Key Industry Program

CemTec

Cement Industry…

WEAR & FUSION TECHNOLOGY

 KNOW-HOW IN THE CEMENT INDUSTRY
For over 100 years, Castolin Eutectic has been a pioneer and leader in wear
and fusion technologies. Welding, brazing, thermal spray and wear plates
CemTec
- these are our core technologies for providing innovative, cost-effective
and complete solutions for prolonging the service life of equipment in all
major industries.

Based upon hundreds of successful applications approved by our clients

across the globe, Castolin Eutectic can provide optimized solutions with a
wide range of products and technologies to combat specific wear in Power
Plants. Castolin Eutectic has a detailed understanding of every major wear
problem within the Cement industry, and can provide industry-tested
application solutions.

Our know-how is shared worldwide through our international CemTec

team, composed of specialists in cement production process applications.
The forces that pull our extensive know-how together around the world are
our Key Industry Program and our unique Terolink applications database.

Your resource for protection, repair and joining solutions

WEAR PROTECTION EXPERT

At Castolin Eutectic, we take the time to study
industry specific types of wear because until
the nature of the wear is fully understood, the
correct solution cannot be identified. Damage

Abrasion Erosion Impact caused by these wear groups costs money,

especially in downtime and lost production,
replacement parts, repair and ongoing main-
tenance.

Friction Heat & Corrosion Cavitation

Castolin Eutectic has proved for more than a century that a

preventive maintenance program can extend the life of criti-
cal machine parts by as much as 500%. Castolin Eutectic has
the «know-how» to identify the most serious wear problems
and «show how» to avoid them. Castolin Eutectic can greatly
increase your plant efficiency and profits.
Metallurgical Laboratory Micrograph of Wear Phenomena

2 Stronger, with Castolin Eutectic

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 INNOVATIONS
Castolin Eutectic has invested in Research & Development in many spe-
cific solutions to wear problems. This includes areas such as carbide selec-
tion, carbide size, carbide distributions, matrix compositions, application
procedures and process equipment.

Micrograph of Coating with Tungsten Carbides

Skills and knowledge of Castolin Eutectic experts have enabled us to cre-
ate a range of overlay materials combating the widest combination of
wear types. This range is continually growing, as we harness new materi-
als to provide better solutions to existing problems as well as answers to
new challenges. The results of this extensive work are demonstrated by
the hundreds of patents registered by Castolin Eutectic in the areas of Fusion of Eutalloy Coating

wear protection and fusion technologies during its 100 year history.

Some examples of products developed which are especially adapted for

the Power industry by Castolin Eutectic are:
High Quality Wear Tubes: CastoTubes
· EnDOtec and TeroMatec cored wires for welding anti-wear coatings.
· Spray and fuse processes; CastoDyn SF Lance and Superjet Eutalloy.
· High quality wear plates and tubes: CDP and Castotubes
· Eutronic Arc System: highest deposition rates and excellent anti-erosion
protection
- CaviTec Patented alloy system producing anti wear coatings with out-
standing cavitation resistance on pumping equipment. EnDOtec cored alloy Wire Welding Process

CDP WEAR PLATES AND CASTOTUBES

Castolin Eutectic develops, manufactures and markets
ready-to- use wear plates and tubes under the brand
name Castodur Diamond Plates (CDP) and CastoTubes.
These composite materials consist of a steel plate or
tube overlaid with wear-resistant deposits by means of
welding or metal powder coating, and provide excep-
CastoTubes CastoDur Diamond Plates
tional protection against erosion and abrasion. Aimed
for complex part-geometries, the material can be cut,
bent and welded.

