Abrasion Resistant Linings for Production and Conveying Systems

The Wear Protection People

01.06

The High Cost of Abrasion

Material Replacements, extra Labor and Lost Production can be Avoided

The problem of abrasion is known to almost everyone involved in the transportation and processing of bulk material. The protection of production systems against abrasion is a top priority. This applies to the economy as a whole as well as to each individual plant. Suitably protected systems will significantly reduce operating costs and contribute to the preservation of valuable resources. A typical phenomenon of transportation and processing of bulk materials is continual abrasion. Quite often these problems are accepted as unavoidable. Frequently, repairs made by substituting original plant components with thicker replacements or slightly better grades of similar material, at a higher cost, are considered remedies. However, in most cases these substitutions often wear out in little more time than the originals. Unscheduled shutdowns, pollution of the plant and environment and heavy expenses for materials and labor usually result from this approach.

These practices are eliminated in plants where economical and reliable operation is the goal and unplanned outages are not acceptable. It is better to design the plant and system components for long term dependable service.

This brochure will provide you with information on important aspects of abrasion protection. It will outline various possibilities for optimum plant utilization and cost savings through the use of abrasion resistant linings.

Simple Solutions Usually dont Last

The highest cost in many situations is the lost production time due to unplanned outages. The money saved by using low cost steel components can result in a much higher cost later. Abrasion resistant pipes and plant components save money as repair frequency is greatly reduced and production time is increased. In some instances, a single avoided repair will pay for the added abrasion protection.

The transport of bulk materials in many basic industries, e.g. coalfired power stations, is associated with heavy wear of the system components. Not only is the original equipment investment lost, plant shutdowns and production loss combine to destroy the capital base of the company. This is unacceptable in view of competitive pressure on the world markets. The solution to this problem is reliable abrasion protection. Of vital importance is the selection of the appropriate material and its correct application.

Critical areas subject to abrasive failure exist in any plant transporting or processing bulk materials. Even materials that appear harmless are often abrasive since the quantities and velocities in which they are transported can destroy a system component quickly.

Welded-on boxes filled with concrete cause increased turbulence as they wear, leading to more severe abrasion and loss of efficiency.

Abrasion is Found in Every Industry

Critical Zones in Production and Conveying Systems

The processing of solid bulk materials will almost always produce wear. In aluminum as well as in sugar plants. In waste treatment as well as in cement production. The system components affected by wear are very similar. The definition of abrasion is the progressive material loss from the surface of a solid body generated by mechanical causes, i.e. by the contact with and relative movement of another solid, liquid or gaseous body. This rather theoretical definition is found in many forms in actual practice. A variety of materials and differences in processing result in most diverse abrasion problems. Hardness and sharpness of the conveyed material, conveying velocity and angle of impact are important factors. Additionally, stress generated by corrosion, high temperature or thermal shock can be critical. All wear problems are different and require individual solutions based on scientific elements and practical experience. This is the starting point in realizing the savings offered in most plants with the proper utilization of abrasion resistant linings.

Typical system components with wear protection linings.

Operating Limitations

Many times production systems have to handle additional capacity. Here, a dust-collecting pipe for clinker dust means additional workload for the cyclones. Even with the increased workload, the cement plant management expects continuous safe operation of the plant. The wear protection offered in this area has stood the test of time.

Reducing Wear with a Cushion of Material being Transported

Practice has shown that this method has serveral drawbacks: to ensure that the material continues to slide, steeper angles and greater constructional heights are almost always required compared to the smooth surface of a lined component. Whenever the material being transported is changed, the system must be cleaned manually. Quite often these cushions are associated with an undesirable breaking up of the grains of the materials transported or by non-uniform material flow.

Corrosion and Wear

Steel structures handling dry materials suffer mainly from abrasion. But, in systems where wet materials are conveyed, corrosion will be an additional factor. Compared with the apparently smooth surface, the effect of corrosion is predominantly in the microscopic range. Continual mechanical abrasion removes the protective oxide layer on the steel, creating a surface of high reactivity which is ideal for increased material loss. This will especially be the case in plants which process ash, ore, lime, coal, coke, waste, sand, salt, slag, cement or the like in large quantities.

