Abrasion Resistant Linings for Production and Conveying Systems

AbrasionResistant Liningsfor Production and Conveying Systems

01.06

The Wear Protection People

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The High Cost of AbrasionMaterial Replacements, extra Laborand Lost Production can be Avoided

The problem of abrasion is knownto almost everyone involved in thetransportation and processing ofbulk material.

The protection of productionsystems against abrasion is a toppriority. This applies to the economy as a whole as well as toeach individual plant. Suitably protected systems willsignificantly reduce operatingcosts and contribute to the pre-servation of valuable resources.

A typical phenomenon of trans-portation and processing of bulkmaterials is continual abrasion.Quite often these problems areaccepted as unavoidable.

Frequently, repairs made by substituting original plant compo-nents with thicker replacementsor slightly better grades of similarmaterial, at a higher cost, are considered remedies. However, inmost cases these substitutionsoften wear out in little more timethan the originals.

Unscheduled shutdowns, polluti-on of the plant and environmentand heavy expenses for materialsand labor usually result from thisapproach.

These practices are eliminated inplants where economical andreliable operation is the goal andunplanned outages are notacceptable. It is better to designthe plant and system componentsfor long term dependable service.

This brochure will provide youwith information on importantaspects of abrasion protection. It will outline various possibilitiesfor optimum plant utilization andcost savings through the use ofabrasion resistant linings.

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Simple SolutionsUsually don’t Last

The highest cost in manysituations is the lost pro-duction time due to unplan-ned outages. The moneysaved by using low coststeel components canresult in a much higher cost later.

Abrasion resistant pipes and plant components save money as repair frequency is greatly reduced and productiontime is increased.

In some instances, a singleavoided repair will pay for the added abrasion protection.

The transport of bulk materials inmany basic industries, e.g. coal-fired power stations, is associatedwith heavy wear of the systemcomponents. Not only is the original equipment investment lost, plant shutdowns and pro-duction loss combine to destroythe capital base of the company.

This is unacceptable in view ofcompetitive pressure on the worldmarkets. The solution to this problem is reliable abrasion

protection. Of vital importance is the selection of the appropriate material and its correct application.

Welded-on boxes filled with concrete cause

increased turbulence as they wear, leading to

more severe abrasion and loss of efficiency.

Critical areas subject to abrasivefailure exist in any plant trans-porting or processing bulk materials.

Even materials that appear harmless are often abrasive sincethe quantities and velocities inwhich they are transported candestroy a system componentquickly.

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Abrasion is Found in Every IndustryCritical Zones in Productionand Conveying Systems

The processing of solid bulkmaterials will almost always pro-duce wear. In aluminum as wellas in sugar plants. In waste treatment as well as in cementproduction. The system compo-nents affected by wear are verysimilar.

The definition of abrasion is the progressive material loss from thesurface of a solid body generated by mechanical causes, i.e. by thecontact with and relative move-ment of another solid, liquid orgaseous body.

This rather theoretical definition is found in many forms in actualpractice. A variety of materialsand differences in processingresult in most diverse abrasionproblems.

Hardness and sharpness of theconveyed material, conveyingvelocity and angle of impact areimportant factors. Additionally,stress generated by corrosion,high temperature or thermalshock can be critical.

All wear problems are different and require individual solutionsbased on scientific elements andpractical experience.

This is the starting point in reali-zing the savings offered in mostplants with the proper utilizationof abrasion resistant linings.

Typical system components with wear protection linings.


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Operating Limitations

Design SolutionsIt is possible to reduce wear problems with design and process solutions. For example,by changing the system configu-ration, cushioning of the materialconveyed, by altering the flowvelocity and similar measures.

Quite often these solutions arelimited by unavoidable obstaclesand required process conditions.

The reduction of the conveyingvelocity is practical only in rarecases. It is usually more impor-tant to increase the productivitywith the same system technologyand to accept the resulting higherwear rates.

Corrosion and WearSteel structures handling dry materials suffer mainly from abrasion. But, in systems where wet materials are conveyed, corrosion will be an additional factor.

Compared with the apparentlysmooth surface, the effect of corrosion is predominantly in the microscopic range.

Continual mechanical abrasionremoves the protective oxidelayer on the steel, creating a surface of high reactivity which isideal for increased material loss.

This will especially be the case in plants which process ash, ore, lime, coal, coke, waste, sand,salt, slag, cement or the like inlarge quantities.

