Stanvac – Superon

Services to Thermal Power Industry

Contents

Why Superon Superon in Thermal PowerStanvac In Thermal Power

Why Superon

…Enhancing Components Life …Cost reduction of 10-15 %

ILL effects of Welding

Heat input, while welding leads to Creation of HAZ besides the Welded Zone

HAZ is the vulnerable area- for the welded joints

to fail

HAZ is hard and brittle – hence Cracks

Sudden/ Dynamic loads make the welded area

crack from the HAZ

Superon’s Technology basis for component life enhancement

- Lowest in class HAZ

How Superon Achieves lowest in Class HAZ

• Lowest in class input amperes

• Lowest in class arc gap

We can Demonstrate our technologies via comparitive

Demonstrations

• Lowest Input Amps

• Lowest Arc Gap

• Bead Finish

Superon’s Applications in Process Industries

• Cement

• Power

• Sugar

• Steel

• Paper

• Forging…

Features Applications Demo Free trials Outcome- FADFO

• Total application – Payment after successful completion of the trial

period– Pro-Rata payments for longer trial periods.– Full job on FOC basis to prove the superiority

One of the above depending on the application and your requirements

Thermal Power Industry

Ring Granulator Hubs

• Application Requirements– Abrasion Resistance– Impact Resistance– Slight Erosion Resistance

• Base Material– 14% Manganese Steel

• Superon Recommendation– Base Layer with Super Stanhard MN

73 ( to be used for building up worn out ones)

– Hardfacing with Super Stanhard AC 76 ( only this for new Hubs)

• Product USP’s– MN 73 is work hardening nickel fortified –

Hence better impact and bond strength – Does not chunk out – 50 HRc ( WH)

– AC 76 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc

• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance

Roller Crushers

• Application Requirements– Abrasion Resistance– Impact Resistance

• Base Material– 14% Manganese Steel/ Cast Steel

• Superon Recommendation– Base Layer with Super Stanhard MN

73/ FC 72 ( to be used for building up worn out ones)

– Hardfacing with Super Stanhard CC 78 ( only this for New Rollers)

• Product USP’s– MN 73 is work hardening nickel fortified –

Hence better impact and bond strength – Does not chunk out – 50 HRc ( WH). To use FC 72 in case of Cast Steel

– CC 78 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc

• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance

Ring Granulators

• Application Requirements– Abrasion Resistance– Impact Resistance

• Base Material– 14% Manganese Steel/ Cast Steel

• Superon Recommendation– Base Layer with Super Stanhard MN 73 (

to be used for building up worn out ones)

– Hardfacing with Super Stanhard AC 76

• Product USP’s– MN 73 is work hardening nickel fortified

– Hence better impact and bond strength – Does not chunk out – 50 HRc ( WH).

– AC 76 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc

• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance

Crusher Sieves

• Application Requirements– Impact Resistance

• Base Material– 14% Manganese Steel

• Superon Recommendation– Crack Joining with Super Stanalloy

EM 35– Hardfacing on the sieve corners with

Super stan hard AC 76

• Product USP’s– EM 35- Best alloy with excellent

elongation & High TS for joining Mn Steel.

– AC 76 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc

• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance

Mill Discharge Valves

• Application Requirements– Erosion Resistance

• Base Material– Cast Steel

• Superon Recommendation– Hardfacing with Super Stan Hard AC 76.– Can give single layer hardness

without affecting the flow parameters

• Product USP’s– AC 76 – High hardness best suited for

Abrasion resistance- High wear Factor – 63-67 HRc

• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance

Multi Port Outlet

• Application Requirements– Erosion Resistance

• Base Material– Cast Steel

• Superon Recommendation– Hardfacing with Super Stan Hard AC 76.– Can give single layer hardness

without affecting the flow parameters

• Product USP’s– AC 76 – High hardness best suited for

Abrasion resistance- High wear Factor – 63-67 HRc

• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance

Mill Table RJ Shaft

• Application Requirements– Frictional Wear Resistance– Low Temperature welding

• Base Material– Forged Alloy Steel

• Superon Recommendation:– Super Stanalloy DS 34

• Product USP’s– DS 34 – can be used at lowest

possible currents in its class– Deposits exhibit a very low coeff of

friction.– Can be used on highly contaminated

surfaces directly– Can be used for all dissimilar steel

and high alloys steels– Highly crack resistance- Longer life of

important components

Sinter Cast Table Liners – Roller Segments

• Application Requirements– Good Bonding on CI– Impact Resistance– High Abrasion Resistance

