EN_Kalenborn_Report_33

REPORT 

Applied 

wear protection solutions 

from Kalenborn 

33rd Issue 

Strong armour: 

KALMETALL protects bucket-wheel excavators 

Insights into cement production 

KALCRET-lining at Canadian cement works 

Our deployment in shale oil production

EDITORIAL 

Market requirements as a 

driver of innovation 

Dear Readers, 

In cement production, large quantities of bulk material are transported in all areas of materials handling 

and storage technology. This is why we are dedicating this issue of the Kalenborn Report to focusing 

on the linings used in cement works. Read how Kalenborn develops wear protection systems for mill 

lining and sifter systems in the form of the KALCRET hard compound and the KALMETALL-W hard overlay 

welded plates and in so doing meets customer demands for longer service lives. 

Our case studies report on applications in a wide range of different areas. The wide variety of our materials 

enables us to offer an appropriate solution for different levels of wear and plant components. Applications 

such as protecting coke warves with KALCERAM hard ceramics or coke silos with ABRESIST fused 

basalt show how important it is to have a wide range of materials which, beside offering abrasion resistance, 

also have excellent sliding characteristics and high resistance to sudden changes in temperature. 

What else is there to report? With the website and brochures having been given a new layout, we now 

have also reissued and revised our former customer magazine KALREPORT. We hope you like the new 

look and wish you an enjoyable read. 

Dr. Conrad Mauritz 

Markus Buscher 

WHY KALENBORN? 

Effective wear protection 

from a single source 

From the development and production of our materials to the lining of the 

plant components, Kalenborn can be relied on to take care of every aspect. 

Close links to customers and the quality and 

durability of our products are the most important 

things. Kalenborn’s experts work with the 

customer to develop individual and sustainable 

solutions that save costs and guarantee process 

reliability – both for optimising existing plants 

and for new constructions. 

In addition, we develop further solutions that 

enhance the level of production efficiency and 

profitability in the plants. The components that 

need to be lined are either provided by the 

customer or made by our experts in their own 

production facilities. We will also fit the wear 

protection lining on site at the customer’s premises. 

Kalenborn offers the crucial benefit that our 

materials undergo constant quality checks to 

ensure that the quality features which we promise 

are delivered at all times. The quality of our materials 

and user solutions set the bench mark. 

Installing the wear 

protection lining on 

site at the customer’s 

premises 

2 Kalenborn Report

KALENBORN FRANCE 

Wear protection for port cranes 

Ports are important facilities that handle all kinds of goods and products. In the north 

of France, the main products that are shipped are foodstuffs and oil products as well 

as ore and coal. Several cranes operate every single day and transport the goods from 

ships to land. 

Because this causes particularly great wear on the 

ship unloaders, the port commissioned the company 

Kalenborn France to provide wear- proof 

lining for its cranes. The challenge: to protect 

chutes and filling shafts as well as channels and 

pipes. A suitable form of wear protection had to 

be found for all elements. 

Kalenborn decided on a combination of three 

materials: KERAFLEX, KALMETALL and KALOCER. 

The transfer chute, whose impact surface has to 

withstand a material throughput volume of 

4,000 tons an hour, was reinforced with KERA- 

FLEX. The ceramic plates vulcanised into rubber 

mats have an extremely hard and wear-proof 

surface. Impact resistance is provided by the 

10-mm-thick rubber layer and optimal vulcanisation 

of the components. The unloading surfaces 

of the conveyor belts were also fitted with 

KERAFLEX. Because the conveyor belts work at a 

speed of between 3.6 and 5 metres a second, high 

wear protection is particularly important here. 

Feeding chutes and filling shafts were lined with 

KALMETALL-W and KALOCER. The combination 

of the KALMETALL-W hard overlay-welded plates 

and the KALOCER high alumina ceramics unites 

optimal wear protection with outstanding gliding 

properties. 

A consignment warehouse has meanwhile also 

been constructed on site: here the employees in 

charge of facility maintenance can independen tly 

remove and process the required materials. 

