Ocel

V ocelárnách jsou součásti, které zpracovávají sintr při velmi vysoké teplotě, vystaveny vážným podmínkám opotřebení. Zejména musí být sintrový drtič, který musí zajistit velký průchod, chráněn proti opotřebení, aby se vyloučila nákladná údržba a časté odstavování zařízení. Manažeři údržby souhlasí s tím, že standardní řešení dostupná na trhu nestačí pro jejich potřeby. Rotory a přerušovače musí být pravidelně vyměňovány za nové.
Nedostatečná odolnost standardních řešení proti opotřebení je způsobena třemi hlavními faktory:

• vysoká teplota sintru, která zhoršuje vlastnosti tvrdého povrchu,
• abrazivní charakter sintru, který opotřebovává součásti,
• silní nárazy, které ničí křehké tvrdé povrchy.

e3 je zákonem chráněné řešení speciálně vyvinuté pro zlepšení produktivity a životnosti sintrového drtiče oceli. Toto řešení se rodí po 4 letech testů prováděných v laboratoři i za skutečných pracovních podmínek. Toto řešení je založeno na unikátní slitině Castolin Eutectic odolné proti opotřebení za vysokých teplot, která nabízí extrémní odolnost i při nárazu a oděru. e3 je zvláště vhodný pro ochranu kritických částí sintrového drtiče, jako jsou kotouče rotoru, zuby a přerušovací tyče. Testy na místě ukázaly, že e3 překonává standardní řešení alespoň o faktor 3. Kromě zvýšení životnosti je zachován geometrický tvar součástí, což zajišťuje lepší účinnost drtiče ve srovnání se standardními řešeními.

Kromě prodloužení životnosti součástí vám e3 umožňuje:

• snížit časté údržby sintrového drtiče a odstavení zařízení,
• dosáhnout vyšší produktivitu drtiče zachováním tvaru zubů,
• snížit nákupní náklady na nové díly,
• vyhnout se použití složitých vodou chlazených vložek.

We offer a comprehensive range of wear-resistant sieves with round, square or oval apertures manufactured from 3 mm thick or higher, perforated sheets. We also manufacture tailor-made solutions according to specific customer requests. Our production technology uses a state-of-the-art, high power laser cladding installation. This system ensures highest quality wearfacing coatings of tungsten carbides dispersed in a nickel-based matrix to protect standard perforated steel sheets with variable mesh sizes.

The ultra hard tungsten carbide phases which are homogeneously distributed within a self-fluxing, tough nickel-based alloy matrix, provide:

• Extreme wear resistance performance against abrasion and erosion up to 10 times higher than standard, monolithic heat-treated steel alternatives.
• Withstands operating service temperatures up to 400°C. For even higher service temperature requirements, a diverse range of special alloy systems may be proposed to meet specific customer needs.

Modern Castolin Eutectic LaserClad technology uses a focused laser beam to ensure low heat input welding conditions, which translates into extremely effective, wear protective coatings on industrial parts.

After mixing the raw materials in the sinter plants (fine iron ores, additives such as limestone and olivine, recycled iron-bearing materials  from downstream operations, and coke breeze) we find a roller just underneath the charging system to constantly feed the sinter belt which is affected by abrasion. The lifetime of this feeding roller can be increased by our turnkey solutions.

In most cases after the sinter discharge, crushing and hot screening, the sintered material proceeds to a separate cooler. This is typically a rotating structure, divided into circular sectors with tipping devices, in which the sinter is placed in a layer more than 1 m thick and cooled by fresh air.

When the sinter has completed the cooling cycle, each sector is emptied via the tipping device. The cooled sinter is transferred to screens that separate the pieces to be used in the blast furnace.

Both the charge and discharge of the cooler deteriorate the surfaces whose lifetime can be increased with our CDP® wearplates.

Along the whole sinter process, several metallurgical and chemical reactions take place which produce dust and gaseous emissions apart from the sinter itself. These gases contain particles such as heavy metals that will weaken the inner surface of air suction systems.

A complete high resistance conduction system including valves and transitions circular to square section can be manufactured with our CDP® wearplates.

Based upon hundreds of successful applications approved by our clients across the globe, Castolin Eutectic can provide optimized solutions with a wide range of products and technologies to combat wear in VRM (Vertical Roller Mill) and many more. Castolin Eutectic has a detailed understanding of the industries where this equipment is used, of every major wear problem and can provide industry tested application solutions.

From the extreme cold of Russia to the heat of Brazil and Mexico, we have a deep knowledge of application solutions for the wear problems in this industry. Innovative technologies and equipment help major industrial Groups to meet their objectives in terms of increased life time and plant performance.

The fume ducts in the Steel Plants are exposed to high erosion wear or corrosion. Moreover, their internal walls are subjected to the impact of erosive particles transported at high speed by ventilation gas at high temperatures. In some applications, ventilation gas is also corrosive.

Since decades, Castolin Eutectic has been the provider of choice for service, repair and preventive maintenance of heavy-duty and industrial process equipment.

In Iron & Steel, protecting your industrial process equipment, fume ducts, tubes and walls from future corrosion and erosion while also extending your tubes’ useful life, is vital to your operation’s bottom line.

Eutronic Arc is the highest productivity and lowest running cost thermal spraying process. Due to the low heat input, there is a very low dilution during the process with limited distortion or metallurgical modification of the substrate without any dilution.

This technology can be applied both in the workshop or in the field. It does not require the use of oxygen, kerosene or combustible gas which means more economic coatings.