Reducing Wear with aCushion of Materialbeing TransportedPractice has shown that thismethod has serveral draw-backs: to ensure that thematerial continues to slide,steeper angles and greaterconstructional heights arealmost always required com-pared to the smooth surfaceof a lined component.

Whenever the material beingtransported is changed, thesystem must be cleanedmanually.

Quite often these cushionsare associated with an un-desirable breaking up of thegrains of the materials trans-ported or by non-uniformmaterial flow.

Many times production systemshave to handle additional capacity.Here, a dust-collecting pipe for clinker dust means additional workload for the cyclones.

Even with the increased workload,the cement plant managementexpects continuous safe operationof the plant. The wear protection offered in this area has stood the test of time.


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We Solve Wear Problemsin Plant Components and Pipes

To achieve both technical and economical wear protection, many factors have to be taken into account. The choice needs to be based on the application.

The best solution for long life andeconomical abrasion protectiondepends upon the proper selection of the lining material as well as the knowledge of expected cost.

Abresist Corporation has lining materials that include a wide range of individual characteristics:

■ ABRESIST

■ ALRESIST

■ KALCOR

■ KALSICA

■ KALCRET

■ KALMETALL

■ augers

■ ash pipelines

■ belt discharge chutes

■ bunker spirals

■ bunkers

■ channels

■ chutes

■ circulating air separators

■ continuous-flow conveyors

■ cyclones

■ dissolving tanks

■ diverter valves

■ drying sections

■ dust collecting equipment

■ dust collecting pipes

■ fan blades

■ fan casings

■ flue-gas ducts

■ flumes

■ gravel release tunnels

■ hoppers of rotary dryers

■ hydrocyclones

■ launders

■ manifolds

■ mixer troughs

■ pipe bends

■ pipes

■ pneumatic backfill lines

■ prilling tower bottoms

■ pulpers

■ receivers

■ rotary valves

■ screw conveyor troughs

■ scrubbers

■ separators

■ settling basins

■ shaft spirals

■ sifters

■ silos

■ sinter troughs

■ tailings lines

■ tanks

■ thickeners

■ tubular chain conveyors

■ turbo separators

■ vibrating troughs

■ washing drums

The large rocks handled in quarries and mines aren’t the only problems for conveying and processing systems.

In modern process plants, characterized by high throughput ratesand conveying velocities, even apparently harmless materialscause significant wear.

Here is a list of typical abrasion problem components:

Principles of Wear-Protected System Components

Good flow properties dueto smooth surface thatlasts

Steel casing

Abrasion resistant lining in zones of turbulences

Reduced pressure losses and low energy cost

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Materials toReduce Repair

Clear Advantages■ long lifetime

■ maintenance free operation

■ no operation interruption

■ no production losses

■ no contamination of theconveyed materials/pro-ducts due to abrasion, mixture or oxidation

■ physiologically harmless, suitable for food products

■ smooth surface to enhanceflow properties and avoidplugs

■ reduced pressure lossesand lower energy costs

■ no spilled material to clean up

Abrasive wear occurs when hardand sharp edged bulk materialsare moved. But, the material to be conveyed cannot be altered to reduce the problem.Therefore, protective measureshave to be implemented for the protection of the systemcomponents.

A wide range of materials with varying characteristics is available to protect against wear.Linings made of mineral, ceramicor metallic materials have proven to work well.

Which Material to use?Wear protection should be matched to each application. The better the material and liningare adapted to the specific problem the more durable andeconomical the solution.

Which material will be most suitable is determined after allinfluencing factors are known.There is no magic formula, butdecisions are based on knowledge gained through 80 years of practical experienceby Abresist Corporation andKalenborn Kalprotect, theGerman parent company.


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ABRESIST LiningsWear Resistant Fused Cast Basaltfor Friction Induced Abrasion

The idea to melt stone is age-old.However, the melting of basalt started with lab tests only at thebeginning of the last century. The development was not succesfulbeyond the lab stage because ofcrystallization problems and inadequate application tests.

However, by the mid-twentiesABRESIST was successfully produced as an abrasion resistant material based on basalt.

Today, under the trade name ABRESIST, fused cast basalt has become a proven product.

ABRESIST fused cast basalt hasbeen used successfully for years for wear protection up to temperatures of approximately350 °C / 662 °F.

