Vertical roller mill
During the height of the COVID-19 pandemic, Welding Alloys undertook a project to repair a vertical roller mill (VRM) at Hanson Cement’s site in Purfleet, Essex. The work involved the repair of a Loesche 46 2+2S VRM grinding table and rollers, which suffered extensive wear during the processing of 3 500 tonnes of granulated blast furnace slag.
Welding Alloys has a long-standing relationship with Hanson Cement and wear services to the Purfleet plant commenced at the commissioning of its VRM, back in 2001.
Following the initial wear audit assessment by Welding Alloys’ technical team, they determined that the grinding components should be taken back to the profile template, using the Integra™ mill wire products. These products are specifically designed for hardfacing and re-profiling of grinding components used in vertical grinding mills. Data from previous projects at Purfleet where these products were applied on rollers and tables, showed very successful results.
Throughout the project, all aspects of welding were monitored by trained Welding Alloys Integra™ team members who held the relevant safety training passports and underwent first aid training. The risk assessments were adjusted to include the COVID-19 measures and to deal with the confined spaces associated with mills. This included taking body temperature readings at the start of each shift; providing hand sanitising stations; travelling to and from sites in separate vehicles; and maintaining social distancing. Welding Alloys completed the work on site ahead of schedule in only three days, including the installation of the equipment in the VRM and the removal of equipment at the end of the refurbishment.