Resisting wear and boosting uptime in limestone quarries and cement plants

It’s a simple fact.  If you are operating a limestone quarry or cement plant, you have to deal with wear – extreme sliding wear that wreaks havoc on equipment, machinery and parts, forcing downtime and costly repairs. While wear is nothing new, wear solutions have changed over time, and continue to do so.  

Today’s most advanced chromium or complex carbide overlay solutions, like Duroxite® from SSAB, offer the very best in extreme wear protection. However, many are unsure of what these materials really are, where they should be used and how they can benefit.

Overlays for sliding wear

In short, Duroxite® overlay products are designed for the most extreme wear situations targeting abrasion, impact, heat, metal-to-metal and erosion wear. They consist of specially formulated materials deposited on mild steel backing plate and are suitable for extremely severe abrasive wear applications. 

In limestone quarry and cement applications, where sliding wear and small particle abrasive impact is the norm, welding these overlay products on top of “at risk” equipment will dramatically increase their useful lifetime. 
Due to its optimal carbide composition Duroxite® provides good wear resistance and homogenous bonding with minimal spalling.

Duroxite® is delivered as plate, pipe, pin and wire, ready for installation or further fabrication in the workshop. For limestone quarries and cement applications, the products Duroxite® 100 plate and wire as well as Duroxite® 200 plate specifically provide the best wear results in a wide range of applications. 

Common applications

In the quarry after primary crushing is completed, Duroxite® 100 is an excellent choice for use in liner plates, chutes as well as all areas subjected to sliding wear. Duroxite® 100 can also drastically increase wear resistance when used in chutes and conveyors that connect all processes within a limestone quarry. 

At the cement plant, Duroxite® 100 is an optimal addition to the grinding zone area of the vertical rolling mill (VRM) as well as for use in ball mill separators. Later during the cement production process, at the inlet and cyclones of the preheat tower, Duroxite® 200 can provide long lasting wear resistance due to its ability to withstand high temperatures.

Jonas Allebert, Wear Technology Specialist at SSAB

“The microstructure of Duroxite® contains primary chromium-rich carbides and refined multiple-alloy complex carbides with a typical hardness of 2500 to 3000HK dispersed evenly in a ductile eutectic austenite matrix. The typical volume fraction of primary chromium-rich carbides is maintained between 30 to 50 percent with 7 to 10% of multi-alloy complex carbides. By welding chromium or complex carbides, or other abrasion-resistant materials on top of mild or quenched and tempered steel, an extremely wear-resistant compound material is created.”

“Duroxite® is hard, but at the same time, it is easy to handle in the workshop. For limestone quarry and cement plant applications, this means that most worn-out equipment can be rebuilt and repaired to perform as new.”

“When joining base metal use 480 MPa (70 ksi) or 560 MPa (80 ksi) consumables. Any surface exposed to severe wear should be protected with hard-surfacing consumables. Cap welding a Duroxite® product with Duroxite® Wire ensures the weld will have the same wear resistance, resulting in a consistent service life for the entire overlay product.”

“If a customer has certain applications, we can help tell them which material will meet their service wear lifetime demands, how to use it, and which thickness to go for. Getting this wrong can be expensive, therefore we use our prior knowledge to ensure customers get the most out of their choice of overlay product.”