Issue 03.

06

www.kalenborn.de
Economic Wear Protection in
Coal fired Power Plants Worldwide

A typical application in power

plants is pulverized fuel piping,
here protected by ABRESIST

Reduce Costs and In addition, Kalenborn have

Avoid Downtime extensive experience in the field
of slide promotion. Interruptions
Large quantities of bulk material
of material flow inside of bunkers
are handled in the conveying and
and silos must be avoided and
storing systems of coal fired
Kalenborn cover the entire mate-
power plants. Unless they are
rial range with plastics as well as
suitably protected these systems
metallic and ceramic materials.
will experience frequent failure
requiring repair or replacement. In any case we can supply a
Kalenborn offer the complete tailor-made solution for your
array of wear protection materials particular problem. Our experts
including not only ceramic and are prepared to be of assistance.
metallic materials but also
plastics and rubber.

Service by Kalenborn:
rebuilding a grinding table with
KALMETALL-W 100
 kalpraxis Typical Applications
for Wear Protection
Reliable Control
of Wear Problems
Work with Kalenborn
for Your Optimal Solution

Material Handled / Plant Lining Material

System Component as Wear Protection / Slide Promotion*
Desulphurization Lime slurry Cooling tower
COAL
11 Bunkers
9 plant
22 Coal transport Transfer chutes
ABRESIST, KALEN*, KALCERAM*, KALINOX*
ABRESIST, KALOCER, KALMETALL-W, KALEN*
Boiler Limestone
19
Pyrite pipes ABRESIST, KALCOR pulverizer 19
21
33 Coal pulverizers Ball mills
- feeding KALMETALL-C, KALMETALL-W, KALCOR 18 20
- housing KALMETALL-C, KALMETALL-W
Roller mills 17
- side walls/housing KALMETALL-W, KALMETALL-C
- rolls, tables KALMETALL-W, KALMETALL-C
44 - separators ABRESIST, KALOCER, KALSICA, KALMETALL-W,
KALCRET
10
55 - Pneumatic discharge
Hammer mills
KALCRET, ABRESIST, KALMETALL-W
Coal 8
- housing
- hammers
KALMETALL-C, KALMETALL-W
KALMETALL-C
pulverizer 11
66 Coal feeding Pneumatic ABRESIST, KALCRET, KALCOR, KALOCER, 7
Mechanical
KALMETALL-C, KALMETALL-W
ABRESIST, KALCOR, KALOCER, KALMETALL-C, 6 Wet ash silos
KALMETALL-W
77 Coal distributor KALSICA, KALMETALL-W 5 12
88 Pulverized coal burners
Fly ash silos Gypsum
Lances KALSICA, KALMETALL-W
2 4 13 22
Reflectors KALSICA, KALMETALL-W 14 15
99 Fly ash
10
Protection of boiler tubes KALSICA 1
12 16
silos
10 Housing KALCRET, KALSICA, KALMETALL-W 3
11
11 Cyclones dust collection KALCOR, KALCRET, KALMETALL-W
12
12 Pneumatic transport ABRESIST, KALCOR, KALOCER
13
13 Silos ABRESIST, KALEN*
14
14 Wet ash (Bottom ash) Wet ash removal systems ABRESIST, KALOCER, KALMETALL-W
Chain conveyors ABRESIST, KALOCER
Coal bunkers require a reliable Fly ash pipes are among the
Granulators ABRESIST, KALMETALL-W material flow. This is ensured by plant components that are
15
15 Silos ABRESIST the use of KALEN slide promotion particularly endangered by
plastics. Slide promotion steel - wear. Kalenborn offer a variety
Mixers (w. fly ash) ABRESIST, KALMETALL-W perhaps combined with KALEN - of materials to ensure optimal
16
16 Hydraulic transport ABRESIST will be best in case of more service lifetimes: ABRESIST
DESULPHURIZATION intense wear. fused cast basalt, KALCOR
zirconium corundum and
17
17 Limestone Bunkers ABRESIST, KALEN* KALOCER high alumina
18
18 Limestone grinding mill ceramics.
- feeding ABRESIST, KALCRET, KALMETALL-W
Reliable wear protection is of
19
19 Pneumatic transport ABRESIST particular importance for
20
20 Silos ABRESIST, KALEN* trouble-free continuous ABRESIST fused cast basalt
operation of the coal injection. is the accepted standard for
21
21 Mixers ABRESIST, KALMETALL-W
These PF-bends are made piping in wet ash pipe systems
22
22 Gypsum Stores (silos, bunkers) ABRESIST, KALEN* of plates with hard all over the world. The picture
overlay welding. shows a plant in India.
2 3 4
 kalpraxis Typical Applications
for Wear Protection
Reliable Control
of Wear Problems
Work with Kalenborn
for Your Optimal Solution