Design Solutions
It is possible to reduce wear problems with design and process solutions. For example, by changing the system configuration, cushioning of the material conveyed, by altering the flow velocity and similar measures. Quite often these solutions are limited by unavoidable obstacles and required process conditions. The reduction of the conveying velocity is practical only in rare cases. It is usually more important to increase the productivity with the same system technology and to accept the resulting higher wear rates.

We Solve Wear Problems in Plant Components and Pipes

The large rocks handled in quarries and mines arent the only problems for conveying and processing systems. In modern process plants, characterized by high throughput rates and conveying velocities, even apparently harmless materials cause significant wear. Here is a list of typical abrasion problem components:

To achieve both technical and economical wear protection, many factors have to be taken into account. The choice needs to be based on the application. The best solution for long life and economical abrasion protection depends upon the proper selection of the lining material as well as the knowledge of expected cost. Abresist Corporation has lining materials that include a wide range of individual characteristics:
ABRESIST ALRESIST KALCOR KALSICA KALCRET KALMETALL

augers ash pipelines belt discharge chutes bunker spirals bunkers channels chutes circulating air separators continuous-flow conveyors cyclones dissolving tanks diverter valves drying sections dust collecting equipment dust collecting pipes fan blades fan casings flue-gas ducts flumes gravel release tunnels hoppers of rotary dryers hydrocyclones launders

manifolds mixer troughs pipe bends pipes pneumatic backfill lines prilling tower bottoms pulpers receivers rotary valves screw conveyor troughs scrubbers separators settling basins shaft spirals sifters silos sinter troughs tailings lines tanks thickeners tubular chain conveyors turbo separators vibrating troughs washing drums

Materials to Reduce Repair

Abrasive wear occurs when hard and sharp edged bulk materials are moved. But, the material to be conveyed cannot be altered to reduce the problem. Therefore, protective measures have to be implemented for the protection of the system components. A wide range of materials with varying characteristics is available to protect against wear. Linings made of mineral, ceramic or metallic materials have proven to work well.

Clear Advantages
long lifetime maintenance free operation no operation interruption no production losses no contamination of the

Which Material to use?

Wear protection should be matched to each application. The better the material and lining are adapted to the specific problem the more durable and economical the solution. Which material will be most suitable is determined after all influencing factors are known. There is no magic formula, but decisions are based on knowledge gained through 80 years of practical experience by Abresist Corporation and Kalenborn Kalprotect, the German parent company.

conveyed materials/products due to abrasion, mixture or oxidation

physiologically harmless,

suitable for food products

smooth surface to enhance

flow properties and avoid plugs

reduced pressure losses

and lower energy costs

no spilled material

to clean up

Principles of Wear-Protected System Components

Steel casing

Reduced pressure losses and low energy cost

Abrasion resistant lining in zones of turbulences

Good flow properties due to smooth surface that lasts

ABRESIST Linings
Wear Resistant Fused Cast Basalt for Friction Induced Abrasion

ABRESIST fused cast basalt has been used successfully for years for wear protection up to temperatures of approximately 350 C / 662 F. For the production of ABRESIST, selected basalt is melted and cast into molds, then carefully annealed. Due to the casting process, precise linings can be produced. ABRESIST has an extremely hard and smooth surface. The material is corrosion resistant to most acids and alkalis. This makes ABRESIST very effective for systems where abrasion and corrosion occur together.

The idea to melt stone is age-old. However, the melting of basalt started with lab tests only at the beginning of the last century. The development was not succesful beyond the lab stage because of crystallization problems and inadequate application tests. However, by the mid-twenties ABRESIST was successfully produced as an abrasion resistant material based on basalt. Today, under the trade name ABRESIST, fused cast basalt has become a proven product.

