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guidelinesCorporate IdentIty © 09.2014
VERTICAL ROLLER MILL CASTINGS
MAXIMIZING YOUR ROI (RETURN ON INVESTMENT)
LABORATORYTESTING3 CONTINUOUSIMPROVEMENT
6
VALIDATION&AGREEMENT
5 PRECISEESTIMATE2
ON-SITETESTING4 AUDIT&ACCESS1
ONE WORLDGLOBAL PRODUCTION NETWORK#SECURITY OF SUPPLY
#ON-TIME DELIVERY
# PLANT SPECIALIZATION TO SUIT MARKET NEEDS
ONE TEAMGLOBAL SALES/TECHNICAL NETWORK#CLOSE CUSTOMER CONTACT
#CONSTANT SUPPORT
#ORDER COMPLIANCE
#AFTER-SALES SERVICE
ONE STANDARDGLOBAL CERTIFICATION BODY#COMMON STANDARDS
#COMMON AUDITING SYSTEMS
#CONSISTENCY
#COHESION
MAGOTTEAUX International s.a.
Rue A. Dumont · B-4051 Vaux-sous-Chèvremont
Tel : +32 (0) 43 617 617 Email: cement&[email protected]
www.magotteaux.com PROCESS OPTIMIZATION PRODUCTS AND SERVICES
FOR HIGH ABRASION EXTRACTING INDUSTRIES
WE OFFER A DIFFERENT VIEW
ONE WORLD ONE TEAMONE STANDARD
CEMENT AND UTILITIES
RETURN ON INVESTMENTMaximum return on investment (ROI) is guaranteed when using Magotteaux products.
This is, among others, achieved by optimizing mill operating campaigns for maximum benefit,
optimizing grinding efficiency, capacity (through-put), product fineness and power consumption.
Resulting in optimized mill performance and processed material output to ensure best possible
balance-of-plant performance.
CERAMIC TECHNOLOGY OFFERED IN TWO GRADESXWIN® CERAMIC - technology developed by Magotteaux. Xwin® is a metal matrix composite composed
of high chromium alloy metal and ceramic. This provides the extreme wear resistance of ceramic with the
mechanical properties of cast alloys. It is manufactured using a specialized casting process.
NEOX® CERAMIC – also developed by Magotteaux. Similar to Xwin® technology, the neoX® technology
is a further advancement in ceramic technology providing improved wear performance for the most
severe applications. Compared to Xwin®, improvements of up to 50% or greater can be expected.
APPLICATION, POSITIONINGXwin® and neoX® ceramic-based technology is available for grinding elements in most vertical
spindle mill applications, tires/rolls and tables. They combine the extreme hardness of ceramic
with the mechanical properties of high chromium metal providing unsurpassed performance. The
result is maximum wear resistance and wear life.
Regardless if your requirements are classical high chromium alloys or if your pulverized-coal
vertical mill application is roll & conical ring, tire & table, ring & hollow ball or pendulum & ring,
Magotteaux products and solutions offer maximum wear resistance, maximum performance and
optimized operating campaigns.
PROCESS MONITORING & PRODUCT KNOWLEDGEWorking in partnership with the customer Magotteaux monitors wear performance along
with critical process parameters to ensure optimum performance and assurance of lifetime.
Such activities allow Magotteaux to validate designs and further push the boundaries of wear
performance.
For more information on Magotteaux’s complete line of Vertical Roller Mill Castings and on our overall product lineup and
other innovative solutions, contact your regional Magotteaux sales office, or mail us at: cement&[email protected]
Magotteaux, the global leader of wear resistant castings, offers a wide range of
solutions when it comes to grinding elements for vertical roller mills; products
that are without a doubt at the top of technical know-how and design, offering
customers wear & lifetime solutions to meet their operating needs. In terms of
money spent per ton of product ground, Magotteaux products outperform any
other available solution on the market providing the best return on investment.
As a leader in process optimization solutions for high abrasion extracting industries, Magotteaux
pioneered the use of specialized alloys and composites. Its unique metallurgical technologies combine
toughness and durability with high wear resistance, providing solutions not available from other compa-
nies in the business.
LONGER LIFE, BETTER CONSISTENCY, INCREASED CYCLES.Vertical Roller Mills (VRMs) are where the return on investment really comes into play. The mills
are a primary cost consideration and once they are running, it is vital that they generate the best
returns over time.
PRODUCT RANGE MON0-METAL High Chromium (HiCr) alloy solution providing HIGH WEAR RESISTANCE for
LONGER LIFE with MECHANICAL DUCTILITY and TOUGHNESS.
DUOCAST Ductile Iron base alloy core with High Chrome inserts. Combines HIGH WEAR
RESISTANCE with the ability to RESIST HIGH MECHANICAL STRESSES.
DUOCAST CERAMIC Ductile Iron base alloy with CERAMIC High Chrome inserts. COMBINES the
EXTREME HIGH WEAR RESISTANCE of ceramic with the ability to RESIST HIGH MECHANICAL
STRESSES. (2.0-3.0x LIFETIME vs. Duocast design depending on the Application, Mill Design and
Mill Operation).
FULL CERAMIC High Chrome base alloy with CERAMIC. Provides FULL surface coverage of
ceramic in the grinding zone for maximum WEAR RESISTANCE. (2.5-4.0x LIFETIME vs Mono-Metal
High Chrome & Duocast design depending on the Application, Mill Design and Mill Operation AND
15-20% improvement vs. Duocast Ceramic design.)
CERAMIC SOLUTIONS• Metal Matrix Composite of High Alloy Metal and Ceramic.
• Extreme wear resistance of ceramic with the mechanical properties of cast alloy.
• Specialized casting process.
• Ceramic offered in 2 different grades: Xwin® and neoX®, with variations of each grade to match
your specific application or needs
REASONS TO TALK TO US • Specific grinding cost reduced by as much as 50% (Depending upon running operating conditions)
• Extended running life of the grinding elements
• Increased mill operating cycles
• Potential to extend or skip a cycle
• Better consistency of the grinding profile
• Improved efficiency and availability, resulting in reduced costs
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MAGOTTEAUX CERAMIC PERFORMANCE VS OTHER PRODUCT SOLUTIONS
COST SAVINGS FOR CERAMIC SOLUTION
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
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50 52
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60 62
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68 70
50,000
40,000
30,000
20,000
10,000
0
10,000
20,000
30,000
40,000
50,000
60,000
80
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40
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AN
NU
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PR
OJ
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D C
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AV
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S (
$)
CE
RA
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IC A
DV
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TAG
E (
%)
OPERATING LIFETIME (Months)
Optimum Projected Ceramic Replacement
Lifetime based on Grinding Efficiency,
Specific Power & Other Required
Pulverizer Maintenance
Projected Maximum
Ceramic Ceramic Lifetime
CERAMIC Break-Even vs.HiCr/HiCr Hardsurfacing
Annual Savings based on 3x Ceramic Lifetime vs. HiCr (or vs. HiCr Hardsurfacing) AND Estimated Material & Maintenance Cost.
Actual results and lifetime may vary based on cost variances, pulverizer design,comparison alloy, feed material quality and pulverizer operation.
HiCr/HiCrHardsurfacing
Lifetime
EXPECTED CERAMIC SUPERIORITY 2X-4X