homogeneous quality, ready-mix concrete with ever faster mixing cycles especially for precast / prestressed concrete. Various stationary concrete mixer models have been developed to process the raw materials (sand, water, aggregates and cement) which cause intensive wear and tear of certain key parts through abrasion-erosion. With more than 100 years’ experience in welding and anti-wear protection, Castolin Eutectic off ers a wide range of standard, made-to-measure and preformed tubes and plates. This selection comprises several options with respect to the diff erent dimensions, coating alloys and welding technologies, which ensures effective protection against abrasion-erosion.

Hot Rolling Mills

The carefully formulated EnDOtec DO*04 gives arise a welding deposit that is oxidation, corrosion and creep resistance. The typical hardness in the as-welded condition is 48 HRC that can reach 51 HRC after its working-hardened. This makes the final machining easier, but the most important feature is the maintenance of the hardness with the temperature (until 600ºC). In the hot rolling, the ductility of the steel is used, which is greater the higher its temperature. The bloom, billets or slabs enter the reheating furnace and they are preheated , heated up and soaked until 1.200°C aproximately, which is above its recrystalization temperature. Afterwards, the long Steel shapes pass through a pair rolls (continous or semicontinous) to permit large deformations with a low number of rolling cycles.

Fume Ducts Repair

The fume ducts in Steel Plants are exposed to high erosion combined with corrosion . The balance of those wear phenomena depends on the temperature, quality of the gases and the position of the duct on the exhaust route. Castolin Eutectic has extensive experience working in partnership with steel producers on programs focused on cost reduction. Our smart Maintenance & Repair program starts with a correct analysis to let our Technical Department propose the best cost effective solution Advantages of Eutronic© Arc This is the highest productivity and lowest running cost thermal spraying process with the following features and benefits: ƒ Low heat input with no dilution ƒ Limited distortion or metallurgical modification of the substrate ƒ Good bonding strength ƒ Cold spray process ƒ Safe process, no flammable gases used ƒ Fine metallic coating (0,6-0,8 mm) ƒ High wear resistance against erosion and corrosion

Wearface Tire Shredder Knives

The customer wanted to replace his multi-wire solution with one hardfacing wire that was capable of a multiple pass build-up of 12 to 20 mm without cracking. Customer’s previous solution included buildup of 7018 and two separate capping wires that cracked when applied in multiple passes. Steel belts in the tires wear into the cracks causing spalling and premature wear. Our EnDOtec DO*327 multiple pass build-up capability and high hardness met the customer’s requirements and provided a single source solution.

Bucket loaders protection

Wear Strips (WS) are a composite material made out of mild steel and coated with a thick wear resistant alloy specifically designed to sustain high abrasion. Experience shows that compared to hardened plates, WS resist wear several times better. This allows customers not only to reduce cost and maintenance time, but also to decrease the weight of their buckets by using our lighter solution. This finally improves overall production efficiency. WS are today commonly used to protect earth moving machines buckets, shovels and dump truck boxes. They can easily be bent to fit the part profile and welded on the area in contact with the soil.

Asphalt Solutions for mixing plants

Our experienced Castolin Eutectic Services technicians will evaluate the wear phenomenon and provide you with the most reliable and cost effective solution. We can provide new and semi-finished parts ready to be installed, saving you costly down time and labor in your maintenance operations. Castolin Eutecitic solutions for asphalt plants: - Inner protection of the dryer made with CDP® - Dryer chute constructed with CDP® - CDP® tube for filler transport - Elevator lined with CDP® - Grate made of CDP® - Chute lined with CDP® - Screw flights made with CDP®, shaft with wear resistant coating - Mixer blades and casing

Cement: Wear Management Solutions for critical equipment.

