WEAR PROTECTION
EDITORIAL
General Management
Markus Buscher, Dr. Conrad Mauritz
WE COMBINE DEDICATION
WITH EXPERIENCE
Kalenborn is the internationally leading We rely on a high-quality range of mineral,
provider of wear protection solutions. ceramic and metallic materials as well as
Our company has a rich tradition characterised compounds and plastics. That variety enables
CONTENTS by competence and experience as well us to create lining systems which are perfectly
Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 23 as durable, quality products. We protect matched to each specific application. Working
Production process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 47 industrial plants and equipment reliably closely together with our customers is particu-
Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 1011 against wear due to abrasion and impact. larly important to us. In close collaboration, we
International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 1213 In steelworks and cement plants, in coal-fired develop concepts for sustainable solutions and
Employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 1415 power plants and recycling plants, in mining then realise them both in our own works and
History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 1619 and in environmental technology, our solu- on-site at the facilities of the customer.
Wear-resistant materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 2223 tions keep production operations running.
Wear-resistant pipe systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 2425
Wear protection for industrial plants and equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 2627
Customer-specific solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 2829
Facts and Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p. 3031
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PRODUCTION PROCESS PRODUCTION PROCESS
In the early 1920s, Kalenborns fused KALOCER is a high-alumina ceramic For especially harsh operating condi- Our hard compounds combine excellent wear protec- Plates made from thermoplastic form the basis of our
cast basalt works successfully pro- compressed in a mould and fired at tions, we have developed special hard tion properties with ease of use. KALCRET has especially material KALEN. They offer corrosion-free, anti-friction wear
duced a wear-resistant material made high temperatures. It is suitable for casting alloys such as KALCAST, for wear-resistant hard materials such as bauxite or corundum protection in bunkers, silos, chutes and troughs. With its
of basalt for the first time ever applications subject to extreme wear example. Alloy components such as permanently embedded in it. Its special advantage lies especially low weight and an operating temperature of
amaterial now known the world over and temperatures of up to 1,000C. chromium and carbon ensure espe- in its versatility. Our employees apply the material with a up to 80C, KALEN has proven effective all over the world
under the brand name ABRESIST. KALCOR zirconium corundum is cially high hardness and abrasion trowel or spray it on to create an extremely wide variety of for decades. It is installed on concrete or steel by means of
Today modern furnaces, in which the particularly well-suited for use in resistance, whilst manganese provides precise components. KALPOXY is an epoxy resin-bonded a mounting system, which we developed specifically for the
rock is smelted at 1,250C, are the castings. In the form of plates, mosaics, impact strength. In our foundry, we compound, which can be used quickly and effectively in purpose. KALEA is a high-performance thermoset and is
heart of the production operations. moulded parts and hollow cylinders, produce cylinders, pipe bends and the seamless lining of plant and equipment components applied extremely rapidly in a thin, seamless layer by means
The liquid basalt is cast in moulds and our ceramic materials are installed in a moulded parts weighing from 30 to and for repairs. The material can be used in chemically of Kalenborn spray technology. The material features out-
subsequently heat treated in a special wide range of plant components such 3,000kg. Our KALMETALL material, aggressive environments. standing wear resistance under very high impact loading
process in order to give the material as pipelines, cyclones, sifters and chutes. from which we manufacture compo- and an operating temperature of up to 120C.
its crystalline structure. That makes This ensures the reliable production nents which can weigh as much as
the rock especially hard and strong. of energy, raw materials and other several tons, consists of steel plates ar-
Along with very good protection important products we all use in our moured with special hard metal alloys.
against wear, ABRESIST also provides everyday life. It exceeds the service life of common
an anti-friction surface. steel several times over.
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PRODUCTION PROCESS PRODUCTION PROCESS
KALEA
Polyurea
Plastic Customised
Polyethylene solutions
KALEN
UNCOMPROMISING QUALITY
We are mindful of the need to continuously optimise our such as microstructural studies and wear tests according to
materials properties and manufacturing processes, and international standards. In addition, other special proce-
thereby their product quality. A certified quality assurance dures are used to determine material hardnesses. Long-
system specifies detailed requirements for all process steps term wear resistance testing is carried out in the laboratory
and control points in production operations. In our in- under various operating conditions.
house test labs, our employees carry out material testing Material testing in the in-house laboratory
ensures the product quality of the materials
and the durability of the lined pipe systems and
plant components.