• Base Material– Special Cast iron with Sinter’s Embedded

• Superon Recommendation:– Super Stan Hard UL 81

• Product USP’s– UL 81 – Exhibits high penetrations

with CI– High Hardness of 68-70 HRc– Minimal or no Stress relief checks– Boron rich carbides showcasing high

abrasion resistance– High Impact resistance on this

application – best suited for this kind of application

Nozzle Ring Segments

• Application Requirements– High Erosion Resistance– Medium Abrasion Resistance– Single Layer Hardness

• Base Material– Wear Resistant Cast Steel

• Superon Recommendation:– Super Stan hard CC 78

• Product USP’s– CC 78 Gives a complex carbide kind of

deposit hence a high wear factor– Very minimal and fine stress relief

checks – hence good erosion resistance

– Deposits are slag free – high metal recovery and higher deposition efficiency

– Deposits Exhibits 63-67 HRC– Good resistance to Erosion/ Abrasion

Coal Mill Body - Liners

• Application Requirements– High Erosion Resistance– Medium Abrasion Resistance– High Wear Factor

• Base Material– Structural Steel

• Superon Recommendation:– Super Stan Plate 55

• Product USP’s– High Hardness of 58-61 HRc– Minimal Relief checks – hence

increased erosion resistance– Better bead wash and Over lap leading

to Better life– Automatic welding leading to uniform

hardness all across.– Due to better orientation of Carbides,

this gives the best erosion resistance for this application

Coal Mill – Reject Cones

• Application Requirements– High Erosion Resistance– Medium Abrasion Resistance– High Wear Factor

• Base Material– Structural Steel

• Superon Recommendation:– Super Stan Plate 56

• Product USP’s– High Hardness of 59-61 HRc– Minimal Relief checks – hence

increased erosion resistance– Better bead wash and Over lap leading

to Better life– Automatic welding leading to uniform

hardness all across.– Due to better orientation of Carbides,

this gives the best erosion resistance for this application

Coal Burner Tips

• Application Requirements– High Erosion Resistance– Temperature– Minimal Turbulence on the weld deposit

• Base Material– SS 310

• Superon Recommendation:– Super Stan Hard (T ) 93

• Product USP’s– High Hardness of 63- 67 HRc– Minimal Dilution inspite of SS 310 BM

and hence low hardness reduction– Comparitively smooth beads – leading

to low turbulence and hence better efficiency

– Can resist high temperatures.– Nil slag design– Low- find stress relief checks hence

better erosion resistance

Coal Burner Nozzles

• Application Requirements– High Erosion Resistance– Minimal Turbulence on the weld deposit

• Base Material– Cast iron

• Superon Recommendation:– Super Stan Hard (T ) 91

• Product USP’s– High Hardness of 61- 63 HRc– Bonds well on Cast Irons– Comparitively smooth beads – leading

to low turbulence and hence better efficiency

– High hardness on the first layer– Nil slag design– Low- find stress relief checks hence

better erosion resistance

Sinter Crushers - AHP

• Application Requirements– High Abrasion Resistance– Temperature resistance– Impact Resistance

• Base Material– Cast Steel/ Manganese Steel

• Superon Recommendation:– Build up with Super Stan Hard FC 72 – Cast

steel / MN 73 for Mn steel– Top layers with Super Stan Hard CC ( T ) 91

• Product USP’s– High Hardness of 61- 63 HRc– Bonds well on Cast steels– Comparitively smooth beads – leading

to low turbulence and hence better efficiency

– High hardness on the first layer– Nil slag design– Low- find stress relief checks hence

better erosion resistance

Screw Conveyors - AHP

• Application Requirements– High Abrasion Resistance– Erosion Resistance– Corrosion Resistance

