Where erosion shortens the life of cement plant equipment, and where precast ceramic parts replace metal shapes or cast refractory.
Clinker, raw meal and fuel all wear the plant from the inside.
Some parts can be made to outlast them.
This Blasch article is about erosion in cement production: it shortens the operating life of equipment and forces key components to be replaced early. The argument is that abrasion resistant precast ceramic parts can replace expensive metallic shapes or cast refractory at the points that wear fastest. In a cement plant these are cyclones, conveying elbows, heat exchanger tube inlets, valves and burner parts.
Erosion in a cement plant happens at the same bends, cones and inlets every campaign, which means the part can be designed for it in advance.
Blasch lists these wear points for cement plants in its product information.
One piece silicon carbide liners for cones and sleeves, and tile linings for scroll inlets. Cyclone and scrubber linings
Cast ceramic liners with a smooth bore and engineered joints, delivered in the steel pipe. Ceramic lined elbows
Thin walled inserts that take the abrasion of hot clinker gas at the tubesheet. Clinker cooler inserts
Metal shapes wear and need replacing. Castable is cheap to place but cures on site and cracks under thermal cycling. A precast ceramic part is cast to its final shape before the shutdown, fired, and only set during it. The Blasch process holds tight tolerances, so the part fits the steel it goes into.
Blasch uses several silicon carbide families for cement service: OXYTRON, NITRON, ALTRON and the reaction bonded InVinCer. The choice depends on abrasion, temperature and thermal cycling at each point. See silicon carbide for the differences.
Valves and seats, thermocouple protection tubes, reactor linings, bubble caps and tuyeres, and burner nozzles are made the same way.
Start with the part you replace most often and the reason it fails. A detailed example for one wear point is Extended Heat Exchanger Life.
Compare cost per year of service, not per piece. The case for ceramics rests on longer life and fewer replacements.
No. Blasch casts solid ceramic parts and liners. It does not apply coatings.
Liners are cast to the dimensions of the existing equipment, and elbows and spools can be delivered complete with steel and flanges.
Tell us which part, the material it carries and how long it lasts today. A Blasch engineer proposes a ceramic design.
