06
www.kalenborn.de
Reduce Costs
and Avoid Downtime
Large quantities of bulk material
are handled in the conveying and
storing systems of cement plants.
Unless they are suitably protected
these systems will experience frequent failure requiring repair or replacement. Kalenborn offer the
complete array of wear protection
materials including not only ceramic and metallic materials but
also plastics and rubber.
Service by Kalenborn:
rebuilding of a grinding roll
with KALMETALL-W 100
kalpraxis
Material Handled /
System
Typical Applications
for Wear Protection
Plant
Component
Reliable Control
of Wear Problems
Lining Material
as Wear Protection / Slide Promotion*
1
1
Bunkers
2
2 Silos
3
3 Transport
4
51
5
Raw Mill
(grinding/drying)
6
6
7
7
8 Pneumatic
8
9
9
ABRESIST, KALEN*
ABRESIST, KALCOR, KALOCER
Transfer chutes
Chain conveyors
ABRESIST
Ball mill
- feeding
Roller mill
- side walls
- rolls, table
- separator
- pneumatic discharge
Raw material
KALMETALL-W, KALMETALL-C
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALMETALL-W, KALOCER
KALCRET
ABRESIST, KALCOR, KALCRET, KALMETALL-W
ABRESIST, KALEN*
10
10 Preheater cyclone
Raw material
grinding
Raw meal
Preheater
7
2
3
23
24
29
27
26
Rotary kiln
15
28
Clinker crusher
KALMETALL-C, KALMETALL-W
Chute
KALCRET
24 Separator
25
Clinker chutes
ABRESIST, KALMETALL-W
Clinker store
ABRESIST, KALMETALL-W
25 Pneumatic transport
26
26 Silo fine coal
27
27 Burner
28
Clinker withdrawal
Chain conveyors
ABRESIST
Cement mills
Ball mill
- feeding
19 Cement separators
18
20 Dust collection
19
KALMETALL-W, KALMETALL-C
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALOCER, KALMETALL-W
Cyclones
Pneumatic pipes
CEMENT
20
21 Pneumatic transport
21
22 Silos
Pipes
21
14
KALMETALL-W
Roller mill
- side walls
- rolls, table
22
KALCRET
Cooler discharge
19
12
Slide promotion
lining of a silo
discharge for
additives with
KALEN-1000
COAL
13
14
13
15
14
16
15
17
16
18
17
30
Cement silos
20
18
17
CLINKER
12 Cooler
12
Cement
Additives grinding
system
16
11
Clinker
store
Cooler
13
Discarded tyres
Used oil
Plastics
25
10
11
11 Kiln feed
26
Coal pulverizing
system
RAW MATERIAL
ABRESIST, KALCRET
22
23 Bunkers
23 Coal pulverizer
24
KALMETALL-W, KALMETALL-C
- rolls, table
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALOCER, KALMETALL-W
Pipes
PRECALCINING
28 Feed
29
KALOCER
high alumina
ceramics lining
of a separator
with mechanically fixed tiles,
100 x 100 mm
ABRESIST, KALCOR
Burner
KALMETALL-W, KALSICA
ADDITIVES
29
30 Gypsum
Bunker
ABRESIST, KALEN*
Marl
Bunker
ABRESIST, KALEN*
BFS
Silo
ABRESIST, KALEN*
Fly ash
Silo
ABRESIST, KALEN*
Pneumatic transport
Pipes
Screw conveyor
protected with
KALMETALL-W 100,
up to 2,000 mm
diameter, up to
10,000 mm length
KALEN*, KALCERAM*
kalpraxis
Material Handled /
System
Typical Applications
for Wear Protection
Plant
Component
Reliable Control
of Wear Problems
Lining Material
as Wear Protection / Slide Promotion*
1
1
Bunkers
2
2 Silos
3
3 Transport
4
51
5
Raw Mill
(grinding/drying)
6
6
7
7
8 Pneumatic
8
9
9
ABRESIST, KALEN*
ABRESIST, KALCOR, KALOCER
Transfer chutes
Chain conveyors
ABRESIST
Ball mill
- feeding
Roller mill
- side walls
- rolls, table
- separator
- pneumatic discharge
Raw material
KALMETALL-W, KALMETALL-C
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALMETALL-W, KALOCER
KALCRET
ABRESIST, KALCOR, KALCRET, KALMETALL-W
ABRESIST, KALEN*
10
10 Preheater cyclone
Raw material
grinding
Raw meal
Preheater
7
2
3
23
24
29
27
26
Rotary kiln
15
28
Clinker crusher
KALMETALL-C, KALMETALL-W
Chute
KALCRET
24 Separator
25
Clinker chutes
ABRESIST, KALMETALL-W
Clinker store
ABRESIST, KALMETALL-W
25 Pneumatic transport
26
26 Silo fine coal
27
