Cement production plants, like many other facilities, can suffer maintenance problems due to their aggressive environments caused by cement dust, chemical attacks, and dry or wet solids. Each of these can lead to accelerated rates of erosion and abrasion, and as a result, machinery and equipment become damaged.
Belzona provides repair and maintenance solutions for the cement industry, some of which include:
- Conveyor belts, for rips and unbonded cleats
- Ball mills for damaged internal surfaces
- Screw conveyors for severe abrasion caused by solids
- Valves and pipes for corrosion by carrying liquids
Our solutions are created to help reduce downtime and save customers money by repairing and protecting the damaged assets, rather than replacing them. This is also something that can help reduce your environmental impact.
TYPICAL PROBLEMS
In ball mills, wedge liners can become misaligned resulting in the damage to the shell underneath. Trunnions and other mechanical parts can be damaged by abrasion and dust.
POTENTIAL SOLUTIONS
Belzona 1000 or 4000 Series materials can repair damage to the shell and secure the wedge liners. Belzona 1000 Series materials are used to repair trunnion’s lost metal and protect from further deterioration.
TYPICAL PROBLEMS
In valves and pipes, typical problems include: abrasion, erosion-corrosion and chemical attack leading to damage, deterioration and leaks.
POTENTIAL SOLUTIONS
Belzona 1000 Series 100% solids paste- and fluid-grade materials can be used for metal rebuilding and corrosion protection. Belzona SuperWrap II composite repair system restores the strength of corroded, weakened and holed pipes, whilst eliminating the need for hot-work. Available to be applied as a pipe wrap, composite patch or a wear pad.
TYPICAL PROBLEMS
Pumps can experience prolonged exposure to erosion, corrosion, chemical attack, wear and cavitation, reducing the performance of the pump or leading to deterioration.
POTENTIAL SOLUTIONS
Belzona 1000, 2000 and 4000 Series paste- and fluid-grade materials can be used for the rebuilding of surfaces, long-term corrosion and erosion protection and the increase of pump efficiency.
TYPICAL PROBLEMS
Heat exchangers are susceptible to erosion damage and galvanic corrosion due to contact between two dissimilar metals, commonly used in the construction of heat exchangers. If this damage is left untreated, the operational efficiency of the system will be seriously undermined, allowing for deterioration of its components.
POTENTIAL SOLUTIONS
Belzona 1000 Series of paste- and fluid-grade materials for stemming live leaks, and wrapping pipes for additional protection. Belzona 1100 Series of paste-grade repair composites for in-situ repair and rebuilding of damaged tube sheets; Belzona 1300 Series fluid-grade coatings for protection against erosion-corrosion and resistance to chemicals. Belzona 4300 Series coatings for maximum chemical protection.
TYPICAL PROBLEMS
Typical problems in tanks and filter chambers include: tank base corrosion, interior linings affected by abrasion, erosion and chemical attack.
POTENTIAL SOLUTIONS
Belzona 1000, 2000, 3000, 5000 and 6000 Series paste- and fluid-grade materials offer cold-applied repair solutions, long-term protection both internally and externally resisting to a wide range of chemicals and environmental damage.
TYPICAL PROBLEMS
Shafts, bearing housings, keyways and other components are susceptible to erosion and abrasion damage, resulting in the loss of metal.
POTENTIAL SOLUTIONS
Belzona 1000 Series fluid- and paste-grade materials can be used to restore lost profiles and prevent further deterioration. Using forming or machining techniques, these 100% solids materials offer a reliable long-lasting solution.
TYPICAL PROBLEMS
For pipework, typical problems include erosion-corrosion and chemical attack related to the use of water filtration chemicals: chlorine, charcoal, water softeners on pipes, pipework, pumps, filtration systems and storage tanks.
POTENTIAL SOLUTIONS
Belzona 1000 Series paste- and fluid-grade materials for metal rebuild and corrosion protection of pipes, pipework and storage tanks. Belzona 5000 Series fluid-grade materials for chemical resistance in chemical containment areas and corrosion protection of pipes.
TYPICAL PROBLEMS
For conveyor systems, typical problems include: rips, tears and damage to the rubber conveyor belts and cleats.
POTENTIAL SOLUTIONS
Belzona 2000 Series elastomers can be used for repairing, bonding and patching damaged conveyor belts in situ.
TYPICAL PROBLEMS
For the facilities maintenance areas of water and wastewater plants, typical problems include: weathering damage of concrete structures, slippery transit areas, roof damage, expansion joint failures.
POTENTIAL SOLUTIONS
Belzona 2000, 3000, 4000, and 5000 Series paste- and fluid-grade materials for waterproofing, concrete rebuiling, expansion joint repairs, and floor slip resistance.
TYPICAL PROBLEMS
For chutes, hoppers, and screw conveyors, a typical problem is abrasion damage by dry or wet solids. Conventional repairs can be time consuming or replacement may be necessary, resulting in lengthy downtime.
POTENTIAL SOLUTIONS
Belzona Belzona 1300 Series and Belzona 1800 Series Series materials for repair and protection from sliding abrasion and impact. Belzona 9811 alumina tiles can be bonded in place in areas of severe abrasion.
Belzona solutions for the cement industry reduce downtime and eliminate replacement costs.
