The applications focused on ducting used to transport solid recovered fuel to the kiln
Welding Alloys has delivered a significant performance improvement for a customer in the cement industry by applying advanced ceramic-lined ducting, demonstrating the value of engineered wear solutions in high-abrasion environments
The applications focused on ducting used to transport solid recovered fuel (SRF) to the kiln. Due to the nature of the process, these bends are subject to continuous abrasive wear, often resulting in a short operational lifespan. Conventional untreated bends lasted between 500 and 700 hours, created frequent maintenance interventions, increased downtime, and ongoing replacement costs.
Welding Alloys extended component life while maintaining the lightweight requirements critical to the installation by implementing a tailored solution incorporating ceramic lining technology.
Following installation, the treated bends have surpassed 2,500 hours of operation, more than four times the lifespan of untreated components. Inspection results indicate that the ceramic lining remains in strong condition, with over half of the original thickness still intact and minimal tile displacement observed. Based on current wear rates, the components are expected to achieve a service life of up to 5,000 hours.
This improvement is particularly significant due to the application’s constraints. The ducting is located in an area without crane access, requiring components to be manually handled. As a result, any wear solution must balance durability with weight considerations. The selective placement of ceramic lining in high-wear zones ensured protection without compromising handling requirements.
The trial has also found that material flow does not always remain central within the bend radius, leading to localised wear at the edges of the lined area. As a result, future designs will incorporate a wider ceramic coverage to ensure full protection across the entire wear profile.
The trial’s success has already led to a confirmed follow-up order for a larger number of components, highlighting the customer’s confidence in the solution and its long-term value. Beyond the performance gains, the extended service life reduces maintenance frequency, lowers the total cost of ownership, and improves plant reliability.
The project also reinforces the role of enhanced wear solutions in supporting more sustainable operations. By extending component life and reducing material consumption, customers can reduce waste and improve overall process efficiency.