For the production of ABRESIST,selected basalt is melted andcast into molds, then carefullyannealed. Due to the casting process, precise linings can beproduced.

ABRESIST has an extremely hardand smooth surface. The materialis corrosion resistant to mostacids and alkalis. This makesABRESIST very effective forsystems where abrasion and corrosion occur together.

ABRESIST

Fused cast basalt is a mineralbased wear protection materialfor plant components when theconveying material producesfriction induced abrasion.

Installation: shaped componentsare normally installed in cementmortar. In special cases epoxiesor synthetic mortars may beused due to strong mechanical stresses and/or vibration. Where higher temperatures are concerned, potassium silicate mortar may be used forinstallation. Mechanical fixing is also possible.

Application temperature: up to 350 °C / 662 °F depending on application and geometry.

Advantage: highly abrasion resistant, smooth surface that lasts, no corrosion.

ABRESIST linings havebeen in service formore than 30 years onall continents.


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Cyclones and separators areamong the system componentswhich are subject to particularlyheavy wear. Repairs are expen-sive because of the frequentlydifficult installation locations.

The cyclone inlets are exposed to especially heavy wear becausethe material hits them at highvelocity. Even inlets made frommanganese steel often withstandthese heavy attacks for only ashort period. Often, the conicalcomponents and inlet ductsrequire efficient protection as well.

Apart from ABRESIST, combinedlinings with other wear resistantmaterials have proved succesful.

Waste paper is recycled in pulpers which are like giant mixers. The bales contain abrasive impurities, but the pulper bottom is durably protected with ABRESIST.

ABRESIST lining in an air separator.

Hopper in a large German blast furnace plant.


ABRESIST Linings

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Flumes and hoppers of any shape can be lined with abrasion resistant ABRESIST.

Submerged drag-chain conveyors for wet ash removal in a coal-fired power plant.

Drains cast into the lining reduce the amount of water carried to the discharge zone thereby lowering thewater consumption rate.

ABRESIST wear protection for a cyclone in thecement industry.

The corrugated wire mesh fastened to the steel surface provides reliable attachment. Temperaturesabove approximately 250 °C / 482 °F require the useof potassium silicate based mortar for installation.


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Since the times of Archimedes, screw conveyors havebeen used for pumping water. Solids entrained bywastewater are a heavy burden for this screw andtrough.

In concrete and steel troughs, abrasion increases theannular gap until the conveying capacity of the screwreaches almost zero. This situation is prevented byusing ABRESIST.

The ABRESIST lining takes into consideration thebending of long conveying screws.

Skid tiles made of ABRESIST fused cast basalt arewell proven for test tracks in the automobile and tireindustries world wide. These installations have improved the safety of car traffic significantly.Abresist Corporation can supply skid tiles in differentshapes, unpolished as well as high grade polished.The references cover installations in Europe, the USand the Far East.

Natural surface (right) and polished surface (left).

ALRESIST Linings

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Abrasion and TemperatureResistant High Alumina Ceramics

ALRESIST is a member of theoxide family of ceramics, with the main component aluminiumoxide. Extremely high abrasionresistance is achieved by careful selection of the particle size and distribution.

Most tiles are formed by pressinga dry powder of the ceramic.Machining of ceramic prior to kilnfiring allows the manufacture ofcomponents with geometricallydifficult shapes.

ALRESIST can be manufacturedin very thin tiles. This is an advantage when existing plantcomponents have to be lined and space or weight are of critical importance.

ALRESIST AdvantagesHighly wear resistant, smooth surface that lasts, no corrosion,available in various thicknesses.

ALRESIST

Special high alumina ceramicsfor plant components with extreme wear and / or temperature conditions, for thinlinings or for smooth surfaces.

Installation: pipes, shaped components, or thin tiles are laid in epoxy mortar, RTV or attachment using KALBOND.

ALRESIST tiles can be vulcanized into rubber mats for installation by gluing. Mechanical fixing by welding is also common.

Application temperature: up to1000 °C / 1832 °F depending onapplication and geometry.

Thin ALRESIST tiles are laid inepoxy mortar. Attachment usingKALBOND or silicone RTV is alsopossible.


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Agitators and mixers subject toextreme wear can be durably

protected with ALRESIST tilesshaped to the specific

equipment design.

