Project Overview
In December 2020, Gia Anh Investment Trading Co., Ltd. carried out a wear protection project for the cement mill at VICEM Tam Diep Cement Plant. The main treatment areas were the mill housing and separator cone.
The cement mill grinds clinker into cement before product dispatch. During the site inspection, GAC identified wear on the mill housing and separator cone from operation.
If not addressed in time, the wear could continue to progress, potentially resulting in perforation of the mill housing and reduced operating capacity. Based on the site inspection, GAC developed a wear protection solution using KALCRET hard compound for the affected areas.
Customer challenges
Wear of the mill housing lining
The site inspection identified wear on the mill housing lining during mill operation
Separator cone wear
Wear was also identified on the separator cone, requiring the implementation of a wear protection solution
Risk of mill housing perforation
Without proper wear protection, continued wear could lead to mill housing perforation during operation
Impact on grinding capacity
Continued wear could cause mill housing perforation and reduce grinding capacity
CURRENT CONDITION OF THE MILL SHELL AND SEPARATOR CONE
Wear was observed on the mill shell liner and the separator cone
Project Objectives
PROTECT THE WEAR-PRONE AREAS
Implement a wear protection solution for the mill housing and separator cone, where wear had been identified during operation
MINIMIZE MILL HOUSING PERFORATION RISK
Use KALCRET hard compound to provide wear protection in the affected areas, minimizing the risk of further wear progression and mill housing perforation
MAINTAIN STABLE OPERATION
Address worn areas to minimize mill housing perforation risk and its impact on grinding capacity during operation
Project execution process
Site condition assessment
Inspect the mill housing and separator cone to identify and document areas affected by wear
Risk assessment
Assess the risk of further wear progression leading to mill housing perforation and reduced grinding capacity during operation
Develop the wear protection plan
Develop a solution using KALCRET hard compound to protect the wear-prone areas
Surface preparation
Prepare and clean the surfaces in the treatment areas before applying the wear protection lining
Weld steel mesh and apply KALCRET
Weld steel mesh in the treatment areas, then apply the KALCRET hard compound lining to the prepared surfaces
Finishing and handover
Complete the treated areas and hand over the equipment in accordance with safety and quality requirements
Project results
COMPLETED WEAR PROTECTION IN THE TREATMENT AREAS
GAC completed the wear protection work on the mill housing and separator cone according to the project scope
COMPLETED KALCRET LINING
The worn areas were surface-prepared, fitted with welded steel mesh, and lined with KALCRET hard compound
HANDOVER IN COMPLIANCE WITH SAFETY AND QUALITY REQUIREMENTS
GAC completed the treatment work and handed over the equipment in accordance with safety and quality requirements
“We highly appreciate Gia Anh’s professionalism and ability to meet the project schedule. The KALCRET cast lining solution has helped improve the operational reliability of the ore conveying pipeline system at Dung Quat while significantly reducing annual maintenance costs. Completing the delivery 20 days ahead of schedule was a highly commendable achievement.”
Ms. Tran Thi Hoa
Project Management Board - VICEM TAM DIEP
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