Cement production is a highly intricate field. It's known that repairs in the cement industry significantly contribute to production costs, typically accounting for 15-25% of total manufacturing expenditure. The recurring erosion and corrosion of refractory material are additional long-standing challenges you've been addressing for years. You're well-acquainted with the usual trouble suspects: poor anchors and subpar welds. While these issues are not new, the solutions continue to evolve, requiring you to stay informed and adapt to the latest advancements.
In response to the industry's evolving needs for modernization and sustainable partnerships, SILICON has a lot to offer. For over 40 years, we have supported cement plants worldwide. Our extensive experience has led us to create a simple Cement Repair Checklist to reduce your maintenance costs for both prefabrication and retrofit work.
Change in cement plants is not just imminent; it is already happening. To be an agent of this transformation, you must kickstart clean manufacturing initiatives with your team now.
To act now, plant managers need to focus on reimagining processes and critically reassessing operations, as traditional repair methods no longer suffice in controlling maintenance costs.
Don’t just keep up – get ahead. Ensure a risk-free repair with sustainable SILICON’s Rapid Arc Welding Technology and pave the way for your next success story.
For decades, we have been researching the challenges in the cement industry, and our solutions have been tested and applied across continents.
Let us guide you through different areas of your cement plant and explain the solutions we offer. We will cover the four main SpeedSeries and their installation areas.
The SpeedBolt® is a movable anchor designed to adapt when the refractory material heats up and expands. These anchors are primarily used in Rotary Kilns, Cyclones, and Clicker Cooler where the movement of refractory material induces significant stress.
A key advantage of the SpeedBolt® is its reusability. The Bolt (eye) can last over 10 years. The Bolt can remain in place for several years, requiring only the replacement of the Bullhorn anchors and Clips. This results in significant reductions in maintenance time and costs.
The refractory needs the right anchor to withstand extreme heat. The SpeedCell® system protects both the refractory from inevitable cracks and the Burner Pipe from potential damage.
Engineered to extend the lifespan of your burner pipe, the SpeedCell® system secures the refractory material in place, allowing for safe and damage-free repetitive expansion and contraction.
Traditional Brick Claws are often associated with slow and poor hand-welded performance. RAW weldable SpeedClaw® and SILICON’s Rapid Arc Welding Technology ensure that installations are not only robust but also completed 10 times faster. SpeedClaw® is specifically designed for use in Rotary Kilns and Calciners, where a thick layer of bricks is applied.
Conventional V anchors, typically hand-welded with an electrode, are unreliable and inefficient, posing serious health risks due to hexavalent chromium. These issues often cause planners to overlook critical preventative maintenance during turnarounds. Additionally, over time, the steel in V anchors becomes sensitized, leading to anchor failure.
SpeedVee® anchors have consistently outperformed conventional V anchors in every vessel where they have been installed. They offer enhanced safety, reliability, and cost-effectiveness, significantly reducing maintenance time. With full fusion welds, V anchors transform from simple refractory attachments into mechanical upgrades with advanced refractory features. SpeedVee® is applied in the Cyclones and Smoke Chamber.
In the fast-paced world of cement production, where every minute counts, having a reliable expert on speed dial can make all the difference.
Whether you are in the midst of a scheduled repair or facing an unexpected emergency, having the right contact number for a second opinion is crucial. It's always better to double-check now rather than regret it later. Even if you think you have everything under control, a quick verification can save you from potential setbacks.
Don't wait until it's too late - ensure you have that essential contact information readily available to avoid costly mistakes and downtime.