27 Burner
28
Clinker withdrawal
Chain conveyors
ABRESIST
Cement mills
Ball mill
- feeding
19 Cement separators
18
20 Dust collection
19
KALMETALL-W, KALMETALL-C
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALOCER, KALMETALL-W
Cyclones
Pneumatic pipes
CEMENT
20
21 Pneumatic transport
21
22 Silos
Pipes
21
14
KALMETALL-W
Roller mill
- side walls
- rolls, table
22
KALCRET
Cooler discharge
19
12
Slide promotion
lining of a silo
discharge for
additives with
KALEN-1000
COAL
13
14
13
15
14
16
15
17
16
18
17
30
Cement silos
20
18
17
CLINKER
12 Cooler
12
Cement
Additives grinding
system
16
11
Clinker
store
Cooler
13
Discarded tyres
Used oil
Plastics
25
10
11
11 Kiln feed
26
Coal pulverizing
system
RAW MATERIAL
ABRESIST, KALCRET
22
23 Bunkers
23 Coal pulverizer
24
KALMETALL-W, KALMETALL-C
- rolls, table
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALOCER, KALMETALL-W
Pipes
PRECALCINING
28 Feed
29
KALOCER
high alumina
ceramics lining
of a separator
with mechanically fixed tiles,
100 x 100 mm
ABRESIST, KALCOR
Burner
KALMETALL-W, KALSICA
ADDITIVES
29
30 Gypsum
Bunker
ABRESIST, KALEN*
Marl
Bunker
ABRESIST, KALEN*
BFS
Silo
ABRESIST, KALEN*
Fly ash
Silo
ABRESIST, KALEN*
Pneumatic transport
Pipes
Screw conveyor
protected with
KALMETALL-W 100,
up to 2,000 mm
diameter, up to
10,000 mm length
KALEN*, KALCERAM*
kalpraxis
Material Handled /
System
Typical Applications
for Wear Protection
Plant
Component
Reliable Control
of Wear Problems
Lining Material
as Wear Protection / Slide Promotion*
1
1
Bunkers
2
2 Silos
3
3 Transport
4
51
5
Raw Mill
(grinding/drying)
6
6
7
7
8 Pneumatic
8
9
9
ABRESIST, KALEN*
ABRESIST, KALCOR, KALOCER
Transfer chutes
Chain conveyors
ABRESIST
Ball mill
- feeding
Roller mill
- side walls
- rolls, table
- separator
- pneumatic discharge
Raw material
KALMETALL-W, KALMETALL-C
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALMETALL-W, KALOCER
KALCRET
ABRESIST, KALCOR, KALCRET, KALMETALL-W
ABRESIST, KALEN*
10
10 Preheater cyclone
Raw material
grinding
Raw meal
Preheater
7
2
3
23
24
29
27
26
Rotary kiln
15
28
Clinker crusher
KALMETALL-C, KALMETALL-W
Chute
KALCRET
24 Separator
25
Clinker chutes
ABRESIST, KALMETALL-W
Clinker store
ABRESIST, KALMETALL-W
25 Pneumatic transport
26
26 Silo fine coal
27
27 Burner
28
Clinker withdrawal
Chain conveyors
ABRESIST
Cement mills
Ball mill
- feeding
19 Cement separators
18
20 Dust collection
19
KALMETALL-W, KALMETALL-C
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALOCER, KALMETALL-W
Cyclones
Pneumatic pipes
CEMENT
20
21 Pneumatic transport
21
22 Silos
Pipes
21
14
KALMETALL-W
Roller mill
- side walls
- rolls, table
22
KALCRET
Cooler discharge
19
12
Slide promotion
lining of a silo
discharge for
additives with
KALEN-1000
COAL
13
14
13
15
14
16
15
17
16
18
17
30
Cement silos
20
18
17
CLINKER
12 Cooler
12
Cement
Additives grinding
system
16
11
Clinker
store
Cooler
13
Discarded tyres
Used oil
Plastics
25
10
11
11 Kiln feed
26
Coal pulverizing
system
RAW MATERIAL
ABRESIST, KALCRET
22
23 Bunkers
23 Coal pulverizer
24
KALMETALL-W, KALMETALL-C
- rolls, table
KALMETALL-W, KALMETALL-C
ABRESIST, KALCRET, KALOCER, KALMETALL-W
Pipes
PRECALCINING
28 Feed
29
KALOCER
high alumina
ceramics lining
of a separator
with mechanically fixed tiles,
100 x 100 mm
ABRESIST, KALCOR
Burner
KALMETALL-W, KALSICA
ADDITIVES
29
30 Gypsum
Bunker
ABRESIST, KALEN*
Marl
Bunker
ABRESIST, KALEN*
BFS
Silo
ABRESIST, KALEN*
Fly ash
Silo
ABRESIST, KALEN*
Pneumatic transport
Pipes
Screw conveyor
protected with
KALMETALL-W 100,
up to 2,000 mm
diameter, up to
10,000 mm length
KALEN*, KALCERAM*
kalpraxis
kalpraxis
Wear Protection
in Cement Plants
Lining Materials
Cyclones
Fan housings
Fan rotors
