Welding Alloys’ subsidiary – Reptec de Guatemala – recently completed a major project for a leading cement producer in Central America. The work, delivered with support from other Welding Alloys subsidiaries based in the Americas, involved responding to significant wear issues on satellite coolers. A satellite, also known as a planetary cooler, uses several cooling tubes arranged around the rotary kiln. As the kiln turns, air cools the hot clinker as it moves through these tubes. During this process, the tubes are subject to wear. Refurbishment became necessary after significant deterioration was identified during planned maintenance on the clinker kiln, where abnormal wear affected several satellite coolers. The extent of the damage required a complete replacement of all twelve units to restore safe and efficient operation of the kiln.
As part of the solution, the project scope included supplying 42 Hardlite™ 2+3 mm wear plates, supported by full manufacturing and fabrication services. Hardlite™ was selected for its high abrasion resistance and lightweight construction, key characteristics that make it well suited to the challenging operating conditions of the kiln.
The repair was urgently needed, which meant the timeline was tight and left little room for delay. To ensure the project could proceed as planned, Reptec worked with teams across several Welding Alloys subsidiaries to identify available stock, source the required plates from multiple locations, and bring everything together in time for shipment.
While the Hardlite™ wear plates were in transit, preparatory work began at a regional workshop, where external structures for the satellite coolers were fabricated using rolled A-36 steel sheets. This approach ensured that production could progress immediately upon arrival of the wear plates.
Following delivery, the Hardlite™ plates were rolled to the specified diameter, cut to size, and formed into internal liners, which were then welded inside the pre-fabricated outer shells to create the fully clad cooling tubes. All twelve satellite coolers were manufactured from scratch, completed on schedule, and installed on the rotary kiln.
This project highlights the combined capability of Welding Alloys’ products, technical expertise, and co-ordinated subsidiary support. From international stock mobilisation through to local fabrication and on-site assembly, every stage of the project demonstrates our commitment to delivering solutions that are completed on time and meet the needs of our customers.
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