Lining of a cyclone handling diatomaceous earth with 6 mm ALRESISTtiles installed in high temperature epoxy resistant up to 180 °C / 356 °F.

50 mm thick ALRESIST shapedelements withstand the coarse-grained ore, coke and limestone

charging a blast furnace.

Skip collection chute with ALRESIST lining in a blast furnace plant.


ALRESIST Linings

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Lining of a cyclone with ALRESIST tiles,mechanically attached.

Weld-on ALRESIST tiles protect this cone against wear and thermal shock stress.

Rocker chute in a blast furnace feed system inEurope. The ALRESIST lining is 50 mm thick.

Octagonal chute for blast furnace feed system. TheALRESIST tiles, 50 mm thick, are shaped and cut inall three dimensions. In areas with higher impact,KALMETALL-C hard cast tiles, 50 mm thick, areinstalled.

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KALBOND High PerformanceAdhesive Bonding System

KALBOND high performanceadhesive bonding system withsuperior adhesion and strength isused in dynamic situations suchas high speed fan blades. It is also extremely impact resistant.

The KALBOND adhesive systempermits bonding of protectivelinings to high speed movingparts subject to impact, abrasionas well as corrosion. High perfor-mance lining materials in tiles asthin as 1mm can protect the surface of many dynamic parts.

Problem components such ascyclone classifiers, fan blades,rotors and other complex shapescan be lined with ALRESIST andtungsten carbide to outlast welded overlays and hardenedmetallic linings.

Curved surfaces and other shapes can be lined due to smalltile sizes. Linings can be appliedto existing components or newdesigns. Lined PF damper using ALRESIST and KALBOND.

Lining of a screw used in thepotash industry with ALRESISTand KALBOND bonding system.

ALRESIST and KALBOND lined 64” diameter fan with tungstencarbide impact pads.


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KALCOR LiningsZirconium Corundum Wear Protection withHigh Temperature and Abrasion Resistance

With the growing knowledge ofpreventive wear protection thedemand for durable materialswith extended service life hasincreased.

■ KALCOR, a fused cast corundum, was developed forextreme abrasion protectionand high temperatures up to1000 °C / 1832 °F. Alumina andzirconia are melted in an electric arc furnace and castinto tiles, shaped componentsand cylinders.

■ KALCOR-S is cold cast and sintered. This materialwithstands temperatures up to1250 °C / 2282 °F. Furtheradvantage: good thermal shockresistance. The fabrication pro-cess allows thin tiles with wallthicknesses of 10 to 12 mm.

KALCOR

Zirconium corundum based onalumina and zirconia for plantcomponents, where extremewear and high temperatureoccur.

Installation: shaped compo-nents in cement mortar or special mastics. Mechanicalfixing is also possible.

Application temperature: up to1250 °C / 2282 °F depending on application and geometry.

Advantages: highly abrasion resistant, impact resistant, temperature resistant, corrosion resistant.

Lining of a collecting hopper in thesinter dust collector of a steel mill:the mixture of abrasive particlesand hot air of approximately 400 °C / 752 °F passes through theKALCOR hopper and the followingKALCOR pipelines in turbulent flow.

The cut demonstrates the compact structure of KALCOR-S,practically free of voids. Thin shapes can also be produced.

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Dust collector cone with pre-engineered KALCOR shapedelements.

Flue-gas dust collection system from a petroleum-coke calciner in an oil refinery:

10 cyclones, including immersion pipes as well as ductwork have abrasion resistant linings installed.

Approximately 500 m2 of KALCORshaped components, 30 mm thick,have been laid in 10 mm thickpotassium silicate mortar.

The operating temperatures range between 250 and 450 °C /482 and 842 °F.

High temperature wear protectionin a dedusting cyclone of a blastfurnace plant in Europe.

Extraction dish for abrasive slurryof a mixer tank constructed as acombination of KALCOR, highalumina ceramics and stainlesssteel.

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KALCOR Linings

Drum mixer for batches in a glass-making plant.

Pre-engineered radial shaped elements provide optimal mixing.

Wear protection for high temperatures involves problemsdue to thermal stress between the outer steel component and the rigid lining.

These problems can be solved by using KALCOR as the wearprotection material and the propermechanical fixing method: boltedconnections or welded steel ins-erts.

Example: drying drum in a chemical plant at 800 °C / 1472 °F.

Even complicated surfaces can be reliably protected against wear with KALCOR.