The VRM’s function is to crush the materials into very fine particles, just prior to being stored or after the primary crushers. The VRM components are subjected to severe wear which can increase dramatically when high silica content is found in the raw materials or where mills are grinding slag. It is known that the largest area of energy consumption in manufacturing cement is in the finish milling process. Consequently, such wear problems can significantly influence the profitability of a plant. A worn VRM roller profile also reduces grinding efficiency, increasing energy demands further. Castolin Mobile Services arrives with fully equipped mobile units offering an optimal on-site service with lightweight state-of-the-art welding machines, Castolin Eutectic’s own power distribution, frequency controller, auxiliary drives for roller and table and wire transportation with a reach of up to 25 meters. Integrated computer-controlled X-Y-Axis for torch movement and semi-automatic welding mode come to combine this Advanced High-Speed VRM Repair Concept mobile package.

Blast Furnace, LD Converter and Electric Arc Furnace

Scrap shredding

The Electric Arc Furnaces in Steel Plants use ferrous scrap among other raw materials. This ferrous scrap has to be shredded before feeding the EAF. There are two main components in the scrap shredder: discs and hammers between the discs. The scrap is fed from a conveyor belt so these discs are exposed to impact and considerable pressure onto their surfaces exerted by contaminated scrap. In M&R, it is not always possible to carry out a proper preparation of the welding surface and edges, to select the more comfortable welding position or properly clean the surface. These conditioning factors were found when rebuilding the rotor’s discs in this scrap shredding machine. In this case, the biggest difficulty was to clean the surface from a thick layer of dust and to have a regular profile without the previously damaged hardfacing. Based on these preliminary conditions, the wear phenomena affecting the discs and our know-how, EnDOtec DO*05 was selected as a buffer layer and TeroMatec 4923 as a hard layer. DO*05 has been successful in many other applications as buffer layer without any porosity and cracks. TeroMatec 4923 has resulted in a well bonded surface resistant against impact, pressure and abrasion. The previous solution lifetime was 2 days and we achieved 3 weeks with our solution.

CastoDur Diamond Plate® LC8

CastoDur Diamond Plate® LC8 is a thin steel plate coated with a highly wearresistant layer. The very high density of ultra-hard Tungsten Carbide phases homogeneously distributed into a nickel-based matrix offer an extreme resistance up to 10 times better than standard heat treated (HT) wearplates. Consequently, similar or even superior life-times over traditional thick and heavy wearplates. CastoDur Diamond Plate® LC8 can be handled manually by operators. It is ideal where lifting devices cannot be installed, in particular inside restricted areas. Due to it’s low temperature, focused beam, laser technology has proved to be extremely effective for protecting parts exposed to high wear. Advantages over hardfacing techniques, such as welding, include: •As dilution is minimal and can be perfectly controlled, the properties of high-quality coating materials are not appreciably affected during application. •The tungsten carbides that provide protection against abrasion and erosion do not dissolve. The carbides are perfectly embedded in the matrix, plus the layers exhibit increased impact resistance. •Of all coating processes, the LaserClad technology has the lowest influence on base material properties. •The uniform coating thickness allows for small tolerances and ensures that less turbulences are generated on the coated surface.

SuperJet-S

CDP® 496

CDP® 496 is a composite material made of a structural steel backing and a self-fluxing metal powder overlay CDP® 496 is a steel plate (mild or stainless) coated with a layer of NiCrBSi alloy, similar to 12496 or 10009. The coating is 100% non diluted and retains all its wear resistance properties Applications Any application requiring extreme resistance to friction and good resistance to erosion, up to 650-700 °C. Corrosion resistance needs to be checked from case to case, investigating the type of corrosive agent, concentration and working temperature of the part.

CDP® 212

CDP 212 contains evenly distributed tungsten carbides and chromium carbides particles in an iron alloy matrix. This economical powder wearplate offers a high abrasion and erosion resistance when it is used in non corrosive conditions.