ABRESIST
Fused cast basalt is a mineral based wear protection material for plant components when the conveying material produces friction induced abrasion. Installation: shaped components are normally installed in cement mortar. In special cases epoxies or synthetic mortars may be used due to strong mechanical stresses and/or vibration. Where higher temperatures are concerned, potassium silicate mortar may be used for installation. Mechanical fixing is also possible. Application temperature: up to 350 C / 662 F depending on application and geometry. Advantage: highly abrasion resistant, smooth surface that lasts, no corrosion.

ABRESIST linings have been in service for more than 30 years on all continents.

Cyclones and separators are among the system components which are subject to particularly heavy wear. Repairs are expensive because of the frequently difficult installation locations. The cyclone inlets are exposed to especially heavy wear because the material hits them at high velocity. Even inlets made from manganese steel often withstand these heavy attacks for only a short period. Often, the conical components and inlet ducts require efficient protection as well. Apart from ABRESIST, combined linings with other wear resistant materials have proved succesful.

Hopper in a large German blast furnace plant.

Waste paper is recycled in pulpers which are like giant mixers. The bales contain abrasive impurities, but the pulper bottom is durably protected with ABRESIST. ABRESIST lining in an air separator.

ABRESIST Linings

Submerged drag-chain conveyors for wet ash removal in a coal-fired power plant. Drains cast into the lining reduce the amount of water carried to the discharge zone thereby lowering the water consumption rate.

ABRESIST wear protection for a cyclone in the cement industry. The corrugated wire mesh fastened to the steel surface provides reliable attachment. Temperatures above approximately 250 C / 482 F require the use of potassium silicate based mortar for installation.

Flumes and hoppers of any shape can be lined with abrasion resistant ABRESIST.
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Skid tiles made of ABRESIST fused cast basalt are well proven for test tracks in the automobile and tire industries world wide. These installations have improved the safety of car traffic significantly. Abresist Corporation can supply skid tiles in different shapes, unpolished as well as high grade polished. The references cover installations in Europe, the US and the Far East.

Since the times of Archimedes, screw conveyors have been used for pumping water. Solids entrained by wastewater are a heavy burden for this screw and trough. In concrete and steel troughs, abrasion increases the annular gap until the conveying capacity of the screw reaches almost zero. This situation is prevented by using ABRESIST. The ABRESIST lining takes into consideration the bending of long conveying screws.

Natural surface (right) and polished surface (left).

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ALRESIST Linings
Abrasion and Temperature Resistant High Alumina Ceramics

ALRESIST is a member of the oxide family of ceramics, with the main component aluminium oxide. Extremely high abrasion resistance is achieved by careful selection of the particle size and distribution. Most tiles are formed by pressing a dry powder of the ceramic. Machining of ceramic prior to kiln firing allows the manufacture of components with geometrically difficult shapes. ALRESIST can be manufactured in very thin tiles. This is an advantage when existing plant components have to be lined and space or weight are of critical importance.

ALRESIST Advantages
Highly wear resistant, smooth surface that lasts, no corrosion, available in various thicknesses.

ALRESIST
Special high alumina ceramics for plant components with extreme wear and / or temperature conditions, for thin linings or for smooth surfaces. Installation: pipes, shaped components, or thin tiles are laid in epoxy mortar, RTV or attachment using KALBOND. ALRESIST tiles can be vulcanized into rubber mats for installation by gluing. Mechanical fixing by welding is also common. Application temperature: up to 1000 C / 1832 F depending on application and geometry.

Thin ALRESIST tiles are laid in epoxy mortar. Attachment using KALBOND or silicone RTV is also possible.

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Lining of a cyclone handling diatomaceous earth with 6 mm ALRESIST tiles installed in high temperature epoxy resistant up to 180 C / 356 F. 50 mm thick ALRESIST shaped elements withstand the coarsegrained ore, coke and limestone charging a blast furnace.

Agitators and mixers subject to extreme wear can be durably protected with ALRESIST tiles shaped to the specific equipment design.

Skip collection chute with ALRESIST lining in a blast furnace plant.