Material Handled / Plant Lining Material

System Component as Wear Protection / Slide Promotion*
Desulphurization Lime slurry Cooling tower
COAL
11 Bunkers
9 plant
22 Coal transport Transfer chutes
ABRESIST, KALEN*, KALCERAM*, KALINOX*
ABRESIST, KALOCER, KALMETALL-W, KALEN*
Boiler Limestone
19
Pyrite pipes ABRESIST, KALCOR pulverizer 19
21
33 Coal pulverizers Ball mills
- feeding KALMETALL-C, KALMETALL-W, KALCOR 18 20
- housing KALMETALL-C, KALMETALL-W
Roller mills 17
- side walls/housing KALMETALL-W, KALMETALL-C
- rolls, tables KALMETALL-W, KALMETALL-C
44 - separators ABRESIST, KALOCER, KALSICA, KALMETALL-W,
KALCRET
10
55 - Pneumatic discharge
Hammer mills
KALCRET, ABRESIST, KALMETALL-W
Coal 8
- housing
- hammers
KALMETALL-C, KALMETALL-W
KALMETALL-C
pulverizer 11
66 Coal feeding Pneumatic ABRESIST, KALCRET, KALCOR, KALOCER, 7
Mechanical
KALMETALL-C, KALMETALL-W
ABRESIST, KALCOR, KALOCER, KALMETALL-C, 6 Wet ash silos
KALMETALL-W
77 Coal distributor KALSICA, KALMETALL-W 5 12
88 Pulverized coal burners
Fly ash silos Gypsum
Lances KALSICA, KALMETALL-W
2 4 13 22
Reflectors KALSICA, KALMETALL-W 14 15
99 Fly ash
10
Protection of boiler tubes KALSICA 1
12 16
silos
10 Housing KALCRET, KALSICA, KALMETALL-W 3
11
11 Cyclones dust collection KALCOR, KALCRET, KALMETALL-W
12
12 Pneumatic transport ABRESIST, KALCOR, KALOCER
13
13 Silos ABRESIST, KALEN*
14
14 Wet ash (Bottom ash) Wet ash removal systems ABRESIST, KALOCER, KALMETALL-W
Chain conveyors ABRESIST, KALOCER
Coal bunkers require a reliable Fly ash pipes are among the
Granulators ABRESIST, KALMETALL-W material flow. This is ensured by plant components that are
15
15 Silos ABRESIST the use of KALEN slide promotion particularly endangered by
plastics. Slide promotion steel - wear. Kalenborn offer a variety
Mixers (w. fly ash) ABRESIST, KALMETALL-W perhaps combined with KALEN - of materials to ensure optimal
16
16 Hydraulic transport ABRESIST will be best in case of more service lifetimes: ABRESIST
DESULPHURIZATION intense wear. fused cast basalt, KALCOR
zirconium corundum and
17
17 Limestone Bunkers ABRESIST, KALEN* KALOCER high alumina
18
18 Limestone grinding mill ceramics.
- feeding ABRESIST, KALCRET, KALMETALL-W
Reliable wear protection is of
19
19 Pneumatic transport ABRESIST particular importance for
20
20 Silos ABRESIST, KALEN* trouble-free continuous ABRESIST fused cast basalt
operation of the coal injection. is the accepted standard for
21
21 Mixers ABRESIST, KALMETALL-W
These PF-bends are made piping in wet ash pipe systems
22
22 Gypsum Stores (silos, bunkers) ABRESIST, KALEN* of plates with hard all over the world. The picture
overlay welding. shows a plant in India.
2 3 4
 kalpraxis Typical Applications
for Wear Protection
Reliable Control
of Wear Problems
Work with Kalenborn
for Your Optimal Solution

