Wear Plate Solutions for Steel Plants
Steel Plant Process and Wear Plate Application
In heavy industries like steel manufacturing, wear and corrosion are the leading causes of equipment failure, accounting for nearly 80% of all mechanical breakdowns. Globally, these losses consume about 4% of the world’s GDP and up to 30% of annual steel output. In China, the wear-related loss alone amounts to 3–5 RMB per ton of steel produced, reflecting both a major cost burden and a significant opportunity for wear materials.
As steel plants face constant exposure to abrasion, impact, and heat, the need for durable wear solutions has never been greater. Wodon provides advanced wear-resistant steel plates tailored for key components, such as hoppers, chutes, bins, and screen plates—helping plants reduce steel loss, extend equipment life, and improve overall efficiency.
Single tooth roller before repair
After single tooth roller repair
Why is the grate bar worn out severely?
1. High-temperature sintering environment
•Long-term high-temperature state causes the grate bar material softening, thermal fatigue and oxidation peeling.
•Frequent alternation of thermal expansion and contraction will cause thermal cracks and structural peeling.
2. Strong particle scouring and abrasive wear
•Sintering raw materials contain high-hardness particles such as iron ore powder, coke powder, and limestone. These scour the surface of the grate bar at high speed during the sintering process, forming severe erosive wear.
•Especially in the stages of material falling, laying, and turning, the particle impact is more concentrated.
3. Frequent mechanical impact loads
•During operation, sintered ore blocks are constantly accumulated, vibrated, and unloaded. The grate plate is subjected to periodic heavy load impact, resulting in fatigue damage.
•Some steel mills use vibrating unloading equipment, which will also aggravate the wear and fractures caused by mechanical impact.
Key Wear-Prone Areas of Steel Plant Fans
Steel plant fans operate under high-temperature, high-dust, and high-load conditions. Over time, several components experience severe wear, especially:
1. Fan Impeller (Blades & Hubs)
•Cause of wear: Constant impact and abrasion from hot particles like sinter dust, iron ore fines, and coal powder.
•Wear type: Abrasive wear, erosion, oxidation at high temperatures.
•Typical issue: Blade thinning, cracking, and imbalance due to mass loss.
2. Casing Inner Liners / Housing
•Cause of wear: High-speed airflow carrying sharp particles scours the inner wall.
•Wear type: Erosive and abrasive wear, especially at bends and inlet areas.
•Typical issue: Liner detachment, local perforation, or wall thinning.
3. Inlet Guide Vanes & Deflectors
•Cause of wear: Directional acceleration of abrasive dust-laden air stream.
•Wear type: Impact wear at fixed angles of deflection.
•Typical issue: Leading-edge chipping or cracking.
Hardfacing Solutions for Wear Protection
Wodon offers reliable hardfacing solutions using chromium carbide overlay (CCO) plates and flux core wire, specifically designed for extreme service conditions.
Benefits of Hardfacing Repair
•Impeller lifespan increased by 2–5 times with CCO hardfacing.
•On-site hardfacing allows for fast turnaround, minimizing costly shutdowns.
•Surface buildup restores original dimensions, improving air flow and reducing vibration.