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ALRESIST Linings

Lining of a cyclone with ALRESIST tiles, mechanically attached.

Weld-on ALRESIST tiles protect this cone against wear and thermal shock stress.

Rocker chute in a blast furnace feed system in Europe. The ALRESIST lining is 50 mm thick.

Octagonal chute for blast furnace feed system. The ALRESIST tiles, 50 mm thick, are shaped and cut in all three dimensions. In areas with higher impact, KALMETALL-C hard cast tiles, 50 mm thick, are installed.

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KALBOND High Performance Adhesive Bonding System

The KALBOND adhesive system permits bonding of protective linings to high speed moving parts subject to impact, abrasion as well as corrosion. High performance lining materials in tiles as thin as 1mm can protect the surface of many dynamic parts. Problem components such as cyclone classifiers, fan blades, rotors and other complex shapes can be lined with ALRESIST and tungsten carbide to outlast welded overlays and hardened metallic linings. Curved surfaces and other shapes can be lined due to small tile sizes. Linings can be applied to existing components or new designs.

Lined PF damper using ALRESIST and KALBOND.

KALBOND high performance adhesive bonding system with superior adhesion and strength is used in dynamic situations such as high speed fan blades. It is also extremely impact resistant.

ALRESIST and KALBOND lined 64 diameter fan with tungsten carbide impact pads.

Lining of a screw used in the potash industry with ALRESIST and KALBOND bonding system.

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KALCOR Linings
Zirconium Corundum Wear Protection with High Temperature and Abrasion Resistance

With the growing knowledge of preventive wear protection the demand for durable materials with extended service life has increased.
KALCOR, a fused cast

KALCOR
Zirconium corundum based on alumina and zirconia for plant components, where extreme wear and high temperature occur. Installation: shaped components in cement mortar or special mastics. Mechanical fixing is also possible. Lining of a collecting hopper in the sinter dust collector of a steel mill: the mixture of abrasive particles and hot air of approximately 400 C / 752 F passes through the KALCOR hopper and the following KALCOR pipelines in turbulent flow. Application temperature: up to 1250 C / 2282 F depending on application and geometry. Advantages: highly abrasion resistant, impact resistant, temperature resistant, corrosion resistant.

corundum, was developed for extreme abrasion protection and high temperatures up to 1000 C / 1832 F. Alumina and zirconia are melted in an electric arc furnace and cast into tiles, shaped components and cylinders.
KALCOR-S is cold cast

and sintered. This material withstands temperatures up to 1250 C / 2282 F. Further advantage: good thermal shock resistance. The fabrication process allows thin tiles with wall thicknesses of 10 to 12 mm.

The cut demonstrates the compact structure of KALCOR-S, practically free of voids. Thin shapes can also be produced.

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Flue-gas dust collection system from a petroleum-coke calciner in an oil refinery: 10 cyclones, including immersion pipes as well as ductwork have abrasion resistant linings installed. Approximately 500 m2 of KALCOR shaped components, 30 mm thick, have been laid in 10 mm thick potassium silicate mortar. The operating temperatures range between 250 and 450 C / 482 and 842 F.

Extraction dish for abrasive slurry of a mixer tank constructed as a combination of KALCOR, high alumina ceramics and stainless steel.

High temperature wear protection in a dedusting cyclone of a blast furnace plant in Europe.

Dust collector cone with pre-engineered KALCOR shaped elements.

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KALCOR Linings

Wear protection for high temperatures involves problems due to thermal stress between the outer steel component and the rigid lining. These problems can be solved by using KALCOR as the wear protection material and the proper mechanical fixing method: bolted connections or welded steel inserts. Example: drying drum in a chemical plant at 800 C / 1472 F.

Drum mixer for batches in a glass-making plant. Pre-engineered radial shaped elements provide optimal mixing.

