Turnkey Solutions

Sinter Breaker & Grizzly Bars

In an integrated steel plant, the Sinter Plant produces agglomerated mass known as Sinter from iron ore, coke, and flux fines.

After the sintering process, the Single Roll Crusher or the Sinter Breaker is the equipment that crushes large blocks of red hot sinter cakes at 650-900°C, falling from the Pellet Car. The Sinter Breakers consist of 9 to 18 sprockets having 3 or 4 integral radial arms mounted and assembled on a shaft to form a roll crusher. The crusher arms pass between the series of similar numbers of grizzly/grate/knife bars while breaking the sinter cake into smaller sized sinter lumps.
The arms of the Sinter Breaker and the top surface of the Grizzly Bars are subjected to severe impact and abrasion at very high temperatures. So, these two components are subjected to the most rapid wear. Enhancement of their wear life is a task of continuous development for tribologists. Our plethora of customised products and turnkey reclamation technology has successfully established one of the best performances of Sinter Breakers and Grizzly Bars in many integrated steel plants of various capacities. Today, we are a leading supplier of new sets of Sinter Breakers and Grizzly Bars, complete with value-added life-enhancing wear-resistant cladding.

Hammers

In an integrated steel plant big boulders of various minerals like coal, limestone and dolomite are crushed into smaller lumps of uniform size for use, with various types of hammers.
So, we see various hammer mills using hammers of different base materials, shapes and sizes engaged in crushing the above raw materials.
The hammers are subjected to severe impact and abrasion which are replaced at frequent intervals as consumables. EWAC Alloys with its six decades of experience in reclamation technology has developed high performance ready to use crusher hammers for coal and flux. We are a leading supplier of these hammers, are established in many integrated steel plants for their life-prolonging factor, high crushing efficiency, reduced downtime and overall techno economics.

1. • Reducing downtime
   • Improvising efficiency
   • Reducing Vibrations
   • Reducing Energy Consumption

• • • Cage/Separator Rotor
    • Guide Vanes
    • Static Blades/Louvres
    • Fans
    • Body Liners
    • Nozzle Ring Segments
    • Yoke
    • Cone
    • Roller Guard
    • Chutes
    • Ducts
    • Hoppers
    • Rotary Airlock

• • • • Crushing (primary reduction)
      • Grinding (fine reduction)

• • 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.
  Pyro Section (Preheater Kiln Cooler)
  • • 1. The milled and blended raw materials from mills go to a silo and then to the kiln through the preheater.
      2. The preheater-kiln system consists of a multi-stage cyclone, rotary kiln, and grate cooler.
      3. The kiln feed is preheated by hot gas from the combustion chamber and rotary kiln.
      4. Clinker formation takes place inside a rotary kiln which gets cooled inside the grate cooler.
      5. 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.
  Fans 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

Coal Burner Nozzle & Tip

                                                                            

• The flue-gas exit temperature is linked with the boiler design rather than the combustor.
• Accurate control of the amount of air is essential to boiler efficiency:

• Too much air will cool the furnace and carry away proper heat.
• Too little air and combustion will be incomplete, unburned fuel will be carried over, and smoke may be produced.

Trash Plates

The trash plate is one of the most critical components of a sugar mill. It is placed in the middle of the three crushing rolls and is adjusted to obtain maximum juice extraction from the canes, increasing efficiency. The trash plate is subjected to abrasive wear combined with corrosive wear from cane fibres and extraneous sand particles and hence to be protected against wear.

Roller Shaft Journal

The Rollers in a sugar mill are given a drive-by to rotate and crush the canes. Due to continuous operations, the journal area of the roller shaft gets worn out, which affects the drive. The journal gets worn out due to frictional as well as corrosive wear. Being an essential component of a sugar mill, it needs to be ensured that the journal is in good condition during the entire crushing season.

Hammers

Hammers used in sugar mills crush the cane to extract juices. They are critical components, and a minimum of one season life is required to ensure productivity. Hammers are subjected to impact, abrasion, and corrosive wear.

Headstock

Headstock in a sugar mill is subjected to corrosive conditions due to juices extracted from sugar cane. This leads to wearing out of the headstock, and it needs to be protected from corrosion.

Bull gears used in the sugar mill are critical components to run the rollers and are subjected to heavy load. A crack in bull gear may lead to high downtime for a sugar mill, especially during the crushing season.

 

Excavator

Excavator is the equipment used to dig, move and handle earth on a large scale. It is extensively

used in the mining industry. The excavator is heavy construction equipment consisting of a boom, stick, bucket and cab on a rotating platform (known as the “house”). The house sits atop an undercarriage with tracks or wheels.

Hammer Cylinder

Ripper

Shovel

Dozer