Refurbishment of Impact Crusher

View of Horizontal Impact Crusher

August 2021 - Welding Alloys Manufacturers In India

Refurbishment of Impact Crusher – The Ador Way

Process industry generally requires the mineral ore’s needs to be processed. In other words, it needs to be crushed into a near powder form from its natural state. Typically, if you take an example from the cement industry, limestone extracted from mines is crushed close to a powder form before it moves on for further processing in grinding mills and then fed into a kiln from the cement-making process. The mines where the crushers are located form the backbone of the industry, making it a vital area for refurbishment as wear rates are very high due to high abrasion & impact caused by abrasive materials.

The most widely used and most efficient crusher machinery system for this task is the Hydraulic Impact Crusher. Nowadays this is predominantly used in Cement Industry as this simplifies crushing by doing the work of both primary & secondary crushers earlier used in the industry. The working process is very simple. Limestone ore is fed into the Horizontal Impact Crusher inlet as it falls into the rotating rotor. Then it gets crushed by the blow bar, inside the impact crusher during the crushing process, the front impact arm ensures the compressive loading of the ore. The rear impactor Arm & Grinding path ensures the fine crushing of limestone for further processing.

View of Horizontal Impact Crusher:

Refurbishment of Impact Crusher

The main wear factors acting on the component are High Abrasion & Impact with compressive loading inside the Horizontal Impact Crusher. The main components get worn out are the front & rear impact arms or impactor arms, grinding path, blow bars, and the rotor body. So all these parts require a complete refurbishment to get the required profile to keep the crushing efficiency & also at the same time ensuring Life Enhancement of the worn-out components.

The best solution in the industry to give wear protection to all worn-out components is the unique single electrode solution developed by Ador Fontech LH TUFF-TECH 58 for high abrasion & high impact application. LH TUFF-TECH 58 is the ideal alloy for this application since its titanium carbide alloy system in martensitic matrix gives the best wear resistance to abrasion combined with impact outperforming all conventional hardfacing methodologies.

With this single titanium carbide alloy system LH TUFF-TECH 58, ADFL has replaced the conventional two electrode combination used as base layer & final layer. The most important aspect is that LH TUFF-TECH 58 outperforms all conventional Alloys with increased life by almost 40% as it gives superior wear resistance to this high abrasion & impact application.

The critical advantage with Ador Fontech is that the job can be executed at customer premises while complete refurbishment can be done at our Premises Life Enhancements services facility in Nagpur. Also, for greater customer convenience, this job can be executed through our authorized repair shops at locations close to the plant with trained manpower completely under our supervision.

The complete refurbishment of the horizontal impact crusher is a critical component highlighting the Ador Fontech way of life enhancement of industrial components. Our specially formulated wear solutions ensure Life Enhancement with maximum safety margin at a marginal cost of replacement giving the best value proposition to customers.

Reclaim –Do not replace

Hypertherm: Cutting Made Easy

Table of Contents

  • Four tough jobs made easier with Duramax Hyamp Long Torch
    • Skeleton removal
    • Scrapping
    • Structural demolition
    • Processing coils, test coupons, and castings
  • Additional benefits for all four jobs

Four tough jobs made easier with Duramax Hyamp Long Torch

We all know that processing metal can be a hard job. It’s hot, dirty, and then there are the physical demands it can put on your body. Metal is heavy, and depending on the size of the plate, difficult to move. It becomes even harder to maneuver when the metal is welded into a sub-assembly or final product. Then to further complicate matters, there are staff shortages, safety concerns, cost constraints, and of course, deadlines to meet.

What if there was a better way to do some jobs? Hypertherm created the Duramax Hyamp Long torch with exactly that aim in mind. Jing Wu, Hypertherm’s lead engineer on this project explains, “We want to help our customers and keep them safe.” Wu and his team based the new handheld torch’s design on what operators told them, and what they themselves observed in shops, yards, and plants. It was clear that “extended reach” is beneficial for several reasons, and by offering longer torch-body lengths, existing Hypertherm – Powermax owners could expand their range of applications.

Hypertherm Cutting


Here are four jobs that get immediately improved by adding the Duramax Hyamp Long torch to your Hypertherm Cutting System.

