Sinter breaker stars
The sintering process used in the steel and associated industries for compacting and forming solid masses of material by heat and pressure results in the exposure of sinter stars to extreme conditions, resulting in aggravated wear. The sinter breaker, situated at the end of the sinter plant, is constantly exposed to extreme levels of wear due to impact and mineral abrasion, all occurring at elevated temperatures. This combination of wear mechanisms makes condition monitoring and management of sinter breakers highly complex and the selection of their materials and design crucial factors to consider.
During the initial customer meeting, our team presented the Welding Alloys class-leading range of wear solutions, including our 3D-Carb™, showing performance improvement data collected from previous projects in the steel industry. Shortly afterwards, our team was invited back to undertake a more in-depth, on-site analysis and to propose a long-term sinter star wear protection solution.
The data collected enabled our team to gain a more comprehensive understanding of the specific challenges and to provide a total cost analysis of implementing a 3D-Carb™ solution for the plant. Customer records revealed that the sinter stars lasted on average only nine months before deteriorating beyond productive use due to the excessive wear the sinter stars experienced. The stars were simply not performing at acceptable industry norms, and the customer was forced to frequently interrupt production in order to perform much-needed repairs. The increased downtime and associated maintenance costs led to reduced production output and sinter quality of the plant.