An external view of the 

ship unloader’s filling shaft 

lined with KALMETALL-W 

and KALOCER wear protection. 

Kalenborn Report 

3

KALENBORN FRANCE 

Good protection is half the 

battle won 

The south of France not only boasts olive plantations and fields of 

lavender. The region is also home to cement works which present 

Kalenborn with new challenges. 

In order to optimise the process of grinding cement, 

a European cement manufacturer decided 

to procure a new vertical roller mill. However, as 

the facility only produces special cement containing 

a high fraction of granulated slag, the mill 

is subjected to heavy loading. This places great 

demands on the wear protection and on extending 

the lifespan of the facility. 

The customer commissioned the experts from 

Kalenborn to line the vertical roller mill and its 

systems. They impressed the customer with the 

wide range of materials produced within the 

company that make it possible to protect components 

that are subject to different levels of 

loading in the best way possible. Kalenborn 

worked with the mill supplier to come up with an 

integrated solution in which three proven materials 

are used. In order to protect the sifter 

housing from the high temperatures which are 

generated, the installation team laid 280 m 2 of 

KALOCER alumina ceramics in the upper section. 

Due to the vibrations that are to be expected in 

the area of the sifter, the KALOCER tiles were securely 

fixed in place with holes and weld-on 

sleeves. In the bottom and top section of the sifter 

and in the bottom section of the return cone, the 

decision was made to use KALMETALL-W hard 

overlay welded plates, which guarantee both high 

wear resistance and impact strength. A total of 

55 m 2 was lined using this material. The Kalenborn 

experts protected the dust line behind the mill 

over an area of lining of around 124 m 2 with the 

hard compound KALCRET, which can be trowelled 

on. KALCRET is suitable for creating a quick and 

seamless lining and also ensures very good wear 

resistance and compressive strength – even at 

high application temperatures. The installation 

team installed all of the lining on site at the 

cement works within the specified schedule. 

Kalen born was thus able to complete the assignment 

to the customer’s complete satisfaction. 

KALOCER alumina ceramic 

tiles as protection 

from the high stresses 

caused by fluctuating 

temperatures 


AREAS OF USE AT CEMENT WORKS 

Versatile applications 

In cement works, large quantities of bulk materials are transported 

across all stages of the production process. Kalenborn 

has many years of experience in lining the various 

components in cement works so that they become wearresistant 

and promote sliding. The large range of metallic 

and ceramic materials as well as plastic-based materials are 

all produced in house. It is the combination of different materials 

that makes it possible to produce a particularly effective 

lining that is adapted to the particular application. 

Limestone 

quarry 

Blending bed 

Crusher 

Clay 

Raw material 

Raw meal 

sifter 

Dedusting filter 

Preheater 

Fuel preparation 

Tertiary air duct 

Raw meal 

mill 

Rotary furnace 

Clinker silos 

Raw meal silo 

Clinker cooler 

Aggregates 

Cement sifter 

Dedusting filter 

Cement mill 

Cement silos 

Solid material flow 

Exhaust air/heat 


5

KALENBORN MATERIAL KALCRET 

KALCRET – wear protection that can 

be trowelled, cast or sprayed on 

Linings with KALCRET protect plant components and pipes. There are already many 

successful applications throughout the raw materials industry, for example in mining, 

in power plants, in the steel and cement industries, and in waste incineration plants. 

In power plants, KALCRET protects the pipe bends 

of pulverised coal pipes. One typical application in 

steelworks is providing wear protection for the agitator 

for extracting the dust from the blast furnace 

gases and the windboxes below the sinter belt. In 

cement works, the pipes in clinker dust pipelines 

are lined with KALCRET and in cement grinding 

KALCRET is used to protect the sifter lining. KAL- 

CRET is easy to apply in lots of versatile ways. As a 

casting compound, flat surfaces can be lined quickly 

and efficiently and with the Kalenborn spray 

technology for KALCRET large surface areas can 

be coated quickly and securely so that the plant 

availability is restored in a short period of time. 

