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Cement

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Cement

Cement is one of the most vital elements for the nation’s infrastructure growth. Along with other additives like sand, water, aggregates it builds the nation. India is the second-largest producer of cement in the world. It accounts for more than 7% of the global installed capacity. UltraTech Cement Limited, a part of the Aditya Birla Group, is the largest manufacturer of cement in India and ranks among the world’s leading cement makers. Aided by suitable Government foreign policies, several foreign players such as Lafarge-Holcim, Heidelberg Cement have invested in the country in the recent past.

A significant factor which aids the growth of this sector is the ready availability of raw materials for making cement, such as limestone and coal mines which are spread throughout our country. India’s overall cement production accounted for 294.4 million tonnes (MT) in FY21 and 329 million tonnes (MT) in FY20.

The cement industries have several components which undergo extreme wear & tear along with fracture during operation. Regular maintenance & periodic repair is the key to the sustainability & efficiency of the plant. EWAC Alloys have been a pioneer in innovating the new & effective techniques for repairing these components & prolonging the life through specialised productions & solutions.

Application

A key concern of any cement plant is the availability of critical processing equipment, including crushing/grinding machines and a vertical roller mill (VRM). VRM is well known in the cement industry as the preferred mill for grinding raw meal coal slag and clinker. The downtime during repair is a high cost, and there are continual efforts to reduce this time to resume full production status. In Situ Repair Welding of rollers and tables is an efficient way to extend the life of the VRM as it helps in the following.

    • Reducing downtime
    • Improvising efficiency
    • Reducing Vibrations
    • Reducing Energy Consumption
EWAC Alloys has developed highly advanced technology for In Situ rebuilding VRM/Table liners and supplying major wear components below.
  • Cage/Separator Rotor
  • Guide Vanes
  • Static Blades/Louvres
  • Fans
  • Body Liners
  • Nozzle Ring Segments
  • Yoke
  • Cone
  • Roller Guard
  • Chutes
  • Ducts
  • Hoppers
  • Rotary Airlock
Apart from VRM, the company has successfully executed many critical breakdown jobs like Girth Gear, Ball Mill shell, Trunion, and Pinion.

Crushers are vital equipment in the cement industry as the manufacturing process starts by crushing raw materials like limestone, coal, dolomite, gypsum, etc. The size reduction of raw materials is affected in at least two main stages:

    • Crushing (primary reduction)
    • Grinding (fine reduction)
    Crushing denotes the size suitable as feed for the following main stage, i.e., grinding. EWAC R&D has developed innovative products withstanding extreme wear against Friction, Impact, Abrasion, and Erosion accompanied by corrosion for life enhancement of crushing equipment and providing the optimal solution for reclaiming all types of crushers such as:
      • Double toggle jaw crushers
      • Cone/gyratory crushers
      • Roll/hammer crushers
      • Ring granulators
      • Hammer mills
      • Impact crushers
      The portfolio includes wobblers, vibratory screens, and grizzly/apron feeders. For Impact Crushers, EWAC has established repair solutions for critical components such as:
        • Wobblers
        • LS Crusher Rotor
        • Impactor Arm
        • Blow Bar
        • Discharge Chute
        • Body liners
        • Grinding Paths, etc.

    • The milled and blended raw materials from mills go to a silo and then to the kiln through the preheater.
    • The preheater-kiln system consists of a multi-stage cyclone, rotary kiln, and grate cooler.
    • The kiln feed is preheated by hot gas from the combustion chamber and rotary kiln.
    • Clinker formation takes place inside a rotary kiln which gets cooled inside the grate cooler.
    • In the entire process, the components have to withstand high temperatures up to 1450°C.
Thus, they are susceptible to serious operating and maintenance problems such as failure of anchors holding castable in Preheater and Cooler, cracking of kiln shell and misalignment of the rollers, and frequent wear of clinker hammers/HRB Rolls etc. EWAC has developed a novel electrode Eunitrode D, a trusted product for anchor joining and other SS/HRCS Grade materials used in high-temperature applications in most cement plants. Similarly, we have developed a unique solution for life enhancement of other applications such as:
    • Tongue plates
    • Inlet Sector
    • Tip Casting
    • Grate Plates
    • Grizzly bar
    • Clinker breaker hammer
    • Discharge chutes
    • HRB Rolls
    • Fans, etc.

The cement industry is one of the leading markets for industrial fans. Fans are heavy duty and perform two essential functions, as follows.

    • Supply of air or removal of exhaust gases
    • Material handling
Different process fans finding their applicability in the industry are as follows.
    • Raw Mill Fans
    • Preheater Fans
    • Induced Draft Fans
    • Cooling ID Fans
    • Raw Mill Exhaust Fans
    • Coal Mill Fans
    • Cooler Exhaust Fans
The problem is that most of these fans are prone to severe erosion. EWAC’s Wear Plates, Terocoat Alloys, and Wear Resistant Coatings help to:
    • Extend the fan service life
    • Save Energy
    • Reduce other components’ maintenance costs