Precision Industrial Castings
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Cement
Ball mill liner / lifter bar (raw ball mill)
Mn14Cr2 / 27%Cr white iron (same as mining ball mill)
Same product as mining ball mill liner. Cement raw ball mills: typically two-compartment – coarse (Mn steel or Hi-Cr) and fine (Hi-Cr) compartments.
Cement
Apron feeder pan / impact plate (raw material feeding)
Cast Steel ASTM A27 / A148 (structural pan); Mn steel or AR450 overlay (wear zones)
Apron feeder carries blasted limestone from primary crushing. Impact load at loading point – Mn liners or AR450 plate overlay. Structural pan: standard cast steel.
Cement
Bucket elevator boot / head section castings (raw meal, clinker, cement)
Cast Steel A27 Gr70-40 (structural); Wear-resistant cast steel / Mn liner for high abrasion zones (clinker)
Clinker bucket elevator: high abrasion + elevated temperature (clinker 100–200°C at elevator). Liner plates: replaceable Mn steel or Hi-Cr white iron plates. Boot section: high impact from falling clinker.
Cement
Cement ball mill liner / lifter bar (finish grinding)
27%Cr Hi-Chrome white iron (fine grinding, high ball charge); Mn14Cr2 (coarser first compartment)
Cement ball mills: very fine grinding – Hi-Cr white iron dominates. Cement abrasiveness (Blaine surface area 3000–5000 cm²/g). OEM: FLSmidth, Polysius, KHD, Gebr. Pfeiffer – drawing controlled.
Cement
Clinker breaker hammer (clinker size reduction before cooler)
Hadfield Mn steel Mn14Cr2 / Mn18Cr2 (impact dominant); Hi-Cr white iron 27%Cr (abrasion dominant)
Clinker temperature: 200–600°C at breaker entry. Material must handle impact at elevated temperature. Mn steel: hardness reduces at >300°C – Hi-Cr white iron preferred for high-temp breakers.
Cement
Clinker cooler grate bar / cast bar (roller-type cooler)
26Cr-1Mo martensitic cast iron; Cr28 white iron; heat-resistant austenitic steel
Roller cooler design (Polysius REFLEX, Claudius Peters): cast bars on roller frames. Temperature gradient lower than grate but still significant abrasion + thermal cycling.
Cement
Clinker cooler grate plate (moving grate cooler)
Heat-resistant cast steel: Cr25Ni12 (HH grade); Cr35Ni25 (HP grade); 25Cr-20Ni for >1000°C zones; Martensitic Cr28 for cooler end
Grate plates operate at 600–1000°C in clinker flow. High thermal shock + abrasion environment. Material selection: hotter zones = higher Ni content. Slot pattern controls clinker flow. LOMA / IKN / FLSmidth grate coolers – OEM drawing controlled. Casting quality (no cracks) critical – thermal shock will propagate existing defects.
Cement
Cooler side wall / support casting
Cast Steel A216 WCB; Heat-resistant Cr25 for hot zone side walls
Structural + some thermal exposure. Hot zones: wear/oxidation-resistant alloy. Cold zones: standard cast steel.
Cement
Crusher jaw plate / cone liner (limestone primary/secondary)
Hadfield Mn steel ASTM A128 Gr B-3; Mn18Cr2 for hard limestone / flint-bearing
Same specification as mining jaw plates – Mn steel ASTM A128 reference. Cement plants: typically jaw or gyratory primary + impact or cone secondary. Material selection same as quarry.
Cement
Hammer crusher hammer / beater (limestone, clay, shale)
Hadfield Mn steel Mn14Cr2 / Mn18Cr2 (primary crushing, impact dominant); 27%Cr white iron (secondary, abrasive)
Cement raw material crushing: limestone (soft-medium), clay (soft), shale (medium). Mn steel suitable for most; Hi-Cr for high-silica abrasive feed. Pin hole geometry: matched to rotor disc. Weight-matched sets for rotor balance.
Cement
Kiln girth gear (large open gear – ring gear)
Cast Steel: ASTM A148 Gr80-50 / SAE 0050 A; Some designs: ductile iron GJS-700-2 (smaller kilns)
Among the largest gears in industry – split into 2 halves for assembly. Tooth profile accuracy (DIN 4 or AGMA 6): critical for gear life. Matched pinion required – normally supplied as set. Weight: 5–50 tonne per segment depending on kiln size.