KALCRET is hard, wear-resistant and can be 

used flexibly 

As a cement-bonded hard compound, KALCRET 

combines excellent wear protection properties 

with easy handling. Its particular advantage is its 

flexibility. Linings over large surface areas and 

repairs, even to complex geometries, can be 

carried out with simple tools. It can also be processed 

overhead. The surface which is lined can 

be subjected to loads again after just 24 hours. 

KALCRET can be supplied for temperatures of up 

to 1200°C and is also capable of being combined 

with other materials from the Kalenborn wear 

protection range. Kalenborn individually matches 

the requirements for the material which is specially 

produced with the customer, in accordance 

with the particular intended uses. 

The Kalenborn spray 

technology enables large 

surface areas to be coated 

quickly and safely. 

For more information and 

to view an application film, 

scan the QR code or go to 

www.kalcret.com 


KALENBORN DO BRASIL 

ABRESIST used to protect 

coke silos 

In late 2012, a major steel producer from Brazil approached the 

Kalenborn do Brasil branch office: at a plant near to Rio de Janeiro 

there were problems with wear on two coke silos. 

Shortly after the plant was constructed, in August 

2011 the silos were each half lined with hardened 

plates and Kalenborn’s ABRESIST material. 

One year later, the plates were already beginning 

to show fairly substantial signs of wear, while 

ABRESIST was still in good condition. The company 

then requested that the silos should be 

fully lined with ABRESIST. 

Closer examination revealed that the friction 

from the coke had already resulted in wear and 

corrosion to the hardened plates. Moreover, the 

gaps between the individual plates meant that 

the structure of the silo was not completely protected, 

as is the case with ABRESIST. In March 

2013, the larger silo was therefore completely 

protected with ABRESIST over the course of 18 

working days, with the smaller one requiring 15 

working days to be completed. A total surface 

area of more than 600 m 2 was laid in the hoppers. 

Eight workers were involved in carrying 

out the work. 

The project was implemented to the client’s 

complete satisfaction. Investigations also showed 

that, under the given conditions and in relation 

to the thickness of the material, ABRESIST is five 

times more abrasion-resistant than the rival 

product. 

ABRESIST: The mineral 

wear protection made 

from cast basalt offers 

high wear resistance, a 

smooth surface that lasts, 

and no corrosion 

Over 

600 m² 

of surface area 

was installed within 

the silos. 


7

KALENBORN KALPROTECT 

KALCERAM – in Europe’s 

largest heavy-plate works 

Europe’s leading manufacturer of heavy plates is a long-standing customer 

of Kalenborn. From steel bridges and skyscrapers to oil and gas pipelines, 

the company’s plates are used in numerous projects all around the world. 

The company’s headquarters is also the site of the coking plant, which 

produces coke for the two blast furnaces at the heavy plate plant. 

In the course of refurbishing the coke ramp, this long-standing 

customer approached Kalenborn because we had previously 

refurbished coke ramps here. During the expansion of the 

coke works in 2006 and 2009, one ramp was wear-protected 

with materials from Kalenborn. During the present-day refurbishment, 

this experience was to be taken into account. 

A coke ramp is a chute onto which quenched coke is tipped. 

The coke slides over a ledge and down to a clearing table, 

from where it is transported on a conveyor belt. Along with 

heavy-duty wear protection, the customer also emphasised 

the need for the coke to slide well on the ramp. The material 

would also need to withstand the temperature changes arising 

from the quenching of the inevitable ember clusters in the 

coke. Around two wagon-loads of coke are placed on the 

ramp every hour. 

Due to the extreme conditions caused by the changes in 

temperature, Kalenborn‘s wear protection experts line the 

chutes of the coke ramps with KALCERAM-K. This material 

features good gliding properties and high thermal shock resistance. 

Kalenborn was able to distinguish itself particularly well 

with the overall package of engineering, material procurement 

and installation services on site. Customers value the excellent 

and reliable working relationship. 