Material Handled / Plant Lining Material

System Component as Wear Protection / Slide Promotion*
Desulphurization Lime slurry Cooling tower
COAL
11 Bunkers
9 plant
22 Coal transport Transfer chutes
ABRESIST, KALEN*, KALCERAM*, KALINOX*
ABRESIST, KALOCER, KALMETALL-W, KALEN*
Boiler Limestone
19
Pyrite pipes ABRESIST, KALCOR pulverizer 19
21
33 Coal pulverizers Ball mills
- feeding KALMETALL-C, KALMETALL-W, KALCOR 18 20
- housing KALMETALL-C, KALMETALL-W
Roller mills 17
- side walls/housing KALMETALL-W, KALMETALL-C
- rolls, tables KALMETALL-W, KALMETALL-C
44 - separators ABRESIST, KALOCER, KALSICA, KALMETALL-W,
KALCRET
10
55 - Pneumatic discharge
Hammer mills
KALCRET, ABRESIST, KALMETALL-W
Coal 8
- housing
- hammers
KALMETALL-C, KALMETALL-W
KALMETALL-C
pulverizer 11
66 Coal feeding Pneumatic ABRESIST, KALCRET, KALCOR, KALOCER, 7
Mechanical
KALMETALL-C, KALMETALL-W
ABRESIST, KALCOR, KALOCER, KALMETALL-C, 6 Wet ash silos
KALMETALL-W
77 Coal distributor KALSICA, KALMETALL-W 5 12
88 Pulverized coal burners
Fly ash silos Gypsum
Lances KALSICA, KALMETALL-W
2 4 13 22
Reflectors KALSICA, KALMETALL-W 14 15
99 Fly ash
10
Protection of boiler tubes KALSICA 1
12 16
silos
10 Housing KALCRET, KALSICA, KALMETALL-W 3
11
11 Cyclones dust collection KALCOR, KALCRET, KALMETALL-W
12
12 Pneumatic transport ABRESIST, KALCOR, KALOCER
13
13 Silos ABRESIST, KALEN*
14
14 Wet ash (Bottom ash) Wet ash removal systems ABRESIST, KALOCER, KALMETALL-W
Chain conveyors ABRESIST, KALOCER
Coal bunkers require a reliable Fly ash pipes are among the
Granulators ABRESIST, KALMETALL-W material flow. This is ensured by plant components that are
15
15 Silos ABRESIST the use of KALEN slide promotion particularly endangered by
plastics. Slide promotion steel - wear. Kalenborn offer a variety
Mixers (w. fly ash) ABRESIST, KALMETALL-W perhaps combined with KALEN - of materials to ensure optimal
16
16 Hydraulic transport ABRESIST will be best in case of more service lifetimes: ABRESIST
DESULPHURIZATION intense wear. fused cast basalt, KALCOR
zirconium corundum and
17
17 Limestone Bunkers ABRESIST, KALEN* KALOCER high alumina
18
18 Limestone grinding mill ceramics.
- feeding ABRESIST, KALCRET, KALMETALL-W
Reliable wear protection is of
19
19 Pneumatic transport ABRESIST particular importance for
20
20 Silos ABRESIST, KALEN* trouble-free continuous ABRESIST fused cast basalt
operation of the coal injection. is the accepted standard for
21
21 Mixers ABRESIST, KALMETALL-W
These PF-bends are made piping in wet ash pipe systems
22
22 Gypsum Stores (silos, bunkers) ABRESIST, KALEN* of plates with hard all over the world. The picture
overlay welding. shows a plant in India.
2 3 4
kalpraxis Wear Protection in
Coal fired Power Plants kalpraxis Wear Protection in
Coal fired Power Plants

Pipes, Components and Service Coal Handling, Coal Pulverizing ...
Coal transfer equipment is protected with ABRESIST
fused cast basalt or KALOCER high alumina
ceramics (example: Philippines)
... to Coal Injection
Time-tested wear protection
material for separators set up
in coal pulverizing systems is
ABRESIST fused cast basalt with
references all over the world

Separators are frequently protected by

Impact coal pulverizers operate in lignite fired KALMETALL-W hard overlay welding or by
power plants; the impact plates have been lined KALCRET hard compound (pictures) installed
with KALMETALL-W 100 without joints

Wear protection for hydraulic Extended service life of Kalenborn Service solves
and pneumatic pipes plant components wear problems on site