Even complicated surfaces can be reliably protected against wear with KALCOR.
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KALSICA Linings
Silicon Carbide Ceramics with Extremely High Temperature Abrasion Resistance

Outstanding resistance against wear and thermal shock is achieved with KALSICA. KALSICA is part of the silicon carbide ceramics group and is available in different qualities:
silicon infiltrated (KALSICA-S) silicon nitride bonded

KALSICA
Silicon carbide ceramics for plant components for extreme wear, high temperature and / or thermal shock. Installation: individual shapes and components laid in mortar, epoxy, or temperature and acid resistant based mastics. Mechanical fixing is also possible. Application temperature: up to 1000 C / 1832 F depending on application and geometry. Advantages: highly abrasion resistant, resistant to thermal shocks and manufactured with small tolerances.

(KALSICA-A, -N, -P)

metal bonded (KALSICA-M)

High precision can be achieved in manufacturing KALSICA shapes, formed by pressing or casting, then sintered in a reactor kiln. Wall thickness from 2 mm for the shaped components is another advantage of using KALSICA wear protection linings.

Pulverized coal distributor made of KALSICA-N installed in a power plant.

Burner cone made of KALSICA-N in a power station in Europe.

Cyclone lining for handling of silane dust. Cone diameter is 1200 mm, with 30 mm thick KALSICA-N lining material.
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KALCRET Linings
Hard Compound can be Trowelled, Cast or Sprayed for Jointless Lining

KALCRET is a mineral based cement bonded hard compound. KALCRET can be trowelled, cast or sprayed, in the workshop or on-site, also by the customer. The lining is densely packed, using hard minerals that are fixed in a matrix. With a defined particle distribution and additional micro silica, KALCRET has a very high wear resistance and strength. After 8 hours the strength of KALCRET has reached 75%, this is the minimum setting time, e.g. for repairs. KALCRET is clearly superior to high-grade concretes. The application temperature is up to 1200 C / 2192 F, depending on the situation. KALCRET is especially useful in protecting components with a difficult geometry.
KALCRET can be trowelled,

KALCRET
Cement bonded hard compound for a jointless lining of plant components where high wear and temperature occur. Installation: by trowelling, casting in molds or spraying. Application temperature: up to 1200 C / 2192 F, depending on application and geometry. Advantages: highly wear resistant, strong and jointless lining, highly temperature resistant.

KALCRET as Prefabricated Shaped Elements

Tiles and shaped elements made from the cast compound are prefabricated in the workshop and equipped with common attachment hardware, such as steel corner inserts. The dimensions of tiles and shaped elements which can be produced range from approx. 100 x 100 mm to approx. 300 x 1000 mm with thicknesses between 20 and 50 mm. The ability to handle a particular piece is the only limit on the size of a tile. If required, reinforcements can be provided.

cast

Prefabricated KALCRET element with isolation and mechanical fixing for high temperature application in the precalciner of a cement plant.

or sprayed.

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Combined Linings
More Economical due to Similar Lifetimes for all Plant Components

High conveying speeds and abrasive materials cause wear in material handling systems. However, the wear is of varying intensity in different areas. This is where a combination of the different wear resistant linings proves successful. Mineral and ceramic linings are very effective against sliding abrasion. Metallic linings provide additional protection against impact. Designed on the basis of prior successful experience, components can achieve similar lifetimes without some failing prematurely or others excessively protected.

Different materials from the wear protection program for special applications or conditions include ABRESIST, ALRESIST, KALCOR, KALSICA, KALCRET and KALMETALL.

Sinter discharge table with the combination of KALCOR and KALMETALL-W. Immersion pipe for a cyclone for separating slag sand in the cement industry. The pipe inside is lined with KALCRET, the lid is protected by KALMETALL-W.

KERAFLEX is a special bonded system combining ALRESIST and rubber, to provide high wear resistance and impact protection.

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Combined Linings

ALRESIST high alumina ceramic

KALCOR fused cast corundum ABRESIST fused cast basalt

KALCOR fused cast corundum

High temperature slide chute in a cokery. The slide areas are lined with KALCERAM-K. The wear resistant sliding properties are up to 1000 C / 1832 F. The sidewalls are made of KALSICA-P: very wear resistant and resistant to temperature changes. The design of the sliding edge utilizes KALMETALL-C: wear and impact resistant with reliable mechanical attachment.