A successful application with CDP in the Cement indus-

try is the wear protection of fans against the hot and
dust laden fumes produced in the furnace.
Wear Resistant Fan built with CDP Wear Resistant Exhaust Fan

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 SOLUTIONS FOR THE CEMENT INDUSTRY
Castolin Eutectic is your resource for protection, wear and joining solu-
tions. We believe in working with our customers to find the best answers
CemTec
to their problems. Expert in wear problems we can provide solutions for:
• Manufacture of new finished and semi-finished wear parts.
• Repair of broken parts
• Rebuilding of worn parts
• Protection against wear and corrosion
• Fusion technology

Primary hammer crusher - Mobile Separator fan blades Elevator bucket lips Crusher bars

Raw mill transport pipe

Coal mill roller shells Clinker breaker discs

Fan housing Raw mill fan Separator diaphragm

Clinker breaker hammer Clinker sieve bars

Clinker breaker housing Drag chain bed Stockyard bucket lips

Finish mill feed Feed trunnion liner Roller press wear Roller press spalling repair Ball mill impact plates

KILN TYRE PROBLEMS

New Boiler Tubes with Protective Coating Spray and Fuse Process Eutalloy Powder Thermal Spray Dense, homogenous structure of a fused
coating, no path for penetration by corrosion.

For protection against high-temperature corrosion, Castolin Eutectic typically recommends very high-chromium
content nickel-based alloys, usually supplied in the form of a Eutalloy® powder and deposited by flame spraying.
These alloys are then fused to increase the bond strength of the coating to the substrate to remove all «open»
porosity. This creates a very dense, homogeneous coating which provides maximum resistance to corrosion. The
discrete «closed» pores block any penetration of corrosion through to the substrate.

4 Stronger, with Castolin Eutectic

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ROLLER PRESS
Compared with traditional jaw, conical or ball mill crushers, roller crushers provide up to
30 % energy savings, reduced working noise levels and 30 % to 100 % increased production
output. Roller Presses crush various materials such as clinker, limestone, minerals, clays etc.
by compression between two rollers but they are subject to high stress abrasion and wear.
Consequently, the roller surface is often weld hardfaced to increase the lifetime. In France,
a cement plant operating a Roller Press experienced 3-4 months roller lifetime using the
traditional 4-6 layer weld overlay approach due to premature spalling of the brittle weld
deposit (see photo)
New Castolin Eutectic Plasma Technology solution
Plasma Transferred Arc is a Modern Hybrid welding wearfacing process using powder and a plasma source. To
improve the wear life, the extremely wear resistant tungsten carbides material in powder form was used in a
special matrix, EuTroLoy PG 6503. Two layers of powder alloy resulting in a total uniform coating thickness of 6
mm (see photos) applied by a specialised Castolin Eutectic subcontractor.
Result : After 16 months, wear was limited to 1mm with no sign of spalling and the cost
of the job was lower than the former solution. In addition, productivity savings were
generated by the increased service life of the PTA and EuTroLoy protected press rollers.

CASTOLAB
We believe in making our extensive know-how fully available to our
customers, but for situations where technology transfer is complex or
requires a rapid turn-around, we have our own maintenance service work-
shops; CastoLabs. These fully resourced skill centers develop advanced
procedures for transfer to end-users.
Castolin Eutectic CastoLabs are located in Germany, Belgium, Holland,
Spain, Austria, Poland, Czech Republic and the United Kingdom, and are Welding

best contacted through Castolin Eutectic via our website (www.castolin.

com). In countries without CastoLabs, Castolin Eutectic collaborates with
approved workshops which are in close contact with Castolin Eutectic’s
specialists and technologies.
Wearfaced Boiler Tubes

Fan built with Wear Resistant CDP

Spray & Fuse on Boiler Tubes

In Situ Wearfacing Thermal Spraying Repair Welding

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 CASTOLIN EUTECTIC
Castolin Eutectic Locations Training

To increase customer know-

how in wear technology and
repair techniques, we have de-
veloped a full line of seminars
The unique Terolink database of Castolin Eutectic and training programs, teach-
contains almost 6,000 fully documented approved ing all relevant personnel
applications from around the globe. The case stud- from welders and engineers
ies include photographs, technical data, detailed to sales teams and managing
descriptions and cost-saving analyses. directors.