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The better matched the material and the lining are to a given problem,
the longer the service life and the more cost-effective the solution.
VALUES VALUES
WE THINK FURTHER
IN ALL DIRECTIONS
Thanks to our materials expertise and decades of application experience, Kalenborns long-lasting
wear protection solutions and services enjoy an outstanding reputation the world over. We take
over responsibility for the satisfaction of our customers. Our orientation is based on the central
core values of on-site service, expertise and sustainability.
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INTERNATIONAL INTERNATIONAL
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EMPLOYEES EMPLOYEES
WEAR PROTECTION
Our production operations combine modern manufacturing technol-
ogy with carefully executed craftsmanship. In our plants we operate
modern machinery and production equipment. But only our employees,
with their many years of experience and their skilled craftsmanship, can
achieve the desired precision and attention to detail.
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HISTORY HISTORY
1921 | ESTABLISHMENT 19371944 | DURING THE WAR 19501959 | THE PATH TO EUROPE 19601969 | ON THE GLOBAL MARKET
On 7th September, Schmelzbasalt AG is established in Linz The company changes its name to Schmelzbasaltwerk Through the establishment of 15 distributors, sales are In the 1960s, sales are expanded to the United States, India
am Rhein, Germany the start of the industrial manufac- Kalenborn Dr. Ing. Mauritz Kommanditgesellschaft. expanded to all Western European countries. At the end of and Australia. Intensive research is conducted, not only into
ture of fused cast basalt. The armament industry consumes all iron and steel the 1950s, exports represent 35% of turnover and produc- metallic and ceramic raw materials, but also into thermo-
resources. In many areas, those materials are replaced by tion reaches the pre-war level. plastics, and further developed by the 2nd generation with
fused cast basalt. Dipl. Ing. Wonter Mauritz.
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HISTORY HISTORY
1977 | EXPANSION TO THE USA 19902010 | INTERNATIONALISATION 2014 | KALENBORN AS AN 2016 | EXPANSION OF RESEARCH AND
With the establishment of Kalenborn Abresist Corpora- By extending the network to include subsidiaries in Canada, INTERNATIONAL BRAND DEVELOPMENT
tion in Indiana, a production operation is created for the Brazil, Poland, France, Hungary, Singapore and the Philippines, The global corporate network bundles its services under Kalenborn expands its in-house research laboratories. In
American market. in-house production operations are rounded out and the the umbrella brand Kalenborn and communicates its world collaboration with recognised institutions and universities
market presence is expanded. With Dr. Conrad Mauritz, the wide claim as a market-leading, innovative and international as well as with the support of government ministries, classic
third generation takes over the leadership of the company. turnkey provider of high-quality wear protection solutions. materials testing is carried out according to international
standards.
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Today what began more than nine decades ago with fused cast basalt
has become a broad spectrum of materials with extraordinary properties.
Add to that the expertise and the experience that we have gained around
the world in many industrial sectors.
PRODUCTS PRODUCTS
WEAR-RESISTANT MATERIALS
We produce our wear-resistant materials in our For the high impact wear typically found
own plants and ensure their quality through in components such as bunker inlets, spiral
material testing in our laboratories in order to chutes and crushers, we recommend metallic
find just the right solution for each customer materials such as the armoured plates made
requirement. One of the prerequisites for of KALMETALL and KALCAST hard casting. The
effective wear protection is also a professional hard compound KALCRET combines easy hand-
installation, which our employees carry out ling with excellent wear protection properties
with special adhesives and fasteners. under high temperature loading. To line large
surfaces such as those of separators on a
ABRESIST fused cast basalt reliably prevents cement mill or of blast furnace dust catchers
abrasive wear in plant components such as in an integrated steel mill the material can
scale flumes, marl hoppers, fly ash pipelines in be applied without joints using a trowel or
coal-fired power plants, and coke bunkers in sprayed on. Within 48 hours, the plant is ready
the iron and steel industry. The cast ceramic for operation again.