Optimal Solution for Wear Protected Components

Every Plant Component
Components Lining Material
Plant components are at risk in all power plant
systems, especially in coal storage and coal Cyclones ABRESIST, KALCOR, KALOCER,
transport. This includes coal pulverizing and KALSICA, KALMETALL-W
injection into the boiler, dust collection and Fan housings KALOCER, KALCRET,
ash removal including fly ash and wet ash. KALMETALL-W, KALMETALL- C
The situation is similar for limestone and Fan rotors KALOCER, KALMETALL-W
gypsum in desulphurization systems.
Gates KALOCER, KALCOR, KALSICA,
Service lifetimes of many years are often KALMETALL-W, KALCRET
achieved with the following materials: Hydraulic ABRESIST, KALCOR, KALOCER,
conveyors KALCRET
n ABRESIST fused cast basalt
n KALCOR zirconium corundum Mechanical ABRESIST, KALOCER, KALCRET,
conveyors KALMETALL-W, KALMETALL-C
n KALCOR-S sintered zirconium corundum Pulverized coal burner Weight saving design of
n KALOCER high alumina ceramics Nozzles KALOCER, KALSICA made with plates of a separator cage with
Kalenborn also supply grinding rolls and grinding KALMETALL-W 100 hard KALSICA-A silicon
n KALCRET hard compound Pneumatic ABRESIST, KALCOR, KALOCER, tables for coal pulverizing; the picture on the left overlay welding ready carbide ceramics;
conveyors KALCRET, KALMETALL-C, KALMETALL-W shows regeneration of a worn grinding roll with
n KALSICA silicon carbide ceramics for installation alternative linings are
KALMETALL-W 100; the cast grinding roll made of KALMETALL-W and
n KALMETALL-C hard casting Pumps KALSICA
KALMETALL-C 155 on the right is a new piece KALOCER mosaics
n KALMETALL-W hard overlay welding Separators ABRESIST, KALCOR, KALOCER, (both have a diameter of 1,500 mm)
KALSICA, KALMETALL-W
n KALINOX slide promotion steel
n KALEN slide promotion plastics Transfer ABRESIST, KALOCER,
stations KALMETALL-W Coal bunkers lined with
In addition, material combinations have been KALEN slide promotion
Valves KALOCER
very successful in practice. They enable both and fittings plastics ensure a reliable Housing of a pulverized coal fan protected with
technically and economically optimal solutions. material flow KALMETALL-W 100; the diameter is 2,600 mm
5 6 7
kalpraxis Wear Protection in
Coal fired Power Plants kalpraxis Wear Protection in
Coal fired Power Plants

Pipes, Components and Service Coal Handling, Coal Pulverizing ...
Coal transfer equipment is protected with ABRESIST
fused cast basalt or KALOCER high alumina
ceramics (example: Philippines)
... to Coal Injection
Time-tested wear protection
material for separators set up
in coal pulverizing systems is
ABRESIST fused cast basalt with
references all over the world

Separators are frequently protected by

Impact coal pulverizers operate in lignite fired KALMETALL-W hard overlay welding or by
power plants; the impact plates have been lined KALCRET hard compound (pictures) installed
with KALMETALL-W 100 without joints

Wear protection for hydraulic Extended service life of Kalenborn Service solves
and pneumatic pipes plant components wear problems on site

Optimal Solution for Wear Protected Components

Every Plant Component
Components Lining Material
Plant components are at risk in all power plant
systems, especially in coal storage and coal Cyclones ABRESIST, KALCOR, KALOCER,
transport. This includes coal pulverizing and KALSICA, KALMETALL-W
injection into the boiler, dust collection and Fan housings KALOCER, KALCRET,
ash removal including fly ash and wet ash. KALMETALL-W, KALMETALL- C
The situation is similar for limestone and Fan rotors KALOCER, KALMETALL-W
gypsum in desulphurization systems.
Gates KALOCER, KALCOR, KALSICA,
Service lifetimes of many years are often KALMETALL-W, KALCRET
achieved with the following materials: Hydraulic ABRESIST, KALCOR, KALOCER,
conveyors KALCRET
n ABRESIST fused cast basalt
n KALCOR zirconium corundum Mechanical ABRESIST, KALOCER, KALCRET,
conveyors KALMETALL-W, KALMETALL-C
n KALCOR-S sintered zirconium corundum Pulverized coal burner Weight saving design of
n KALOCER high alumina ceramics Nozzles KALOCER, KALSICA made with plates of a separator cage with
Kalenborn also supply grinding rolls and grinding KALMETALL-W 100 hard KALSICA-A silicon
n KALCRET hard compound Pneumatic ABRESIST, KALCOR, KALOCER, tables for coal pulverizing; the picture on the left overlay welding ready carbide ceramics;
conveyors KALCRET, KALMETALL-C, KALMETALL-W shows regeneration of a worn grinding roll with
n KALSICA silicon carbide ceramics for installation alternative linings are
KALMETALL-W 100; the cast grinding roll made of KALMETALL-W and
n KALMETALL-C hard casting Pumps KALSICA
KALMETALL-C 155 on the right is a new piece KALOCER mosaics
n KALMETALL-W hard overlay welding Separators ABRESIST, KALCOR, KALOCER, (both have a diameter of 1,500 mm)
KALSICA, KALMETALL-W
n KALINOX slide promotion steel
n KALEN slide promotion plastics Transfer ABRESIST, KALOCER,
stations KALMETALL-W Coal bunkers lined with
In addition, material combinations have been KALEN slide promotion
Valves KALOCER
very successful in practice. They enable both and fittings plastics ensure a reliable Housing of a pulverized coal fan protected with
technically and economically optimal solutions. material flow KALMETALL-W 100; the diameter is 2,600 mm
5 6 7
kalpraxis Wear Protection in
Coal fired Power Plants kalpraxis Wear Protection in
Coal fired Power Plants

