Modification of Steel Roller Composition to Curb Excessive Wear

Abstract

Incorporation of roller presses in the grinding circuits of cement manufacturing plants was borne out of the dire need to reduce the power consumed by ball mills in its finish grinding process. This study evaluated the wear phenomena of a roller press installed in a cement plant. Two improvised wear measuring devices (IWMDs) were constructed on a laboratory scale with chevron lines created on each of the rollers. One of the IWMDs had 1.00% chromium and 0.20% molybdenum exhibiting the exact properties of the existing roller press. The other IWMD had 1.10% chromium and 0.22% molybdenum. The IWMDs were subjected to grinding operation with the same raw material of sized media fed at 0.2 tonnes/h for a continuous grinding period of about 6 h per day. Wear measurements were taken on the lines monthly for trending and up till the end of 733 h test running. The chevron lines on the IWMD with Xuper 646 XHD chipped off after 17.5 h of operation, while that with chevron lines made with AbraTec 6710 XHD was in operation for a cumulative period of 733 h within 7 months. Results on the AbraTec 6710 XHD model showed a maximum of 0.04 mm/tonne average wear within a span of 7 months compared to the chipped-off lines and an average wear rate of 1.75 mm/tonne on the Xuper 646 XHD IWMD having characteristics of the existing equipment. The AbraTec 6710 XHD IWMD indicated its suitability for clinker–limestone grinding roller press compared with Xuper 646 XHD.