CDP® 112

Contains densely and evenly distributed tungsten carbide particles in a 60 HRC Ni alloy matrix CDP® 112 is a steel plate (mild or stainless) coated with a layer of NiCrBSi alloy additioned with 35%WC. The coating is 100% non diluted and retains all its abrasion and erosion resistance properties. Industry Examples Cement - steel - coal fired power plants - wooden panel industry - mines and quarries - glass (raw materials transport and processing, glass recycling) - waste and recycling Applications Any application requiring extreme resistance to abrasion and erosion up to 700 °C. Its lightweight makes it ideal for coating of industrial ventilator blades.

CDP® 4623i

CDP® 4623i is the ideal wearplate for chutes, buckets, crushers and any other application that suffers impact and mild abrasion CDP® 4623i is a composite material made of an easy-to-weld steel plate coated by means of open arc welding with a layer of impact and abrasion resistant alloy. Applications Any application involving impact or impact plus abrasion. CDP® 4623i is at the top of the range of welded CDP when impact and abrasion are present at the same time.

CDP® 4624

CDP® XuperWave 4624 DXW is the ideal wearplate for the application where the right balance between price and service life is required CDP XuperWave 4624 is the ideal wearplate for applications where the right balance between price and service life is required, thus maintaining the Castolin high standard welding quality and smooth surface. The exclusive XuperWave weld bead pattern drastically reduces the wear rate, especially in applications exposed to high velocity erodent fluxes. The extreme hard weld cladded surface is specially designed for erosion and abrasion applications. Industry Examples Steel, coal fired powerplants, cement, pulp and paper, wooden panel, others Applications Fan blades and housings, cyclones, square pipe elbows, any part exposed to erosive attack from small particles flows.

CDP® 4666

CDP® 4666 is a composite material made of a structural steel backing and a hard weld surfacing, corresponding to DIN 8555 CDP® 4666 is a composite material made of an easy-to-weld steel plate coated by means of open arc welding with a layer of abrasion and erosion resistant alloy. The complex carbides coating shows a superior wear resistance when compared to CrC wearplates due to: 1. higher carbide density = higher resistance to finer abrasives 2. higher average carbides hardness = higher resistance to abrasives Industry Examples Cement, Mines and Quarries, Steel, Waste and Recycling, Glass, Coal Fired Power Plants and in general any industry where raw materials handling and processing, up to 500-600 °C, causes wear by means of abrasion and erosion. Applications Any application involving abrasion and/or erosion. CDP® 4666 is at the top of the range of welded CDP®. For better performance against abrasion and especially to improve the erosion resistance, only CDP® 112 or PTA CDP® 6503 can be taken into consideration. When applied for high temperature applications, above 450-500 °C, or when used at high temperature as a structural part, a material with higher mechanical and oxydation resistance should be chosen.

CastoTube®

CastoTubes® are Castolin Eutectic's response to the market request for erosion-resistant pipe sections and elbows. They consist of a mild steel tube which has been internally wearfaced with TeroMatec® 4666 alloy. This provides the exceptional wear resistance of our well-known 4666 CastoDur Diamond Plates®. Furthermore, by avoiding expensive forming operations of flat plates into tubes, seamless small diameter CastoTubes® are available. CastoTubes® offer many advantages: •Exceptional wear resistance •Highly cost effective solutions for plant productivity •Lightweight •Easy to replace •Easy to join •Absence of harmful linear weld joints, can operate at high pressures •Small diameters availableStandard CastoTubes® Range Tubes with a minimum internal diameter of 82 mm are available and a maximum length of 3 m. CastoTubes® can be installed with standard flanges so that the replacement of worn out tubes can be done quickly and easily. Virtually any inner diameter from the 82 to 282mm can be produced by applying a different wearfacing thickness inside the standard base tube. This allows a smooth joint to the existing installation so as to avoid turbulent media flow. Industries and Applications Our CastoTube is installed in extremely demanding applications. Typical industries are: •Cement and concrete •Mines and quarries •Sand and gravel pits •Shredders and recycling plants •Iron and steel mills •Cement and ready-mix concrete plants •Brickworks •Foundries and coking plants •Incineration plants and electric power stations