KALSICA

Silicon carbide ceramics for plant components for extremewear, high temperature and / or thermal shock.

Installation: individual shapes and components laid in mortar,epoxy, or temperature and acid resistant based mastics.Mechanical fixing is also possible.

Application temperature: up to1000 °C / 1832 °F depending onapplication and geometry.

Advantages: highly abrasion resistant, resistant to thermalshocks and manufactured withsmall tolerances.

KALSICA LiningsSilicon Carbide Ceramics with ExtremelyHigh Temperature Abrasion Resistance

Outstanding resistance againstwear and thermal shock is achieved with KALSICA. KALSICA is part of the siliconcarbide ceramics group and isavailable in different qualities:

■ silicon infiltrated (KALSICA-S)

■ silicon nitride bonded (KALSICA-A, -N, -P)

■ metal bonded (KALSICA-M)

High precision can be achieved inmanufacturing KALSICA shapes, formed by pressing or casting, then sintered in a reactor kiln.

Wall thickness from 2 mm for theshaped components is anotheradvantage of using KALSICAwear protection linings.

Pulverized coal distributor made of KALSICA-N installed in a powerplant.

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Burner cone made of KALSICA-N in a power station in Europe.

Cyclone lining for handling of silane dust. Cone diameter is 1200 mm, with 30 mm thick KALSICA-N lining material.

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KALCRET LiningsHard Compound can be Trowelled, Cast or Sprayed for Jointless Lining

KALCRET is a mineral basedcement bonded hard compound. KALCRET can be trowelled, castor sprayed, in the workshop oron-site, also by the customer.

The lining is densely packed,using hard minerals that are fixed in a matrix. With a defined particle distribution and additionalmicro silica, KALCRET has a very high wear resistance andstrength.

After 8 hours the strength of KALCRET has reached 75%, this is the minimum setting time, e.g. for repairs.

KALCRET is clearly superior tohigh-grade concretes. The application temperature is up to 1200 °C / 2192 °F, dependingon the situation.

KALCRET is especially useful inprotecting components with a difficult geometry.

KALCRET as PrefabricatedShaped ElementsTiles and shaped elements madefrom the cast compound are prefabricated in the workshopand equipped with common attachment hardware, such assteel corner inserts.

The dimensions of tiles and shaped elements which can beproduced range from approx. 100 x 100 mm to approx. 300 x 1000 mm with thicknessesbetween 20 and 50 mm. The ability to handle a particular pieceis the only limit on the size of atile. If required, reinforcementscan be provided.

KALCRET

Cement bonded hard compoundfor a jointless lining of plant components where high wear and temperature occur.

Installation: by trowelling, casting in molds or spraying.

Application temperature: up to 1200 °C / 2192 °F, depending on application and geometry.

Advantages: highly wear resistant, strong and jointless lining, highly temperature resistant.

Prefabricated KALCRET elementwith isolation and mechanicalfixing for high temperature application in the precalciner of a cement plant.

KALCRET can be trowelled, …

…cast …

…or sprayed.

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Combined Linings

High conveying speeds and abrasive materials cause wear in material handling systems.However, the wear is of varyingintensity in different areas. This is where a combination of the different wear resistant liningsproves successful.

Mineral and ceramic linings arevery effective against slidingabrasion. Metallic linings provideadditional protection againstimpact.

Designed on the basis of prior successful experience, compo-nents can achieve similar lifetimeswithout some failing prematurelyor others excessively protected.

More Economical due to Similar Lifetimes for all Plant Components

Different materials from the wear protection program for special applications or conditions include ABRESIST, ALRESIST, KALCOR, KALSICA, KALCRET and KALMETALL.

Immersion pipe for acyclone for separatingslag sand in the cementindustry. The pipe insideis lined with KALCRET,the lid is protected byKALMETALL-W.

KERAFLEX is a special bonded system combining

ALRESIST and rubber, toprovide high wear

resistance and impact protection.

Sinter discharge table with the combination of KALCOR and KALMETALL-W.

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Combined Linings

Separation of extremely abrasive silicon powder:ABRESIST in the sliding zone and KALSICA-N in the areas subject to major wear.

High temperature slide chute in a cokery. The slideareas are lined with KALCERAM-K. The wear resistantsliding properties are up to 1000 °C / 1832 °F. Thesidewalls are made of KALSICA-P: very wear resistantand resistant to temperature changes. The design ofthe sliding edge utilizes KALMETALL-C: wear andimpact resistant with reliable mechanical attachment.