KALENBORN MATERIAL KALMETALL-W 

KALMETALL-W – tough, impactresistant 

and indestructible 

The metallic materials from Kalenborn are suitable for a wide range of industrial 

applications – and KALMETALL-W is one of them. The armour plates with different 

thicknesses and quality grades are noted for their excellent wear resistance 

and impact strength. 

The reinforced plates are made up of a steel 

base plate and a hard metal overlay which is 

welded on, in some cases in several layers. The 

base plate ensures the static strength of the 

component whereas the wear resistance and 

impact strength comes from chromium carbides 

that are embedded in the metal structure. By 

varying the base plate and the hard metal alloy, 

applications at high temperatures of up to 750°C 

or aggressive process conditions can also be 

carried out. 

Modern processing techniques and metallurgical 

know-how allow us to manufacture highly complex 

and precise components, housings and plant 

parts in line with the customer’s specifications. 

For example, fans, cyclones, sifters, chutes and 

mixers can all be fabricated as a self-supporting 

structure made from KALMETALL-W. 

The material is also suitable for use in regenerating 

grinding rollers and grinding tables in vertical 

roller mills. The original geometry of the components 

is restored, which means they can continue 

to operate effectively for many thousands 

of hours. This solution is not only cheaper, it is 

also more flexible than procuring new components 

and makes it possible to get the vertical 

roller mill back into operation again quickly. Our 

company Kalenborn Delma has many years of 

experience in deposit welding – on site or alternatively 

in our plant in Poland. 

For more information and 

to view an application 

film, scan the QR code 


9

KALENBORN KALPROTECT 

Protect what keeps us warm 

Kalenborn’s wear protection solutions are also needed in Northern regions. 

At the plant of Estonia’s leading producer of shale oil, oil shale is separated to 

produce shale oil and shale gas. 

The raw materials which are obtained are required to produce 

fuel for households. Shale oil is also a popular fuel used by 

ships sailing in the Atlantic Ocean and the Arctic Ocean. The 

company produces more than 250,000 tonnes of shale oil per 

year. More than two million tonnes of oil shale are processed to 

produce this quantity of oil. This is a complicated process – 

resulting in challenges for wear protection. 

The plant grinds wet oil shale around the clock and guides 

the rock via conveyor belts into a flash dryer where it predries. 

The fine-grained, dried oil shale is then blown at high speed 

and in air at a temperature of 800 degrees through a riser 

pipe up into laterally adjacent cyclones. At this level, the 

moist air escapes while the dry oil shale is discharged downwards 

in the cyclone. 

The issue of wear protection in the flash dryer had hitherto 

largely been ignored. As a result, the plant components were 

sensitive and only had short service lives. Already in 2013, the 

company asked Kalenborn to develop specific wear protec tion 

solutions for the plant parts with a wide range of different 

geometries and operating conditions. These solutions were 

intended above all to guarantee long service lives for the 

components. With a wide range of wear protection materials 

manufactured internally and many years of experience in 

this field, Kalenborn was able to offer the right solution. 

Kalenborn installed a lining system comprising KALSICA-N 

and KALCOR-S offering outstanding resistance to abrasion 

at high temperatures and high thermal shock resistance in the 

lower heating section of the flash dryer. In the middle section, 

ABRESIST and KALMETALL-W were used due to the shape of 

the riser pipe. In order to improve the impact strength, the 

engineers from Kalen born employed a structure comprising 

KALMETALL-W and 100 mm thick KALSICA-N bars in the upper 

section of the distributor. The cyclones were also lined with 

KAL METALL-W100. The plant was able to start operating the 

same year. 

The adapted wear protection solutions from Kalenborn met 

the customer’s expectations. Two further plants were lined in 

2014 and 2015. The longer service life now enables the company 

to manufacture products efficiently and reliably. 


KALENBORN DELMA 

Strong armour 

Kalenborn has been a partner to one of the largest 

manufacturers of steel in North Africa since 2015. The 

company supplies customers all over the world, 

handling 5.8 million tonnes of steel per year. 