• Base Material– Structural Steel

• Superon Recommendation:– Super Stan hard CR 77

• Product USP’s– Exhibits High hardness of 57-60 HRc.– High Wear factor due to Complex and

primary Hexagonal Chromium Carbide deposit

– Deposits are bald – exhibiting high erosion resistance

– Can take temperatures also– Good corrosion resistance also

Pumps- AHP

• Application Requirements– High Erosion Resistance– Corrosion Resistance– Moderate Impact

• Base Material– Alloyed Cast Iron

• Superon Recommendation:– Super Stanalloy FN 65 for base– Hardface with CR 77

• Product USP’s– Best suited for Alloyed Cast iron– Excellent bonding to these types– Ease of machining– High Crack resistance– CR 77 has good resistance

• Abrasion• Erosion• Corrosion• Impact &• Heat

ID Fans

• Application Requirements– High Erosion Resistance– Moderate Heat

• Base Material– Structural Steel

• Superon Recommendation:– Super Stan alloy HT 79

• Product USP’s– Best suited for High erosive

atmospheres– Can withstand high heat– Minimal and fine stress relief check

making it the best suited for highly erosive applications

– Nil slag design – Hence high recovery and deposition efficiency

Coating Applications

Power Industry

Machine Stacker Reclaimer

ComponentAlkyde Enamel Structures

Base MetalFabricated structure

Stanvac Solution

Polyhyb 2050 (1040+725)

Customer Benefits• Low Application Time• Self Priming• Higher Corrosion Resistance• Double the Life of Alkyede Enamel

Power Applications

Power Applications

Machine Stacker Reclaimer

Component Conveyor Belts

Base MetalRubber with Cotton/ Nylon Ply

Stanvac Solution

717 Polyurethane Kote- Black

Customer Benefits

• Lower Cost of Reclamation• Better than Hot/ Cold Vulcanising• Fast curing- Lower down time• Can be used on all areas like edges, Centre portion or

any

Power Applications

Machine Bowl Mill

Component Pipe Bends

Base Metal Struc Steel

Stanvac Solution

731Stangard ER

Customer Benefits

• Zirconium Carbide based- High abrasion/ erosion resistant.

• Lower down time.• Insitu application.• Enhanced life > 4 times MS

Power Applications

Machine Coal Lines

Component Orifices

Base MetalStruc Steel+ Ceramics

Stanvac Solution

731Stangard ER

Customer Benefits

• Zirconium Carbide based- High abrasion/ erosion resistant.

• Lower down time.• Insitu application.• Enhanced life

Power Applications

MachineElectrical panel Areas

ComponentDie Electric Flooring

Base MetalConcrete/ Tiles/ marbles

Stanvac Solution

1311 Insulkote A / B

Customer Benefits

• Meets requirement of 15652.• BDV of more than 34/ 45 KV in air medium• Abrasion resistant & No tracking due to non

accumulation of dust.• Non Inflammable• Repairable

Power Applications

Machine Pumps- utilities

ComponentCasing & Impellors

Base Metal Grey Cast Iron

Stanvac Solution

1170/1180 or731/1180

Customer Benefits• Improves the efficiency- hene lower energy consumption• Higher Abrasion/ Erosion resistance- Higher life

Power Applications

Machine Work Shop

ComponentShafts/Emergency Leak Reapairs

Base MetalForged Steel / bar stock

Stanvac Solution

815 StangardSteel Putty

Customer Benefits

• Ultra High Compressive strength• Fast curing• Repeated no of applications• Machinability. Good Shore hardness• Temperature range -100C to +2000C

Power Applications

Machine Chimney

Component Chimney

Base Metal Concrete

Stanvac Solution

754( Inner)754+ 725 ( Outer)