Cement
Kiln inlet / outlet seal castings (sector plates, seal rings)
Cast Steel A216 WCB; Heat-resistant cast steel for inlet end (>900°C)
Inlet: high temperature – heat-resistant grade (HH, HP austenitic or Cr25Ni12). Outlet: clinker abrasion + heat – Cr content important.
Cement
Kiln pinion casting (small gear driving girth gear)
Cast Steel ASTM A148 Gr105-85 / Gr120-95; Alloy steel (some prefer forged pinion at large kilns)
Pinion is the faster, smaller gear – higher tooth contact stress. Some large kilns use FORGED pinions for higher toughness. Smaller kilns: cast pinion acceptable. Hardness: pinion typically harder than girth gear (HB 220–280).
Cement
Kiln thrust roller casting
Cast Steel A148 Gr80-50; alloy steel
Controls axial position of kiln. Contacts tyre flange or rim face. Face surface and perpendicularity to axis critical.
Cement
Kiln tyre (riding ring) – rotary kiln support tyre
Cast Steel ASTM A148 Gr80-50 / Gr105-85; medium carbon alloy steel (Mn-Cr-Mo) – large tyre castings
One of the largest castings in cement – kiln tyre for large kilns 50–80 tonne weight. OD up to 8–10m diameter. Ovality and runout critical for smooth kiln rotation. Loose-riding design (designed clearance to shell) or fixed-riding. Careful pattern allowance for contraction on OD.
Cement
Mill trunnion casting (feed / discharge trunnion, ball mill)
Cast Steel ASTM A216 WCB / A148 Gr80-50
Critical safety casting – supports mill shell. Journal machined to H7/k6 for white metal bearing. Weld repair: pre-qualified WPS only. FMEA / safety case required for first article.
Cement
Raw mill grinding roller / tyre (VRM roller shell)
27%Cr Hi-Chrome white iron; Martensitic Cr15MoNi; Ni-Hard IV; composite (cast + welded hard-facing)
Roller shell profile matched to table segment. Replaced by sliding over axle – bore dimensional accuracy critical. Same OEM drawing control as table. Hard-facing option: welded overlay (Chromocarbide / tungsten carbide) applied post-casting for life extension.
Cement
Raw mill grinding table / table segment (vertical roller mill – VRM)
Ni-hard white iron Ni4Cr2 (Ni-Hard IV) / 27%Cr Hi-Chrome white iron; Martensitic Cr15MoNi
VRM table: segments (typically 3–4 per mill). Weight per segment: 500–3000 kg. Profile accuracy (taper angle) critical for correct roller nip. OEM (FLSmidth ATOX, Polysius, Loesche, Pfeiffer) drawing controlled. Bolt hole pattern per OEM.
Cement
Raw mill separator / classifier housing casting
Cast Steel ASTM A27 Gr70-40; wear-resistant cast steel for abrasive zones
Classifier housing handles fine abrasive raw meal. Abrasion-resistant cast steel or ceramic tile lining for high-wear zones.
Cement
Separator rotor / cage casting (dynamic separator – finish mill)
Cast Steel A216 WCB; austenitic Cr-Ni for high-abrasion zones
Dynamic air separator: rejects coarse particles back for re-grinding. Vane profile affects separation efficiency. Balance of rotating cage important.
Cement
Support roller casting (kiln riding roller)
Cast Steel A148 Gr80-50 / Gr105-85; medium carbon alloy steel
Carries kiln tyre – matched surface hardness to tyre. OD runout critical for smooth operation. Journal: machined H7/k6 for bearing assembly.
Cement
Vertical mill grinding table & roller (VRM finish mill)
27%Cr Hi-Chrome / Mn18Cr2 / composite – same as raw mill (similar duty, slightly lower abrasion for cement)
VRM cement mills: Loesche LM, Polysius DOROL, FLSmidth ATOX, Pfeiffer MVR. Profile and dimensional requirements same as raw mill – OEM drawing governed.
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