MillCarb – The future of grinding component refurbishment

The enormous impact of wear in the cement industry has been evident since the invention of milling and crushing equipment but is most notable in mills. As a vital component in the cement manufacturing process, mills need to run at optimum performance for as long as possible to enhance productivity, while reducing operating costs per ton.

The Welding Alloys Smart Welding Concept

The Welding Alloys Group believes in providing customers with optimised solutions.  The company’s vast experience in the cement industry has led to the development of its Smart Welding Concept, based on the principles of thorough investigation of operating conditions, optimised, tried-and-tested welding processes and a selection of premium application and condition-specific hardfacing consumables.

What is MillCarb?

MillCarb is a fully repairable, welded ceramic composite metal matrix alloy providing an optimised engineered wear protection solution for grinding components.

Real-time field testing under normal operating conditions shows that MillCarb outperforms all other materials in a coal milling environment.

MillCarb showed the same levels of wear after 300 000 operating hours as experienced by embedded rollers after only 190 000 operating hours.

The combination of the welded chromium and complex carbide-rich matrix and the added ceramic-carbide particles gives MillCarb class-leading wear resistance. The ceramic-carbide particles act as deflectors, effectively repelling abrasive particles away from the welded surface of the grinding component. In addition, MillCarb ensures uniform wear rate throughout the deposit thickness. 

Data gathered through the Smart Welding Concept is analysed by mill, wear and welding experts to deliver tailored solutions to where they are most needed and where they will have the biggest impact on reducing operational costs.