KALOCER, KALMETALL-W
Gates
Hydraulic conveyors
KALSICA
Separators
Sieves
KALMETALL-W, KALMETALL-C
Transfer stations
KALOCER
KALOCER, KALSICA
Grinding table
segments of
a roller mill
of 5,000 mm
diameter
made of
KALMETALL-C;
smaller
diameters are
cast in one
piece
Wear Protection
in Cement Plants
kalpraxis
kalpraxis
Wear Protection
in Cement Plants
Lining Materials
Cyclones
Fan housings
Fan rotors
KALOCER, KALMETALL-W
Gates
Hydraulic conveyors
KALSICA
Separators
Sieves
KALMETALL-W, KALMETALL-C
Transfer stations
KALOCER
KALOCER, KALSICA
Grinding table
segments of
a roller mill
of 5,000 mm
diameter
made of
KALMETALL-C;
smaller
diameters are
cast in one
piece
Wear Protection
in Cement Plants
kalpraxis
kalpraxis
Wear Protection
in Cement Plants
Lining Materials
Cyclones
Fan housings
Fan rotors
KALOCER, KALMETALL-W
Gates
Hydraulic conveyors
KALSICA
Separators
Sieves
KALMETALL-W, KALMETALL-C
Transfer stations
KALOCER
KALOCER, KALSICA
Grinding table
segments of
a roller mill
of 5,000 mm
diameter
made of
KALMETALL-C;
smaller
diameters are
cast in one
piece
Wear Protection
in Cement Plants
kalpraxis
Wear Protection
in Cement Plants
Protection
of a raw
meal mill:
KALCRET for
the piping,
KALMETALLW 100 for the
mill lining
kalpraxis
Wear Protection
in Cement Plants
kalpraxis
Materials at a Glance
Material Hardness
Mohs(1) Vickers
HV (2)
Process Parameters
Max. conveying volocity
m/sec
Material
density
g/cm
Remarks
Max.
Thermal
Impact
temperature (3) shock
wear
C
F resistance resistance
KALSICA-S silicon
carbide ceramics
9.3
(2,300)
35
>3.0
1,000 1,832
++++
++
For extreme
applications
KALOCER high
alumina ceramics
9.1
(2,100)
>30
>3.0
350
662
KALCOR zirconium
corundum
(2,000)
>30
>3.0
800
1,472
++
++
KALSICA-N silicon
carbide ceramics
8.8
(1,800)
>25
>3.0
1,000 1,832
+++
Good temperature
resistance/thermal
shock resistance
KALCOR-S sintered
zirconium corundum
8.5
(1,600)
>25
KALCRET-B
hard compound
8.1
(1,250)
22
ABRESIST
fused cast basalt
(1,140)
KALMETALL-W 100
hard overlay welding
(7.5)
KALMETALL-C
hard casting
KALCERAM
hard ceramics
800
1,472
+++
++
Economic KALCOR
3.0
800
1,472
+++
Supplied in bags,
no joints, high
temperatures
22
3.0
350
662
Flow volumes
up to 3.0 g/cm,
up to 22 m/sec,
limited temperatures
700
20
350
662
++
++
Impact resistant,
low weight
(7.2)
580
20
350
662
++
+++
Impact resistant,
economic in case
of large quantities
(500)
350
662
Bunker lining,
slide promotion
(1) The Mohs scale is applicable only to ceramic materials - no more than comparison values for other materials (values given in brackets)
(2) The Vickers HV values are only valid for metallic materials - no more than comparison values for other materials (values given in brackets)
(3) The specified temperatures refer to standard applications; other temperatures must be agreed upon with the technical departments of Kalenborn
Slide Promotion
Max. Temp.
C
KALEN slide
promotion plastics
12
Wear Resistance
Remarks
+++++
80
176
KALINOX slide
promotion steel
+++
550
1,022
++
KALCERAM
hard ceramics
+++
350
662
+++
ABRESIST
fused cast basalt
+++
350
662
++++
KALMETALL-W hard
overlay welding
KALCOR
zirconium corundum
KALMETALL-C
hard casting
KALOCER
high alumina ceramics
KALCRET
hard compound
KALSICA silicon
carbide ceramics
KALEN slide
promotion plastics
Plastic lining
Material combinations
kalpraxis
Wear Protection
in Cement Plants
Abresist Corporation
5541 North State Road 13
P.O. Box 38
Urbana, IN 46990, USA
Phone
(800) 348-0717
(260) 774-3327
Fax Business (260) 774-8188
Sales
(260) 774-3832
eMail
info@abresist.com
Internet
www.abresist.com
Kalenborn Kalprotect
Dr. Mauritz GmbH & Co. KG
Vettelschoss, Germany
Internet
www.kalenborn.de