1. Skeleton removal

If you’re using oxyacetylene to cut and remove skeletons from your table bed, it’s slowing down your production line. Undoubtedly, Hypertherm Plasma Cutting is faster than oxyfuel but by switching to the Duramax Hyamp Long torch, you can do the same job in a third to a quarter of the time. Existing long torch customers report skeleton removal from heavy industrial CNC beds is so fast, that jobs previously taking an hour, now can be finished in less than 15 to 20 minutes. The savings add up fast.

plasma cutting2. Scrapping

Every scrapper will benefit from having a long torch in their yard. Not only can plasma cut steel, stainless, and aluminum, it cut exotic metals, like copper and brass, and alloys too. The portability of Hypertherm Powermax plasma systems like Powermax 45 & Powermax 65 makes it possible to demolish large-scale depreciated machinery out in the yard, allowing for larger, more lucrative trades with mills. The Duramax Hyamp Long torch is also better than a shear at making long cuts. Plus, it frees up shears to cut the smaller pieces into dimensions required by steel mills, thus making the shear more productive as well.

Hypertherm powermax

3. Structural demolition

Structural steel companies tearing down buildings and other facilities, like decommissioned nuclear plants or sports stadiums, use multiple long torches to speed up the job. Completing the job faster saves on labor costs, but it helps them earn their contractual performance incentives too. Hence this Long torch solution connected with Hypertherm Power Systems is most ideal for such jobs.

4. Processing coils, test coupons, and castings

Mills manufacturing steel and other metals are hot places. Furnace’s heat, melt and liquefy raw ore and recycled scrap metal to form new rolled and cast metal products. As noted above, the long torch creates more distance and allows operators to stand further away from the radiant heat, translating to less fatigue and more productivity to customers underlining the benefits of Hypertherm Plasma Systems.

Additional benefits for all four jobs

The Hypertherm Plasma with Duramax Hyamp Long torch is safer to use. It’s ergonomic, allowing operators to work from comfortable positions. The length of the torch body and the angle of the cutting head lets operators stand upright, while still gaining the accessibility they need. Operators avoid back pain that results from having to bend over repeatedly to ignite the flame torch with a striker and operators can stand beside CNC tables, rather than on top of the cutting bed.

This is why Ador Fontech Limited, the name synonymous with total solutions for any Maintenance & Repair solutions offers Hypertherm Duramax Hyamp Long torch as a Robust Cutting solution to our customers.

Reclaim, Do not Replace

Rotary Air Lock – Refurbishment for Life Enhancement

The rotary airlock is an important component for pneumatic conveying, bulk solid handling & batching systems. Rotary airlock or RAL is also known as rotary valve, rotary feeder, or airlock feeder. The main function of RAL is to control the flow of bulk solids from the silo, mixer, cyclone, or hopper even in mills so the material is transported under gravity, pressure, and vacuum conditions.

In a cement plant, it is primarily used as a mechanism for feeding limestone, clinker, and cement to the mills. The main function of this valve mechanism is delivering the various ores (limestone, clinker, or cement) into the mill without the mixing of false/ambient air. The unintended mixing of ambient air has an adverse impact on cement machinery by reducing the performance & life, hence it’s widely used in all areas where control of feeding is required.

RAL consists of a rotor bucket mounted on a casing. This rotary system gets worn out due to high grinding abrasion, moderate impact & erosion caused by the continuous flow of abrasive material like limestone (Clinker or cement) through the valve.

Rotary Air Lock Refurbishment for Life Enhancement

RAL is a key component in the cement industry that requires complete refurbishment of all components. The main parts damaged are the RAL casing including side covers, liners, rotor & rotor blades. So all the parts are completely replaced with our Life Enhancement solution including the shaft which gives the rotary action to the equipment.

Ador Fontech’s solution to this problem is a complete dismantling of RAL components and repair & fabrication of all parts. The complete welding is done with our special Alloy LH-1105 having the best hydroscopic property and very high tensile strength ideal for joining applications. All the buckets are given wear protection with Hardox wear plates. Complete Machining & alignment is done in a VTL ensuring all vital parameters are maintained for enhanced performance & Life Enhancement of refurbished RAL.

Rotary Air Lock Refurbishment for Life Enhancement

Ador Fontech brings you a state-of-the-art LE services facility in Nagpur, which specializes in this kind of precision job having executed more than 100+ RAL refurbishments for the Cement Industry in India. The unique capability of Ador Fontech is the experience in manufacturing and refurbishment of RALs from 650 Diameter to 2200 diameter.

Rotary Air Lock Refurbishment for Life Enhancement

The complete refurbishment of rotary airlock signifies our policy of Life Enhancement of industrial components in the Ador Fontech way using specially formulated wear solutions to ensure Life Enhancement with maximum safety margin at a marginal cost of replacement with new RAL ensuring the best value proposition to the customer while re-enforcing our ideals of Reclaim –Do not Replace…