Project Overview
In November 2019, Gia Anh Investment Trading Co., Ltd. carried out a new cement mill installation project at VICEM Hoang Thach Cement Plant. The wear protection work focused on the mill separator system
The scope of work covered two groups of areas: the mill housing and separator cone; and the mill outlet area. An appropriate wear protection solution was applied to each group according to the project requirements.
For the mill housing and separator cone, GAC used 13 × 100 × 100 mm Kalocer wear-resistant ceramic with a hardness of 2,100 HV. The ceramic was bonded to the steel shell using Kalfix E20 (E21+E22) specialized adhesive in combination with welded steel retaining rings.
At the mill outlet area, Kalcret hard compound was used as the wear protection solution. The installation was carried out by skilled, properly trained workers under the direct supervision of Kalenborn and GAC engineers.
Customer challenges
Multiple areas requiring wear protection
The wear protection scope covered the mill housing, separator cone, and mill outlet area
Material selection for each location
Kalocer wear-resistant ceramic was used for the mill housing and separator cone, while Kalcret hard compound was used for the mill outlet area
Bonding ceramic to the steel substrate
Kalocer ceramic was bonded to the steel shell using Kalfix E20 (E21+E22) specialized adhesive in combination with welded steel retaining rings
Workforce and supervision requirements
The installation was carried out by skilled, properly trained personnel under the direct supervision of Kalenborn and GAC engineers
MILL SEPARATOR SYSTEM
The wear protection scope included the mill housing, separator cone, and mill outlet
Project Objectives
MAIN WEAR PROTECTION AREAS
Complete the protective lining for the mill housing–separator cone assembly and the mill outlet area
MATERIAL SELECTION BY AREA
Use Kalocer wear-resistant ceramic for the mill housing and separator cone, and Kalcret compound for the mill outlet
KALOCER CERAMIC HARDNESS
Install 13 × 100 × 100 mm Kalocer ceramic with high hardness, using a suitable bonding system for the steel substrate
Project execution process
Define the scope of work
Define the wear protection scope covering the mill housing, separator cone, and mill outlet area
Select the material solution for each area
Use Kalocer ceramic for the mill housing and separator cone, and Kalcret hard compound for the mill outlet area
Bond the Kalocer ceramic
Bond the Kalocer ceramic to the steel shell using Kalfix E20 (E21+E22) specialized adhesive in combination with welded steel retaining rings
Install the Kalocer lining
Install the Kalocer wear-resistant ceramic lining on the mill housing and separator cone
Apply Kalcret at the mill outlet
Apply Kalcret hard compound to the mill outlet area
Organize and supervise the installation
Carry out the installation with skilled, properly trained workers under the direct supervision of Kalenborn and GAC engineers
Project results
COMPLETED WEAR PROTECTION IN TWO MAIN AREAS
GAC completed the protective lining solutions for the mill housing, separator cone, and mill outlet area
COMPLETED KALOCER CERAMIC LINING
The mill housing and separator cone were lined with Kalocer ceramic with a hardness of 2,100 HV, bonded to the steel substrate using Kalfix E20 (E21+E22) adhesive in combination with welded steel retaining rings
COMPLETED KALCRET PROTECTIVE LINING
Kalcret hard compound was applied to the mill outlet area as the wear protection material
“Along the same raw material handling line, some locations are exposed to direct impact, while others mainly experience sliding wear or erosion. GIA ANH worked with our technical team to inspect these locations, analyse the wear mechanisms and recommend suitable materials. Technical specifications and the scope of application were clearly discussed, making it easier for us to assess material options before implementation.”
Mr. Hong Diep Vu
Deputy General Director - VICEM Hoang Thach Cement
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