Separation of extremely abrasive silicon powder: ABRESIST in the sliding zone and KALSICA-N in the areas subject to major wear.
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Concrete mixer lining with ALRESIST at the mixer bottom and KALMETALL-W on the sidewalls.

KALDETECT Wear Detection

Electrical, Pneumatic or Mechanical Systems to Monitor Wear

Even superior wear resistant linings do not have unlimited lifetimes, especially in cases of extremely abrasive materials and harsh operating conditions. This can become critical, e.g. when for environmental protection reasons, certain harmful materials cannot be allowed to pollute the enviroment. For example: pneumatic conveying lines within waste incineration plants that are designed for the

incineration of hazardous waste. The leakage in a conveying line as a result of unexpected abrasion would cause dangerous or environmentally harmful substances to be released. For these and other cases, systems are offered that monitor possible wear in the lining before material leaks into the atmosphere or soil.

Electrical Wear Detection

The wear resistant lining is fitted on the outside with a low voltage electrical circuit. If the wear resistant lining wears through due to abrasion, the electrical circuit will be interrupted. Options in the electrical circuit design will allow the system to initiate an alarm with an indication of the relevant lined section or shut down the plant automatically. The electrical wear detection is available for all of the wear resistant materials and also for combined linings of any plant components.

Pneumatic Wear Detection

The steel casing is twin-walled. With changes of the pressure level in the space between the two walls caused by a leak, an indicator or alarm will be activated or the plant will be shut down. This system can be used for single components or complete systems.

Mechanical Wear Detection

A serrated wear-measuring tape is placed in a continuous groove of the abrasion resistant lining. The width of the visible saw tooth is an indication of the condition of the protective lining. Additionally, the wear resistant lining can be fitted with a borehole. The length of an indicator pin installed in the hole monitors the thickness or condition of the protective lining when removed and inspected.

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Design Details
Individual Fixing Alternatives Depending on Conditions and Processes

Installation and Erection

A precondition for effective wear protection is proper installation. Appropriate installation and erection of the lining depend on material conveyed, application, equipment design and installation position. It also depends on

whether sliding or impact wear prevail, temperature or thermal shock stress, corrosive or acid exposure is present. ABRESIST, ALRESIST, KALCOR and KALSICA normally are laid in cement mortar or special mastics.

Higher temperatures require additional measures like mechanical fixing, i.e. especially if the subsurface has a different thermal expansion than the wear protection lining.

Setting in cement mortar.

Potassium silicate based mortars used in case of high thermal stress.

Use of synthetic resins.

Mechanical fixing to meet special requirements.

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Mechanical Fixings and High Temperature Applications

Weld on Tile
These are usually fastened to vertical and overhanging steel surfaces by means of countersunk bolts, conical weld sleeves or weld studs.

Tile with Steel Corner Inserts and Weld Straps

This mechanical fastening method enables installing the lining to steel surfaces by welding.

Tile with Groove

This method has proved useful as well and allows the fastening of linings to steel surfaces by welding.

High Temperature Applications

KALCOR, ALRESIST and KALSICA are wear protective materials capable of withstanding high temperatures. A wide range of mechanical fixing methods and design details permit finding cost effective wear protection for any application. Moreover, KALCRET hard compound can be installed either by casting or trowelling.

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The Wear Protection People

Design, Manufacture, Delivery and Installation of Tailor-Made Wear Resistant Linings

Abresist Corporation and Kalenborn have been dedicated to plant protection since developing fused cast basalt for wear reduction and cost savings.

Design
Our engineers design customized, cost saving solutions for new or existing equipment. We provide the total package in one source: starting with advice on application, measurements on-site, design services, manufacture of the lining through to proper installation. This is the Abresist Corporation approach which offers long lasting protection.

