Project Overview
In January 2021, Gia Anh Investment Trading Co., Ltd. collaborated with Kalenborn to implement a wear protection solution for the coal mill separator guide vanes at VICEM Hai Phong Cement Plant. The solution used Kalocer wear-resistant ceramic combined with a steel backing.
The separator vanes had previously been fabricated from UPX composite steel. After approximately 3–4 months of operation, wear began to develop along the outer edges of the vanes and progressively advanced inward.
If not replaced or protected in time, the vanes could become completely worn, reducing the coal feed rate to the kiln and affecting the plant’s production operations.
Following the site inspection, GAC and Kalenborn developed a solution combining a steel backing with Kalocer wear-resistant ceramic to protect the separator guide vanes and extend their service life. The ceramic installation was carried out step by step in accordance with Kalenborn’s recommendations. Upon completion, the finished components met the specified technical requirements, with the ceramic and adhesive securely bonded to the steel backing.
Customer challenges
Outer edge wear after 3–4 months
After approximately 3–4 months of operation, wear had developed along the outer edges of the UPX composite steel separator guide vanes
Wear continues to progress inward
Wear started at the outer edges and continued to progress inward into the vanes
Risk of complete vane wear
If not addressed in time, the wear could continue to spread and eventually affect the entire separator vane
Reduced coal feed to kiln
If the vanes become fully worn, the coal feed rate to the kiln may decrease, potentially affecting plant production
CURRENT CONDITION OF THE STATIC SEPARATOR VANES
Wear appeared along the outer edge of the static separator vanes after 3–4 months of operation
Project Objectives
PROTECT THE WEAR-EXPOSED VANE EDGE
Enhance protection of the outer-edge areas where wear develops during operation and tends to progress further inward
COMBINE STEEL AND KALOCER CERAMIC
Combine the steel backing with Kalocer wear-resistant ceramic to improve wear protection and extend the service life of the separator guide vanes
MINIMIZE THE IMPACT ON CAPACITY
Minimize the risk of complete vane wear to prevent a reduction in the coal feed rate to the kiln and its impact on production operations
Project execution process
Site inspection
GAC and Kalenborn jointly inspected the separator guide vanes and identified wear along their outer edges
Wear condition assessment
Determine that wear had developed along the outer edges and begun to progress inward into the vanes
Develop the wear protection plan
GAC and Kalenborn developed a solution combining a steel backing with Kalocer wear-resistant ceramic
Prepare the steel backing to specification
Prepare the vane and steel backing surfaces to the required geometry, dimensions, and technical specifications
Install Kalocer ceramics
The ceramic bonding process was carried out strictly in accordance with the step-by-step procedure recommended by Kalenborn
Inspect and finish the component
Check the dimensional accuracy of the vane and the bonding quality between the ceramic, adhesive, and steel before final completion
Project results
COMPLETED STEEL–KALOCER CERAMIC SOLUTION
GAC completed the solution combining a steel backing with Kalocer wear-resistant ceramic for the coal mill separator guide vanes
MEETS THE REQUIRED TECHNICAL SPECIFICATIONS
The finished components met the specified dimensional and technical requirements for the separator guide vanes
SECURE CERAMIC–ADHESIVE–STEEL BOND
The ceramic and adhesive were securely bonded to the steel backing to minimize the risk of delamination during operation
“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. Nguyen Thi Linh
Project Management Board - VICEM Hai Phong
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