Customer Benefits

• Stops carbonation of the concrete• Improved Aesthetics- Prevents lichen, moss and fungus

growth• Protects moisture and Vapour Migration- Rebar

Protection

Power Applications

Machine Cooling Towers

Component Cooling Tower

Base Metal Concrete

Stanvac Solution

1311 MVT System

Customer Benefits

• Stops carbonation of the concrete• Improved Aesthetics• Enhances Life.• High Tolerance to Salt & Chloride• Wet Tolerance capability – best suited for Cooling towers

Power Applications

Machine DM Plant

Component DM Tank

Base Metal Concrete

Stanvac Solution

1311MVT System

Customer Benefits

• Stops carbonation of the concrete• Improved Aesthetics• Enhances Life.• High Tolerance to Salt & Chloride• Wet Tolerance capability – best suited for Cooling towers• Minimum Downtime – On damp surface• Negative Pressure applications

Power Applications

Machine DM Plant

Component DM Flooring

Base Metal Concrete

Stanvac Solution

754/756*+ 727 System

Customer Benefits

• Stops carbonation of the concrete• Improved Aesthetics• Stops Water Ingress• Increased Flooring life

Power Applications

Machine Bowl Mill

ComponentReject Cone - Outer

Base Metal Strutural Steel

Stanvac Solution

Stangard 731 ER/1190

Customer Benefits

• Abrasion Resistant• Erosion Resistant

Power Applications

Machine Bowl Mill

Component MDV

Base MetalSt Steel+ Ceramic Tiles

Stanvac Solution

731Stangard ER

Customer Benefits• Abrasion Resistant• Erosion Resistant• No need to replace the total MDV.• Low downtime

Power Applications

Machine Bowl

Component Multi Port Outlet

Base MetalSt Steel+ Ceramic Tiling

Stanvac Solution

731Stangard ER

Customer Benefits• Abrasion Resistant• Erosion Resistant• No need to replace the total MPO.• Low downtime

Power Applications

Machine Boiler

Component Coal Nozzle

Base Metal Cast Steel

Stanvac Solution

731Stangard ER

Customer Benefits• Abrasion Resistant• Erosion Resistant• Low downtime• Higher Life

Power Applications

Machine Bowl Mill

Component Nozzle Ring

Base Metal Fabricated/ Cast

Stanvac Solution

731Stangard ER

Customer Benefits

• Abrasion Resistant• Erosion Resistant• Insitu applications- No down

time

Power Applications

Machine Battery room

Component Flooring

Base Metal COncrete

Stanvac Solution

4029 System

Customer Benefits• 98% H2SO4 33% HCL resistance• 100 % Volume Solids• High Build

Power Applications

Machine GCT

Component Scrubbers

Base Metal Steel

Stanvac Solution

1040+ 718EGF-NV+ 727*

Customer Benefits• 98% H2SO4 33% HCL resistance• 100 % Volume Solids• High Build

Power Applications

Machine Flue Gas Ducts

Component Flue Gas Ducts

Base MetalSt Steel With Insulation

Stanvac Solution

Aluclad 710/ 706 Stangard

Customer Benefits• Heat Resistance- upto1600C• Stops Corrosion due to sweating• No reduction of shell thickness• 710- Stop Moisture Entry into the Ducts

Power Applications

Machine Condensors

Component End Shields

Base Metal Cast Steel

Stanvac Solution

1180

Customer Benefits• Heat Resistance• Stops Corrosion• No reduction of Plate thickness.• Stops leakage

Power Applications

MachineAlkali & Acid Metering Tanks

Component Tanks

Base Metal Structural Steel

Stanvac Solution

Stangard706+1040Stangard+715 Stangard EGF( NV)

Customer Benefits• Resistance to Alkali’s & Acids• Good adhesion to Structural• Good Flexural Strength• Resistance to 33 % HCl, 98% H2So4

Applications for 1040+ 725/727*• Bowl Mills Outer• Stacker Reclaimer• Boiler Structures• Ash Handling plant Structures• Ash Handling Pumps.• Coal Handling plants

• Cleaning by Water• Coating before drying – Wet Surface Tolerance• Long durable life than standard Epoxies• No Blistering – Hence higher life.• PUTC gives anti sticking properties apart from UV resistance

Power Applications

Thank You