Pipes, Components and Service Coal Handling, Coal Pulverizing ...
Coal transfer equipment is protected with ABRESIST
fused cast basalt or KALOCER high alumina
ceramics (example: Philippines)
... to Coal Injection
Time-tested wear protection
material for separators set up
in coal pulverizing systems is
ABRESIST fused cast basalt with
references all over the world

Separators are frequently protected by

Impact coal pulverizers operate in lignite fired KALMETALL-W hard overlay welding or by
power plants; the impact plates have been lined KALCRET hard compound (pictures) installed
with KALMETALL-W 100 without joints

Wear protection for hydraulic Extended service life of Kalenborn Service solves
and pneumatic pipes plant components wear problems on site

Optimal Solution for Wear Protected Components

Every Plant Component
Components Lining Material
Plant components are at risk in all power plant
systems, especially in coal storage and coal Cyclones ABRESIST, KALCOR, KALOCER,
transport. This includes coal pulverizing and KALSICA, KALMETALL-W
injection into the boiler, dust collection and Fan housings KALOCER, KALCRET,
ash removal including fly ash and wet ash. KALMETALL-W, KALMETALL- C
The situation is similar for limestone and Fan rotors KALOCER, KALMETALL-W
gypsum in desulphurization systems.
Gates KALOCER, KALCOR, KALSICA,
Service lifetimes of many years are often KALMETALL-W, KALCRET
achieved with the following materials: Hydraulic ABRESIST, KALCOR, KALOCER,
conveyors KALCRET
n ABRESIST fused cast basalt
n KALCOR zirconium corundum Mechanical ABRESIST, KALOCER, KALCRET,
conveyors KALMETALL-W, KALMETALL-C
n KALCOR-S sintered zirconium corundum Pulverized coal burner Weight saving design of
n KALOCER high alumina ceramics Nozzles KALOCER, KALSICA made with plates of a separator cage with
Kalenborn also supply grinding rolls and grinding KALMETALL-W 100 hard KALSICA-A silicon
n KALCRET hard compound Pneumatic ABRESIST, KALCOR, KALOCER, tables for coal pulverizing; the picture on the left overlay welding ready carbide ceramics;
conveyors KALCRET, KALMETALL-C, KALMETALL-W shows regeneration of a worn grinding roll with
n KALSICA silicon carbide ceramics for installation alternative linings are
KALMETALL-W 100; the cast grinding roll made of KALMETALL-W and
n KALMETALL-C hard casting Pumps KALSICA
KALMETALL-C 155 on the right is a new piece KALOCER mosaics
n KALMETALL-W hard overlay welding Separators ABRESIST, KALCOR, KALOCER, (both have a diameter of 1,500 mm)
KALSICA, KALMETALL-W
n KALINOX slide promotion steel
n KALEN slide promotion plastics Transfer ABRESIST, KALOCER,
stations KALMETALL-W Coal bunkers lined with
In addition, material combinations have been KALEN slide promotion
Valves KALOCER
very successful in practice. They enable both and fittings plastics ensure a reliable Housing of a pulverized coal fan protected with
technically and economically optimal solutions. material flow KALMETALL-W 100; the diameter is 2,600 mm
5 6 7
 kalpraxis Wear Protection in
Coal fired Power Plants