The bucket-wheel 

excavator transports 

the iron ore pellets to 

the steelworks via the 

conveyor belt 

The iron ore pellets that are processed for steel 

production arrive at the port by ship. A bucketwheel 

excavator is responsible for unloading the 

pellets from the ship and at the same time transports 

them by conveyor belt to the steelworks. 

From time to time in the past, the pellets got 

caught in the wear protection on the bucketwheel 

structure. The stray pellets caused additional 

weight on the bucket wheel and thus disrupted 

the smooth running of the machine. Here, 

a solution was needed. 

As Kalenborn was already known as the supplier 

of wear protection, the customer had a closer 

look at the range of materials on offer and was 

impressed. Working in close collaboration, 

agreements were then made on how to optimise 

the key aspects of the wear protection. The goal: 

Achieving a long lasting life and trouble-free 

operation for the bucket wheel. 

protection were also covered with armour plates 

or manually reinforced with KALMETALL-W 100. 

The project was implemented to the customer’s 

complete satisfaction. The customer particularly 

praises the personal contact with the counterparts 

from Kalenborn. This close collaboration 

makes it possible to find the right solution to 

every problem. The large number of materials 

and options for lining that Kalenborn offers has 

been very helpful here. The next bucket wheel 

has already been ordered. 

At the end of 2015, Kalenborn produced the 

bucket wheel as a complete welded structure 

including attachments. The areas which needed 

to be protected were made from KALMETALL-W 

100. The hard overlay steel plate offers a very 

persuasive choice with excellent wear resistance 

and impact strength. Areas requiring special 


11

Kalenborn 

Phone: +49 (0)2645 18-0 

www.kalenborn.com 

KALENBORN BRANCHES 

USA: 

Kalenborn Abresist 

PO Box 38 

5541 North State Road 13 

Urbana, IN 46990 

Phone: +1 (800) 348 0717 

info@abresist.com 

Kalenborn Technologies 

1000 Sequoyah Road 

Soddy Daisy, TN 37379 

Phone: +1 (423) 531 4161 

info@kaltechtn.com 

Canada: 

Kalenborn Canada 

602-755 Blvd. St Jean 

Pointe-Claire, PQ H9R 5M9 

Phone: +1 (514) 426 0460 

info@abresistkalenborn.ca 

Brasil: 

Kalenborn do Brasil 

Rua Boaventura, 1621 

Belo Horizonte/MG 

Phone: +55 (31) 3499-4000 

kalenborn@kalenborn.com.br 

France: 

Kalenborn France 

24, rue Maurice Ravel 

28130 Maintenon 

Phone: +33 (0) 23727 19 89 

kalenborn@kalenborn.fr 

Germany: 

Kalenborn Kalprotect 

Asbacher Str. 50 

53650 Vettelschoss 

Phone: +49 (0) 2645 18 0 

kalenborn@kalenborn.com 

Poland: 

Kalenborn Delma 

ul. Olszowa 60 

58-150 Strzegom 

Phone: +48 74 855 54 00 

kalenborndelma@kalenborndelma.pl 

Odlewnia Świdnica 

ul. Kliczkowska 53 

58-100 Świdnica 

Phone: +48 74 640 20-25 

info@odlewnia.swidnica.pl 

Kalenborn Bazalt 

ul. M. Piłsudskiego 68 

27-200 Starachowice 

Phone: +48 41 274-5351 

ptbbazalt@bazalt.com.pl 

Hungary: 

Kalenborn Refmon 

Bereki út 1 

9246 Mosonudvar 

Phone: +36 96 578-578 

info@refmon.hu 

Singapore: 

Kalenborn Asia 

80 Genting Lane 

Singapore 349565 

Phone: +65 6745 2988 

frankie_neo@kalasia.com.sg 

Philippines: 

Kalenborn Weartech Philippines 

No. 322 Marcos Highway, Bo. Mayamot, 

Antipolo City 1870 

Phone: +63 (632) 696 9001 

contact@kalenborn.com.ph

EN_Kalenborn_Report_33

Create successful ePaper yourself

Delete template?

Save as template?