Table of Contents
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The Problem: Damaged Cooler Section
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The Solution: Using LoTherme 352
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Why LoTherme 352 Was the Best Choice
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Key Takeaways
Rotary kilns are crucial in oil, petrochemicals, and cement manufacturing industries. These massive rotating cylinders are used to process material under extreme conditions, making regular maintenance essential to prevent breakdowns and ensure efficiency. One of the key components of a rotary kiln is the cooler section, which regulates temperature and enhances performance. Over time, key parts like the dam ring can experience significant wear, reducing kiln performance and increasing the risk of costly failures.
This blog highlights how D&H Sécheron successfully restored a damaged cooler section using LoTherme 352, providing a durable, high-strength, and cost-effective welding solution.
The Problem: Damaged Cooler Section
The cooler section of a rotary kiln is responsible for managing high-temperature materials, ensuring efficient heat transfer and prolonging equipment lifespan. However, continuous exposure to extreme heat and operational stress can lead to significant wear and degradation of critical components like the dam ring.
Challenges Faced:
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Excessive Wear On The Dam Ring: Continuous exposure to high temperatures and operational stress lead to significant wear, reducing kiln efficiency, increasing energy consumption, and causing production delays
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Potential Breakdown Risks: Neglecting wear and tear increases the likelihood of unexpected breakdowns, which can be costly. In fact, unplanned downtime costs industrial manufacturers up to $50 billion annually
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Urgent Need For A Durable Repair Solution: A proactive maintenance strategy is crucial for extending equipment lifespan and minimising operational costs
The Solution: Using LoTherme 352
To restore the dam ring, D&H Sécheron utilised LoTherme 352, a high-strength, heat-resistant welding electrode engineered for heavy-duty industrial repairs. The resulting welds demonstrated excellent ductility and impact resistance, ensuring durability in both ambient and sub-zero temperatures.
How the Repair Was Done?
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Removing Damaged Dam Ring: The first step involved was careful removal of worn-out dam ring using gas cutting for a clean repair.
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Surface Preparation for Welding: The surface thoroughly cleaned to eliminate oil, grease, rust, and other contaminants, ensuring a strong and lasting weld.
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Welding With LoTherme 352: Skilled welders applied LoTherme 352 using proper techniques to enhance durability and reduce the risk of equipment failure.
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Quality Testing to Ensure a Perfect Weld: After the welding was completed, a dye-penetrant (DP) test was conducted to verify the weld's strength and durability.
Why LoTherme 352 Was the Best Choice
The selection of LoTherme 352 was based on its superior welding properties and proven performance in industrial repairs. Here’s why it was the ideal choice for this project:
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High-Strength Welds: LoTherme 352 is a hydrogen-controlled electrode that produces high-quality, crack-free radiographic welds. Its tensile strength of 550 MPa and 28% elongation ensures durability under extreme operational stress. High-performance welding electrodes improve weld strength to a great extent.
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Minimal Downtime: The efficient repair process using LoTherme 352 minimised kiln downtime, allowing operations to resume swiftly. Proper welding techniques can reduce the likelihood of equipment failure rates, ultimately preventing costly disruptions and ensuring long-term productivity.
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Cost-Effective Solution: Utilising LoTherme 352 extended the equipment’s lifespan, reducing the need for frequent maintenance. Studies indicate that a well-maintained rotary kiln can significantly extend the operational lifespan, ensuring efficient performance over many years.
Proper Kiln maintenance and the use of high-quality welding solutions are essential for extending the lifespan of industrial equipment. By choosing reliable welding consumables like LoTherme 352, industries can ensure strong, long-lasting repairs, minimise downtime, and enhance operational efficiency. The successful renewal of the rotary kiln’s cooler section with LoTherme 352 demonstrates the effectiveness of D&H Sécheron’s welding solutions in handling heavy-duty industrial repairs.
For a detailed understanding of this case study, visit Repair of Cooler Section of Rotary Kiln.
Key Takeaways:
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Rotary Kilns: Crucial in industries like oil, petrochemical, and cement and require regular maintenance to ensure optimal performance
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LoTherme 352: Specialised welding electrode designed for heavy-duty repairs, offering high strength and durability
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Repair solution: Repair process using LoTherme 352 was efficient, minimising downtime and reducing overall maintenance costs
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Experts Support: Rely on industry leaders like D&H Sécheron for top-quality welding solutions and professional guidance.
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