KALCORfused cast corundum

ALRESISThigh alumina ceramic

ABRESISTfused cast basalt

KALCORfused cast corundum

Concrete mixer lining with ALRESIST at the mixer bottom and KALMETALL-W on the sidewalls.

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KALDETECT Wear Detection

Even superior wear resistant linings do not haveunlimited lifetimes, especially in cases of extremelyabrasive materials and harsh operating conditions.This can become critical, e.g. when for environ-mental protection reasons, certain harmful materialscannot be allowed to pollute the enviroment.

For example: pneumatic conveying lines withinwaste incineration plants that are designed for the

Electrical Wear DetectionThe wear resistant lining is fittedon the outside with a low voltageelectrical circuit.

If the wear resistant lining wearsthrough due to abrasion, the elec-trical circuit will be interrupted.

Options in the electrical circuitdesign will allow the system toinitiate an alarm with an indicationof the relevant lined section orshut down the plant automatically.

The electrical wear detection isavailable for all of the wear resistant materials and also forcombined linings of any plantcomponents.

Pneumatic Wear DetectionThe steel casing is twin-walled.With changes of the pressurelevel in the space between thetwo walls caused by a leak, anindicator or alarm will be activated or the plant will be shut down.

This system can be used forsingle components or completesystems.

Mechanical Wear DetectionA serrated wear-measuring tapeis placed in a continuous grooveof the abrasion resistant lining.The width of the visible saw toothis an indication of the condition of the protective lining.

Additionally, the wear resistantlining can be fitted with a bore-hole. The length of an indicatorpin installed in the hole monitorsthe thickness or condition of the protective lining when removed and inspected.

incineration of hazardous waste. The leakage in aconveying line as a result of unexpected abrasionwould cause dangerous or environmentally harmfulsubstances to be released.

For these and other cases, systems are offered thatmonitor possible wear in the lining before materialleaks into the atmosphere or soil.

Electrical, Pneumatic or Mechanical Systems to Monitor Wear


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Design DetailsIndividual Fixing AlternativesDepending on Conditions and Processes

Installation and ErectionA precondition for effective wearprotection is proper installation.

Appropriate installation and erection of the lining depend onmaterial conveyed, application,equipment design and installationposition. It also depends on

whether sliding or impact wearprevail, temperature or thermalshock stress, corrosive or acidexposure is present.

ABRESIST, ALRESIST, KALCORand KALSICA normally are laid incement mortar or special mastics.

Use of synthetic resins.

Setting in cement mortar.Potassium silicate based mortars used in case of high thermal stress.

Higher temperatures require additional measures like mechanical fixing, i.e. especially if the subsurface has a different thermal expansion than the wear protection lining.

Mechanical fixing to meet special requirements.


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High TemperatureApplicationsKALCOR, ALRESIST and KALSICA are wear protectivematerials capable of withstandinghigh temperatures. A wide rangeof mechanical fixing methods and design details permit findingcost effective wear protection for any application. Moreover, KALCRET hard compound can be installed either by casting ortrowelling.

Weld on TileThese are usually fastened to vertical and overhanging steelsurfaces by means of counter-sunk bolts, conical weld sleevesor weld studs.

Tile with Steel Corner Inserts and Weld StrapsThis mechanical fasteningmethod enables installing thelining to steel surfaces by welding.

Tile with GrooveThis method has proved useful as well and allows the fasteningof linings to steel surfaces bywelding.

Mechanical Fixings andHigh Temperature Applications

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The Wear Protection PeopleDesign, Manufacture, Delivery and Installation of Tailor-Made Wear Resistant Linings

Abresist Corporation andKalenborn have been dedicatedto plant protection since developing fused cast basalt forwear reduction and cost savings.

ManufacturingThe foundation of the wear resistant systems offered byAbresist Corporation andKalenborn consists of differentmaterials with a wide range ofindividual characteristics:

■ ABRESIST

■ ALRESIST

■ KALCOR

■ KALSICA

■ KALCRET

■ KALMETALL

Starting with fused cast basaltmore than 80 years ago, a widerange of wear resistant materialshas been developed with eachmaterial offering special wearresistant characteristics.