Manufacturing Product Portfolio - Widest in the Industry

Castolin Eutectic Cored Wire Production

R&D-Wear Test Laboratory Together with our sister company, the Messer Group,
we can offer our customers a very powerful range
of products and services. Being «Part of the Messer
World» means:

• Investing €420 million before 2008

• More than 6,000 motivated employees

• Over 100 factories to meet the needs of customers

• Technical sales support in over 120 countries

• 2,000 technical sales people in the field with our

Laboratory of Metallurgy Micrograph of Wear Phenomena customers every day

6 Stronger, with Castolin Eutectic

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HISTORY OF CASTOLIN EUTECTIC
1906: Foundation of Castolin in Lausanne, Switzerland by Jean-Pierre
Wasserman. His stroke of genius: to discover a way of welding
cast iron at low temperature; in the following years, this innovation
was further developed for all industrial metals including
aluminium alloys.
1940: Foundation of Eutectic Welding Alloys Corporation in New York
1952: Foundation of Castolin France
1959: Foundation of Eutectic Japan Ltd
1962: Foundation of Eutectic India Ltd.
1960’s: International consolidation under Castolin Eutectic
1970’s: Creation of training centers for Maintenance & Repair technologies
1978: Establishment of World Head Quarters in St-Sulpice, Switzerland
2000: Merger with Messer Cutting & Welding and creation of the
MEC Group - Messer Eutectic Castolin
2005: Part of the Messer World
2006: 100 years

ADDRESSES OF CASTOLIN EUTECTIC COMPANIES IN EUROPE

Austria, Hungary, South East Europe Netherlands Switzerland
Castolin GmbH Castolin Benelux N.V. MESSER Eutectic Castolin Switzerland
Brunner Strasse 69 Rotterdamseweg 406 SA
1235 Wien 2629 HH Delft Swiss Market Centre
+43-(0)1-869 45 41-0 +31-(0)15-256 9203 Ch. de la Venoge 7
1025 St. Sulpice
Belgium Norway +41-(0)21 694 1111
s.a. Castolin Benelux n.v. Castolin Scandinavia
222-228, Blvd de l’Humanité Teknologiparken, Akersvn. 24 C Russia
1190 Bruxelles 0177 Oslo Messer Cutting & Welding OOO
+32-(0)2-370 1370 +47-22-11 18 70 Ul. Bolschaja Tulskajya 10/9
Office 9506
Czech Republic Poland 115191 Moscow
Castolin pol.s.r.o. Castolin Sp.z.o.o.
Trojska 18/122 P.O. Box 502, ul. Robotnicza United Kingdom & Ireland
18200 Praha 8 44-100 Gliwice Eutectic Company Ltd.
+42-(0)2-83 09 00 77 +48-(0)32-230 6736 Merse Road
North Moons Moat
France Spain, Portugal Redditch B98 9NZ
Castolin France S.A. Castolin Iberica S.A. +44-(0)1527 58 2200
22, Av. du Québec BP 325 P. I. de Alcobendas
Z.A. Courtaboeuf 1- Villebon c/ San Rafael, 6
91958 Courtaboeuf Cedex 28108 Alcobendas (Madrid)
+33-(0)1-69 82 69 82 +34-914 900 300 For all others Countries please contact:

Germany Sweden, Denmark MESSER Eutectic Castolin Switzerland

Castolin GmbH Castolin Scandinavia AB S.A.
Gutenbergstrasse 10 Transportgatan 37 Export Market Center
65830 Kriftel 42204 Hisings-Backa P.O. Box 360
+49-(0)6192-403-0 +46-(0)31-570 470 CH-1001 Lausanne, Switzerland

Your resource for protection, repair and joining solutions

For further information,
please visit our homepages:

www.castolin.com www.eutectic.com

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Stronger, with...
Castolin Eutectic
WEAR & FUSION TECHNOLOGY

Ask for a demonstration

from our Application
Specialists.
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