Solutions for Pulverized Fuel Transport

Kalenborn have extensive experi-

ence and offer a complete range of
solutions for PF-pipe. With diame-
ters between 400 and 800 mm
many possible combination linings
have been used in practice.
Depending on the specific opera-
ting conditions (such as particle
size, ash portion, volume to be
conveyed and transport velocity)
successful designs have achieved
service lifetimes of more than
10 years.
Jointless lining with KALCRET Material combinations of KALCOR
hard compound - also possible and ABRESIST provide economic
with asymmetric cross section wear solutions

Lining of a PF-pipe with KALCOR zirconium corundum lining and unlined transition elements;
KALMETALL-C 488 mm diameter

KALCOR-S allows the use of large Long lifetimes at favorable costs are achieved with KALMETALL-C hard
lining segments, thin walls and casting; this example shows 518 mm diameter bends up to 700 kg weight
homogeneous structure
8
KALMETALL-W hard overlay welding enables the production of self- Typical solution for PF-bends:
supporting structures for PF-bends without an additional lining pipe-bricks made of KALOCER
high alumina ceramics

PF-distribution boxes protected with KALCOR for large area lining and PF-distributor made of KALSICA-N
KALOCER to ensure maximum wear resistance silicon carbide ceramics

Reflectors of PF-burners protected PF-burner lined with

by KALSICA-N (photo) or KALMETALL-W
KALMETALL-W
9
 kalpraxis Wear Protection in
Coal fired Power Plants

Ash Handling and Flue-Gas Desulphurization

Solution adopted
for economizer
tubes to handle
large dust
quantities: tube
protecting
shapes made of
KALSICA silicon
carbide ceramics

When particularly
high dust loads
occur, the waste
gas ducts are
protected by
KALCRET hard
compound or
KALMETALL-W
hard overlay
welding

Chain conveyors for wet ash removal are efficiently

lined with ABRESIST fused cast basalt; KALCOR,
KALOCER or KALMETALL-W can be used as well

Time-tested materials for fly ash Limestone may have a very Sticky FGD gypsum is stored in
pipes: ABRESIST, KALCOR or abrasive effect on FGD systems; a bunkers; KALEN slide promotion
KALOCER typical lining material is ABRESIST plastics ensure trouble-free discharge
10
Specialist in Wet Ash Pipes

In the last 50 years Kalenborn

have supplied many thousands of
meters of wet ash pipes to plants
all over the world, normally lined
with ABRESIST fused cast basalt.
This material has proven to be an
excellent choice for this particular
application.
ABRESIST combines the proper-
ties of high wear resistance and
high corrosion resistance. The
service lifetimes of these piping
systems frequently cover more
than 20 years. There is no other
material that has reached similar
service lives in practice.
Wet ash pipe in North
Kalenborn offer wet ash pipes of America; the pipes are
many different configurations with flanged together
inside diameters between 200
and 500 mm. The steel casing
can also be efficiently protected
against corrosion.
The pipes are usually joined by
flanges. However, any type of
coupling is feasible. In addition,
welded and screwed joints have
proven successful in practice. Pipes in Australia;
the pipes are
connected by
"Victaulic"
couplings

Erection of wet ash pipes in Long pipes require the use of Pipe for several units running to
Malaysia (350 mm diameter) expansion joints for compen- the central disposal site in Brasil
sation of length
11
 kalpraxis Materials at a Glance

Wear Resistant Linings

Lining Material Hardness Process Parameters Remarks
Mohs(1) Vickers Max. con- Material Max. Thermal Impact
HV (2) veying volocity density temperature (3) shock wear
m/sec g/cm C F resistance resistance

KALSICA-S silicon 9.3 (2,300) 35 >3.0 1,000 1,832 ++++ ++ For extreme
carbide ceramics applications

KALOCER high 9.1 (2,100) >30 >3.0 350 662 0 + Standard tiles, thin
alumina ceramics wall cylinders and tiles

KALCOR zirconium 9 (2,000) >30 >3.0 800 1,472 ++ ++ Large tiles, shaped
corundum elements, great wall
thickness

KALSICA-N silicon 8.8 (1,800) >25 >3.0 1,000 1,832 +++ + Good temperature
carbide ceramics resistance/thermal
shock resistance

KALCOR-S sintered 8.5 (1,600) >25 800 1,472 +++ ++ Economic KALCOR
zirconium corundum