Manufacturing
The foundation of the wear resistant systems offered by Abresist Corporation and Kalenborn consists of different materials with a wide range of individual characteristics:
ABRESIST ALRESIST KALCOR KALSICA KALCRET KALMETALL

Starting with fused cast basalt more than 80 years ago, a wide range of wear resistant materials has been developed with each material offering special wear resistant characteristics. The materials are valuable, but the knowledge from experience gathered all over the world in more than eighty branches of industry is just as important.

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Installation and Erection

Proper installation and erection require knowledge based on a wide range of experience. Installation of the engineered wear resistant linings can be performed or supervised by Abresist Corporation and Kalenborn specialists in our workshops or on-site all over the world.

About Abresist Corporation

Abresist Corporation is the U.S. subsidiary of Kalenborn Kalprotect, the German company that has continued to develop abrasion resistance technology for more than 80 years. We are confident that, whatever your abrasion or impact wear problem is in Canada, Mexico or the U.S.A., you can get the help you need by contacting us.

We Solve Wear Problems in Plant Components and Pipes

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Materials at a Glance
ABRESIST
ABRESIST is a basalt based wear protection for plant components in which the material to be conveyed predominantly causes friction-induced abrasion, in bunkers, troughs, chutes, chain conveyors, mixers, separators, pipes, pipe bends, cyclones, etc. Installation: the shaped cast tiles are laid in cement mortar. To meet special requirements other setting materials may be used, such as synthetic mortar or potassium silicate based mortar for high temperatures. Mechanical fixing is possible. Application temperature: up to approximately 350 C / 662 F. Advantages: high abrasion resistance, lasting smooth surface, no corrosion.

KALCOR
KALCOR are wear resistant materials composed of alumina and zirconia. It is recommended for particularly high abrasion and/or thermal stress, e.g. in cyclones and separators, in chutes for hot sinter or clinker, for mixers, pipelines, etc. Installation: the shaped cast tiles Application temperature: up to are laid either in cement mortar or approximately 1250 C / 2282 F. special setting materials. Mechanical fixing is possible as well. Advantages: high abrasion resistance, high temperature stability, resistant to impact and corrosion.

ALRESIST
Special high alumina ceramics for system components exposed to extreme wear and/or thermal stresses for which thin linings or smooth surfaces are required, such as in circulating air separators, cyclones, screw centrifuges, vibrating chutes, fans, fan blades, etc. Installation: shaped elements or thin tiles laid in epoxy mortar, RTV or by KALBOND. ALRESIST tiles are also vulcanized into rubber mats to be fastened by adhesive. Weld-on attachment is common. Application temperature: up to approximately 1000 C / 1832 F. Advantages: high abrasion resistance, lasting smooth surfaces, no corrosion. Available in various thicknesses.

KALMETALL
Metallic wear protection available in different qualities is resistant against sliding and impact abrasion. Hard cast iron materials in different alloying qualities are possible as well as hard faced steel sheets and self supporting structures. Installation: individual shaped hard cast components for mechanical fixing or laying in mortar, epoxy or mastics. Hard faced sheets as self supporting structures or for mechanical fixing. Application temperature: up to 750 C / 1382 F depending on material, application and geometry. Advantages: highly impact and abrasion resistant.

KALCRET
Cement-bonded hard compound for continuous lining of plant components where high wear and temperature occur. Installation: by trowelling, casting in molds or spraying. Application temperature: up to approximately 1200 C / 2192 F. Advantages: highly wear resistant, strong and jointless lining, highly temperature resistant.

Ask Abresist Corp. for additional information

Abrasion Resistant Linings USA 5000 K / WA 01/06 by Abresist 2006

Kalenborn Kalprotect Dr. Mauritz GmbH & Co. KG Vettelschoss, Germany www.kalenborn.de

Abresist Corporation 5541 North State Road 13 P.O. Box 38 Urbana, Indiana 46990, USA Phone (800) 348 -07 17 (260) 774-33 27 Fax Business (260) 774-8188 Sales (260) 774-38 32 info@abresist.com www.abresist.com

The Wear Protection People

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