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Sintercast vs Hardfacing Comparison

HARD FACING

WAYS OF HARD FACING

IN SITU

IN THE WORKSHOP

WHAT CUSTOMER BELIEVES ABOUT HARD FACING

It has short delivery time as compared to new set .

Possibility of re-use of base material more number of times.

In situ hard facing helps in keeping original profile.

Availability of many suppliers and variety of electrodes in the market.

No specific technique is required. Cheap labor available in the market.

WHAT IS THE RISK IN HARD FACING

Very high risk of casting breakage during operation.

Limited Layer of hard facing due to safety reason.

Multiple time hard facing results in cracking of casting.

Difficult to maintain same performance even with identical layer of hard

facing.

Unable to maintain the same profile due to expansion and shrinkage.

Fumes generate during hard facing is health hazardous for human being.

Generation of surface crack is inevitable and always risk of failure. and reduces mill

In case of in situ hard facing , down time increases

availability

Direct Loss of production and revenue generation during stoppage for in

situ hard facing.

Hard facing at in situ condition may cause bearing failures.

Shaping a world of Performance CRACK ON HARD FACED LAYER ,

AND TRANSFORM INTO PIECES

INITIALLY START WITH SMALLER CRACK

Shaping a world of Performance ROUGH SURFACE ,

CRACK ON HARD FACED LAYER

VIZAG SLAG LM 46.2+2

CRACK ON HARD FACED LAYER

ULTRATECH TADIPATRI LM 53.3+3

CRACK ON HARD FACED LAYER

ULTRATECH GINIGERA 53.3+3

LM

CRACK ON HARD FACED LAYER

DALMIA

LM 46.2+2

CRACK ON HARD FACED LAYER

ACC BARGARH - MPS 5600 BC

ORIGINAL MATERIAL HI-CHROME. WELDING AFTER 800 HRS. BREAKAGE IN FEW DAYS AFTER HARD FACING

Shaping a world of Performance SPALLING ON HARD FACED LAYER ,

ADVANTAGES OF SINTER CAST OVER HARD FACING

Reduces the maintenance cost

No risk of casting breakage during operation. Original profile can be maintained for much longer time and due to

which performance will be consistent. Sinter layer will be more harder than hard facing layer and create uniform

wear on the casting. It reduces the power consumption. Reduce the stoppage for in situ hard facing and minimize the risk of

production loss and direct revenue generation. Much lesser wear rate as compared to hard facing and gives much

higher wear life. Reduces the maintenance and operating cost .

Mills can operate at higher operating pressure and improves the operating and performance parameters.

We have observed that some of the customer is hard facing on the roller tire after wear of hardened sinter layer. We are not in a favor of hard

facing on the wear resistant casting.

WHY SINTER CAST ?

AIAE / Vega always strive to achieve total customer satisfaction:

- By providing better solutions in abrasion resistance products.

- These solutions help customers reduce their total cost of production.

ADVANTAGES OF SINTER CAST

Improved wear life

Life time is increased by 1.5 2.5 times depending on the characteristics of the raw material ground. Total safety against breakage

The hard inserts are embedded in the core of nodular iron. The nodular iron is highly ductile and capable of withstanding severe shocks.

The inserts are mechanically bonded to the base metal. There is no metallurgical bond, hence even if small cracks appear in the inserts, these can not penetrate through the ductile core

ADVANTAGES OF SINTER CAST

Consistency of Mill performance:

Tailor made solution provides uniform wear profile.

Uniform wear profile results in consistently maintaining mill operating parameters.

The construction results in biting action on the raw material thereby reducing the slippage. Reduced slippage results in better grinding efficiency. Reduction in Mill down time:

Higher lifetime reduces the no. of stoppages.

Mill availability increases due to less adjustments.

Replacement can be planned to match the annual shutdowns.

COST COMPARISON

Madras Cement-(Alathiyur), LM56.20+2

COST COMPARISON BASED ON ACTUAL DATA , MAY NOT BE SAME FOR OTHER PROJECTS. WE SUGGEST NOT TO CONSIDER THIS PEROFMANCE AND PRACTICE OF HARD FACING AS A SOLUTION.

Contd--

Madras Cement-(Alathiyur), LM56.20+2

COST COMPARISON

Cost Comparison of Hard Facing roller with Sinter Cast

Cement Mill 8400 Kg Calculation Cost USD 72240 10000 Running hours Remarks Cost for two roller tire. Multiple hard facing up to 10000 hrs operation. After Every 700 Hrs Operation. Normally possible hard facing in between 14 times on each roller tire Total 300 kg electrodes consumption on two roller tire per 700 hrs operation 700 Hrs 700 Hrs 10000 10000 USD / hr. USD / hr. Including Hard operation 11.9 Facing up to 10000 Hrs 20-30 mm per 1000 hrs operation After Every 700 Hrs Operation No Of Roller 2 Plant MCL Jayantipuram

Mill Type

Weight of each Roller Tire

Type

Conventional

No Of times Hard Facing

14

Cost of welding per Kg 14-20 mm 3240 46286 118525.7 4.6

10.8

Maximum Wear at the time of hard facing

Total Cost of Hard Facing After every700 hrs operation

Total Cost of Hard Facing

Total Cost of original set plus hard facing / Hour for original set

Cost / Hour for Hard Facing

Cost Per hour including Original set with Hard Facing

COST COMPARISON
Cost Comparison of Hard Facing roller with Sinter Cast Cement Mill 8400 Kg Ni Hard IV with Hard Facing Sinter cast 40 10000 20.0 87360 8.7 11.9 3.1 ADDITIONAL in 10000 Hrs 96628.0 11015592.0 1101.6 USD/hr By saving min 14 stoppage of 29 hrs each for hard facing USD / hr. 4.29 mm Life achieved Without Hard Facing IN 7000 HRS and still in operation In case of Sinter cast max wear of 30 mm was observed after 5400 hrs operation USD USD / hr. 40 Units No Of Roller 2 Plant MCL Jayantipuram

Mill Type

Weight of each Roller Tire

Alloy

Maximum wear

Run hrs

Wear Speed

Cost of set

Cost / hrs

Equivalent Cost for 10000 Hrs

Saving in Sinter cast in comparison to Ni Hard IV with No of times Hard Facing

Extra Cement ground Operation ( Tons)

Revenue due to extra grinding of cement

Extra Revenue per hrs due to Sinter Cast

Indirect advantages

1. Consistency in mill output; 2. Reduced Maintenance; 3.Consistency in Performance Parameters like Power Consumption, Fineness etc; 4. 100 % Safety against breakage ; 5. Uniform Wear Profile ( due to insert design)