KALCRET-B 8.1 (1,250) 22 3.0 800 1,472 +++ + Supplied in bags,

hard compound no joints, high
temperatures

ABRESIST 8 (1,140) 22 3.0 350 662 0 + Flow volumes

fused cast basalt up to 3.0 g/cm,
up to 22 m/sec,
limited temperatures

KALMETALL-W 100 (7.5) 700 20 - 350 662 ++ ++ Impact resistant,

hard overlay welding low weight

KALMETALL-C (7.2) 580 20 - 350 662 ++ +++ Impact resistant,

hard casting economic in case
of large quantities

KALCERAM 6 (500) - - 350 662 0 + Bunker lining,

hard ceramics 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 Linings

Lining Slide Promotion Max. Temp. Wear Resistance Remarks
C F

KALEN slide +++++ 80 176 + No corrosion, very smooth

promotion plastics surface, low weight
KALINOX slide +++ 550 1,022 ++ Slide promotion in case both sliding
promotion steel wear and sticking problems exist
KALCERAM +++ 350 662 +++ Slide promotion and more
hard ceramics efficient wear protection
ABRESIST +++ 350 662 ++++ Good material flow in case of
fused cast basalt hard, abrasive conveyed material

12
Proven Kalenborn Offerings

ABRESIST KALMETALL-W hard

fused cast basalt overlay welding
Mineral protection made of Tough basic body and hard
cast basalt to protect overlay welding with primary
against abrasive wear. chromium carbides.
Advantages: high wear Advantages: highly wear resistant,
resistance, permanent smooth good resistance against impact
surface, no corrosion. wear, self-supporting structures.

KALCOR KALMETALL-C
zirconium corundum hard casting
Cast or sintered material made Different materials characterized
of alumina and zirconia oxide. by corresponding resistance
against abrasion and impact
Advantages: high wear
wear.
resistance, resistant against
high temperatures, corrosion Advantages: alloy matched to the
resistant. specific application, of advantage
in case of larger quantities.

KALOCER KALCRET
high alumina ceramics hard compound
Special oxide ceramics for plant Cement bonded compound for
components subject to extreme jointless protection to be trowelled,
wear. cast or sprayed-on.
Advantages: high wear resistance, Advantages: high wear resistance
permanent smooth surface, and compressive strength,
no corrosion. jointless, temperature resistant.

KALSICA silicon KALEN slide

carbide ceramics promotion plastics
Suitable for plant components Range of different polyethylene
that are exposed to extreme wear (PE) and polyurethane (PU)
and/or high temperatures. materials.
Advantages: highly wear resistant, Advantages: good durability,
resistant against thermal shocks free of corrosion, smooth surface.
and producible with narrow
dimensional tolerances.

Advantages of Lining Materials

Ceramic wear protection Plastic lining

n very good abrasion resistance n excellent slide promotion
n tile, cylindrical or jointless lining n good resistance against impact wear
n temperatures up to 1,000 C / 1,832 F n low weight

Metallic wear protection Material combinations

n good resistance against sliding and impact wear n optimal wear protection for every application
n thin walls, self-supporting structures n optimized lining cost
n good thermal shock resistance n optimized weight

13
kalpraxis Wear Protection in
Coal fired Power Plants

Optimal Solution for all Requirements

Kalenborn supply wear protected plant components.

In addition we provide for regeneration of worn
components - here a grinding table of a coal pulverizer.

Material combinations allow

safe and economic operation
of PF-pipes. Here a combination
of KALCOR zirconium corundum
and KALOCER high alumina
ceramics.

Reliable protection of pipe.

ABRESIST fused cast basalt as
time-tested solution for the
transport of wet ash in the USA
(250 mm diameter).

Ask Kalenborn for further information Kalenborn Kalprotect -

Dr. Mauritz GmbH & Co. KG
KRAFTWERKE GB 2 000 WA-GAE/PE by Kalenborn 2006 04/25

Asbacher Strasse 50
D-53560 Vettelschoss
Germany
Phone +49.(0) 2645.18-0
Fax +49.(0) 2645.18-180 (Export)
kalenborn@kalenborn.de
www.kalenborn.de

Photo cover page: Power station Voerde STEAG, Essen

KALENBORN, ABRESIST, KALCOR, KALOCER, KALSICA, KALCRET, KALMETALL, KALINOX and KALEN are trademarks of Kalenborn.
This brochure and other technical information are general only. They do not cover any guarantee with legal effect. Technical changes and errors are reserved.