The materials are valuable, butthe knowledge from experiencegathered all over the world inmore than eighty branches ofindustry is just as important.

DesignOur engineers design customized,cost saving solutions for new orexisting equipment.

We provide the total package inone source: starting with adviceon application, measurements on-site, design services, manufacture of the lining throughto proper installation.

This is the Abresist Corporationapproach which offers longlasting protection.

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Installation and ErectionProper installation and erectionrequire knowledge based on awide range of experience.

Installation of the engineeredwear resistant linings can be performed or supervised byAbresist Corporation andKalenborn specialists in ourworkshops or on-site all over the world.

About Abresist CorporationAbresist Corporation is the U.S. subsidiary of Kalenborn Kalprotect,the German company that has continued to develop abrasion resistance technology for more than 80 years. We are confident that,whatever your abrasion or impact wear problem is in Canada, Mexicoor the U.S.A., you can get the help you need by contacting us.

We Solve Wear Problems in Plant Components and Pipes


Materials at a Glance

ABRESIST is a basalt based wear protection forplant components in which the material to beconveyed predominantly causes friction-inducedabrasion, in bunkers, troughs, chutes, chain conveyors, mixers, separators, pipes, pipebends, cyclones, etc.

Installation: the shaped cast tiles are laid in cement mortar. To meet specialrequirements other setting materials may be used, such as synthetic mortar or potassium silicate based mortar forhigh temperatures. Mechanical fixing is possible.

ABRESISTApplication temperature: up to approximately 350 °C / 662 °F.

Advantages: high abrasion resi-stance, lasting smooth surface, nocorrosion.

KALCOR are wear resistant materials composedof alumina and zirconia. It is recommended forparticularly high abrasion and/or thermal stress,e.g. in cyclones and separators, in chutes for hotsinter or clinker, for mixers, pipelines, etc.

Installation: the shaped cast tiles are laid either in cement mortar orspecial setting materials. Mechanical fixing is possible as well.

KALCORApplication temperature: up toapproximately 1250 °C / 2282 °F.

Advantages: high abrasion resis-tance, high temperature stability,resistant to impact and corrosion.

Special high alumina ceramics for system com-ponents exposed to extreme wear and/or thermalstresses for which thin linings or smooth surfa-ces are required, such as in circulating air separators, cyclones, screw centrifuges, vibrating chutes, fans, fan blades, etc.

Installation: shaped elements or thintiles laid in epoxy mortar, RTV or byKALBOND. ALRESIST tiles are alsovulcanized into rubber mats to befastened by adhesive. Weld-onattachment is common.

ALRESISTApplication temperature: up toapproximately 1000 °C / 1832 °F.

Advantages: high abrasion resis-tance, lasting smooth surfaces, nocorrosion. Available in variousthicknesses.

Metallic wear protection available in differentqualities is resistant against sliding and impactabrasion. Hard cast iron materials in differentalloying qualities are possible as well as hardfaced steel sheets and self supporting structures.

Installation: individual shaped hardcast components for mechanicalfixing or laying in mortar, epoxy ormastics. Hard faced sheets as selfsupporting structures or for mechanical fixing.

KALMETALLApplication temperature: up to750 °C / 1382 °F depending on material, application and geometry.

Advantages: highly impact and abrasion resistant.

Cement-bonded hard compound for continuouslining of plant components where high wear andtemperature occur.

Installation: by trowelling, casting inmolds or spraying.

KALCRETApplication temperature: up toapproximately 1200 °C / 2192 °F.

Advantages: highly wear resistant,strong and jointless lining, highlytemperature resistant.

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KALENBORN, ABRESIST, KALCOR, ALRESIST, KALSICA, KALCRET, KALMETALL, KALINOX und KALEN are trademarks of Abresist Corporation and Kalenborn Kalprotect.

This brochure and other technical information are general only. They do not cover any guarantee with legal effect. Technical changes and errors are reseverd.

The Wear Protection People

Ask Abresist Corp. for additional information

Kalenborn KalprotectDr. Mauritz GmbH & Co. KGVettelschoss, Germany

www.kalenborn.de

Abresist Corporation5541 North State Road 13P.O. Box 38Urbana, Indiana 46990, USA

Phone (800)348-0717(260)774-3327

Fax Business (260)774-8188Sales (260)774-3832

[email protected]

Documents

Abrasion Resistant Linings for Production and Conveying Systems