Tvrdý kompozitní povlak XuperCoat je již více než 20 let vyvinut střediskem společnosti Castolin Eutectic v Newcastlu ve Velké Británii, pro aplikace v ocelářském průmyslu, zejména pro nástřik měděných desek pro kontilití. Testy ukázaly, že povlak je tvrdší než jakýkoli jiný dostupný měděný povlak forem. Má nízký koeficient tření, což pomáhá redukovat výstrahy slepení a povlak je inertní vůči tekuté oceli a práškovým odlitkům. Potahovací systém nemá žádný vliv na detektory naplnění formy nebo elektromagnetická míchadla. Bylo také prokázáno, že povlak má zanedbatelný vliv na rychlost přenosu tepla.

Díky mnohaletým údajům z provozu za nátěrem byla prokázána významná zlepšení životnosti měděné desky: 3 až 4krát pro odlévače desek a až 6krát pro odlévače úzkých desek doprovázené vylepšeným tvarem produktu. V provozu se ukázalo, že potah umožňuje prodloužené cykly odlévání díky dramatickému zvýšení odolnosti proti opotřebení. K eventuální postupné degradaci povlaku dochází v důsledku tepelné únavy v místech s vysokým napětím. CastCoat je nyní vyspělá technologie se zákazníky po celém světě a nadále zajišťuje uživatelům snížené náklady na tunu.

Potažením všech čtyř čelních ploch formy se během celého procesu udržuje rozměrová stabilita, což vede k trvalému a efektivnímu tvaru produktu a růstu pláště. Nedostatek znatelného opotřebení znamená, že mezi výměnami forem jsou možné delší cykly, čímž se dosahuje vyšší dostupnosti slévače. Kromě toho zajišťuje ochrana poskytovaná povlakem prodlouženou životnost měděných desek, což vede k ročním úsporám mědi a přináší významné snížení nákladů na údržbu i na provoz. Díky nedávnému vývoji kompaktního zařízení HVOF lze nyní nanášet kompozitní povlak CastCoat na trubkové formy.

Since a very long time we are successfully applying a partnership program, focused on cost reductions. This smart Maintenance and Repair program can be summarized in six steps:

1. Analysis: The first step to a good solution is a correct analysis.
2. Technical Report: With the information provided, our Technical Department prepares a report.
3. Job development: Once the client considers the repair to be feasible, Castolin Eutectic puts at your service all the Technical Department for the development of the procedure outlined above.
4. App registration: Always subject to the customer’s approval, we first propose to register the job done in our confidential “FAR” database where the short application summary remains on hold until confirmation  of service results.
5. EcoTest: At the end of the service life of the part involved, we are ready to establish a detailed cost analysis to evaluate the practical direct savings achieved through mutual collaboration.
6. Terolink: Finally we propose to submit the complete application as verified in our Terolink Database.

Iron ore, coal, limestone, fluxes and scrap are unloaded in the raw material area. They are classified, stored, crushed, grinded and handled for transport into the next production process. All these activities produce a combination of wear phenomena in the different machines and parts involved. Their service lifetime can be extended with different solutions, thanks to the cost reduction program from Castolin Eutectic.

After processing the respective raw materials, they pass through the blast furnace, electric arc furnace (EAF) or basic oxygen furnace (BOF) to get pig iron or Steel. The first step for a good solution is a correct analysis. To facilitate this, we have created an analysis document that can easily be completed in collaboration with our technical delegate. The document reflects the most important parameters to be considered to develop in-house solutions to your wear problems.

Continuous casting rolls are critical parts that are used for making the slabs, blooms or billets just after the tundish and moulds, at a very high temperature. The extreme working loads as well as the high temperature wear-out the rolls surface and, as a result, parts are damaged. Maintenance managers regularly have to decide to either scrap these expensive parts or try to repair them according to OEM specifications.

The semifinished products obtained after the continuous casting process have to be shaped before being comercialized. The first of these processes is hot rolling, from which sometimes final products are obtained and other times semifinished products intended for cold rolling or coating.

In all rolling processes, cooling the steel is a critical factor. The speed at which the rolled product is cooled will affect the mechanical properties of the steel. Cooling speed is controlled normally by spraying water on the steel as it passes through and/or leaves the mill, although occasionally the rolled steel is air-cooled using large fans.

Since the installation of laser cladding technology in the Castolin Eutectic Services Centers the wear protection of key tools such as rolls and guides has been raised to a new level. The utilization of 8kW High Power Direct Diode (HPDD) with automation leads to flexible production and superior quality. In addition, the powerful laser enables high deposition rates that can reduce the cost of the cladding operation. Compared to standard welding techniques, the dissolution of the carbides and the dilution of the cladding material are the lowest that can be achieved. As a result, the wear-resistance is maximized and the service-life is longer. The unique broad beam (up to 23mm wide) produces a flat coated surface that minimizes subsequent machining or grinding. Rolls can often be used as welded without further processing. The low heat input of the laser process means the lowest distortion of large and thin wall parts that can easily be cladded.

OEMs usually provide parts that have the surface coated with high wear resistant alloys such as Eutalloy® RW 12496. This coating is applied first by spraying a powder on the roller surface and then by fusing it just above the liquidus temperature. The process allows the coating to offer its best wear resistant properties and to perfectly bound on the steel substrate. On long and heavy parts, fusion is extremely difficult to be done correctly. Just after the spraying step, the part must be pre-heated homogeneously and kept in temperature while several torches fuse the powder all along the roll. In 2m long massive rolls, fusion may require up to 7 hours and any variation in temperature may result on an irregular surface quality. Since the part is exposed to very high temperature, deformation is also critical, especially on rolls made with thin wall tubes. Finally, if cooling is not well managed, thermal stresses can be so high that cracks may appear on the overlay. Our well-equipped service workshops as well as more than 10-years experience  allow us to offer high quality overlays. Parts are coated by highly skilled operators that follow strict manufacturing methods. They regularly apply several powders according to what has been defined by OEMs.