material KALCOR has proven effective for lining
plant components that are subject not only to Very different requirements arise under
extremely harsh abrasion, but also high operating conditions which demand especial-
temperatures, for example in chutes for hot ly good anti-friction properties, e.g. in silos
sinter or clinker, in asphalt mixers and hot gas and bunkers. Such applications use not only
pipelines. KALOCER high-alumina ceramics are KALEN, as a thermoplastic material with ideal
available in thin, smooth moulded elements anti-friction properties, but also the mineral
and are particularly well-suited for lining material KALCERAM. They prevent the material
conveyor belt transfer points, concrete mixers which is being conveyed from building up,
or cyclones in the food industry. thereby ensuring uninterrupted material flow.
For rapidly applying a thin, jointless coating
to large surfaces or pipes, Kalenborn offers
KALEA, a sprayable material with its own appli-
cation technology.
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PRODUCTS PRODUCTS
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PRODUCTS PRODUCTS
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PRODUCTS PRODUCTS
CUSTOMER-SPECIFIC
SOLUTIONS
Our customer-specific solutions are innovative wear protec- With an initial air temperature of 800 C, the fine-grained
tion applications for complex industrial plants. These wear oil shale is then blown upward at high speed through the
protection solutions take various factors into account along riser into the adjacent cyclone. The geometry and process
with the specific operating environment of our customers conditions change with every metre that the material rises.
plants.
In the hot area at the lower section, we install ceramic
We satisfy customer requirements for safe and econom- materials with very high resistance to hot abrasion and
ical production as well as longer equipment service life thermal shock. In the middle section, relatively moderate
through the right selection, combination and mounting of operating conditions prevail, which require a material with
materials. The key to the success of our solutions lies not primarily good resistance against abrasive wear. And finally,
only in analysing the actual conditions, but also in work- in order to improve impact strength in the upper section
ing together with our customers during the development at the turnaround, especially impact-resistant and massive
process. Time and again, our expert knowledge is chan- components are installed.
nelled into new developments for the steel industry, for
coal-fired power plants, for mining and for environmental This unique combination of materials, the special mount-
engineering. ing systems, and the installation on-site demonstrate how
Kalenborn works as a partner to meet special requirements.
Our solutions are used, for example, in petrochemistry, We ensure the long service life of plants and equipment and
where oil and gas are extracted from shale. The plant crush- help to sustain the economical production of gas and oil.
es the wet stone and conveys it via belts to a flash dryer.
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FACTS AND FIGURES FACTS AND FIGURES
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Imprint: Kalenborn International GmbH & Co. KG, Asbacher Str. 50, 53560 Vettelschoss, Germany general managers: Dr. Conrad Mauritz, Markus Buscher photo credits: p. 13 Jean-Louis Burnod HappyDay / Grand Porte Maritime de Dunkerque / all other photos: Kalenborn International GmbH & Co. KG
AT A GLANCE 443 Production
70 Administration
Further information: www.kalenborn.com
68 Sales and Marketing
German
English
French
Italian
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Portuguese
Polish
Piping
Hungarian
Russian
Filipino
5,500,000
Chinese
Strzegom, PL
Vettelschoss, DE
Starachowice, PL
metres
Maintenon, FR Mosonudvar, HU
Pointe Claire, CA Basalt production
widnica, PL
Urbana, USA
Soddy-Daisy, USA
550,000
tonnes
Singapore, SG
550
Markets
football fields
Belo Horizonte/MG, BR
Active customers
21 % 23 %
Americas Germany
30 %
Rest of World
26 %
Rest of 5000
Europe
Industries
Quality Management according to ISO 9001 | Certificate as specialised welding firm according to DIN 3834-2 | Qualification as manufacturer and
welding company for pressure equipment according to AD2000 information sheet HP0 | Qualification as manufacturer and welding company Environmental
according to Pressure Equipment Directive DGRL 97/23/EC annex 1, para. 3.1 | Installation firm according to SCC (Safety Certificate Contractors) Power plants Iron and steel Cement Mining technology
30 31
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