Cement Industry

The cement industry is among the most capital intensive industries and the cost of cement plants is typically above US$200mil / mil tonnes of capacity annually. As an energy intensive industry, each tonne of cement produced requires 60 to 140 kg of fuel oil and about 120 KWh of electricity depending on the cement variety and the process used. 

Cement is manufactured through a closely controlled chemical combination of calcium, silicon, aluminum, iron and other ingredients. Common materials used to manufacture cement include limestone, shells, and chalk or marl combined with shale, clay, slate, blast furnace slag, silica sand, and iron ore. These ingredients, when heated at high temperatures form a rock-like substance that is ground into the fine powder that we commonly think of as cement.

The method to manufacture cement is commonly known as a dry method. The processes involved quarrying the principal raw materials and crushing the rocks before processing further in crushers or hammer mills to reduce the rocks to about 3 inches or smaller. Thereafter, the cement kiln heats the rocks with other ingredients such as iron ore or ground, mixed fly ash to about 2,700°F in huge cylindrical steel rotary kilns lined with special firebrick.

As the material moves through the kiln, certain elements are driven off in the form of gases. The remaining elements unite to form a new substance called clinker which further cooled before the final stage of grinding and mixing with small amounts of gypsum and limestone. 

Industry and megatrends

Due to the high capital cost of this industry, there is a strong emphasis on the durability of the key processing equipment and its associated parts. The components are always subjected to high temperature, erosion, abrasion, impact stresses and corrosion. While it is essential to improve the wear resistance performance of the equipment, lifespan of the parts are critical to ensure cost and performance efficiency.

Dura-Metal supported the industry with the introduction of hardfacing technologies using welding and thermal spray methods. The intent of hardfacing is to enhance the component parts’ profiles while as the same time, maintaining their performance in the production conditions. The commonly applied materials include iron-based, copper-based, cobalt-based alloys (such as stellite), nickel-based alloys, chromium carbide alloys and NOREM. In addition, Dura-Metal plays a vital role in joint development of parts for the various Cement industries’ applications. 

Some of our Applications

  • Arc spray on roller
  • Pre Fabricated Hammers
  • Clinker cooler plate
  • Blow bar and hammer
  • Fan blade
  • High pressure cement roll
  • Arc Spray On RollerPre-Fabricated Hammers
  • Arc Spray On RollerPressure roll
  • Arc Spray On RollerArc Spray On Roller
  • Cut Wear LateCut Wear Plate
  • Pre Fabricated HammersPre Fabricated Hammers
  • DMG Clinker Cooler PlateDMG Clinker Cooler Plate
  • Fan BladeFan Blade
  • FlangeFlange
  • High Pressure Cement RollHigh Pressure Cement Roll
  • Kiln Tire RepairKiln Tire Repair
  • Kinon Pump Screw ScrewKinon Pump Screw
  • Cement crush roller