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KALOCER was a proven solution for wear protection. As it can be produced in very thin shapes, the screw conveyor could be lined with precisely shaped parts for all-round edge protection. At the largest copper mine in Europe, ore is transported for processing by means of a screw conveyor. The high silicon content in the rock causes serious abrasive wear to the spiral vanes and edges, which leads to frequent repairs bringing high costs and process downtime. Thanks to good experiences they have had up to now with the wear-proof KALOCER material in outflow hoppers, hydrocyclones and chutes, the company decided to line the screw conveyor vanes and edges with similar KALOCER oxide ceramic. The key improvement over the previously unprotected conveyor is the all-round edge protection, since this is where the worst wear occurs, to the extent that the functionality of the conveyor itself is impaired. One other essential benefit of KALOCER is the capability to manufacture it into very thin shaped forms. This meant the screw conveyor vanes and edges could be lined with accurately shaped pieces, which were also optimised for weight. The shaped pieces were bedded

Every mixing and stirring process puts continuous wear on the equipment used. This applies to manufacturers of building materials, asphalt and concrete as well as to the glass industry. Normal steel is not suitable for a mixer in the glass industry if the batch is mixed with glass fragments. It therefore makes sense to line the mixers with materials to protect them from wear. For mixers of all types, Kalenborn uses combinations of materials that are matched to each other depending on the stresses on the side wall, base and mixing tools. For a customer from the glass industry, we lined the mixers and slide valves with fittings made of the aluminum-oxide ceramic KALOCER. The fittings are already available with thin wall thicknesses from 1.5 mm, so that they can be adapted to geometrically difficult surfaces. KALOCER protects particularly well against extreme abrasion and is easy to clean due to its smooth surfaces. The lining meets the customer’s requirements

Wear-resistant materials KALMETALL, KALCAST and KALEN have proven to be the ideal solution to protect machinery in quarries from wear and tear. Wear protection in quarries: Excavators, loaders and dump trucks are very important machines when working in mines and quarries. Due to their intensive use, they are exposed to high loads, which is why they need to be protected with particularly resistant materials. To effectively protect our customer’s machines against abrasion and thus extend their service life, we recommend the use of our wear-resistant materials KALMETALL, KALCAST and KALEN. They have proven to be the ideal solution. A proven method for protecting excavator buckets: The metals used in excavators buckets must not only be abrasion-resistant but also withstand heavy impacts. To further protect our customer’s equipment, we used KALMETALL liners. We adapted the welded hard surfacing material to be as abrasion-resistant as possible on the one hand and to provide the best impact resistance on the other in order to significantly extend the life of the excavator buckets. How do you protect loaders

For critical applications, Kalenborn markets systems that indicate the possible wear of protective linings, thereby informing the operator in time to take necessary action. This applies to pneumatic conveyor systems, for example, where measures must be taken to prevent the release of toxic or environmentally harmful substances. KALDETECT electrical The exterior of the wear protection lining is equipped with a low-voltage measuring conductor. If the wear protection layer inside the piping wears through due to abrasion at any point, the conductor will be interrupted there. This triggers an alarm and – in combination with suitable evaluation logic – indicates the affected section of piping or automatically shuts the plant down. Wear protection monitoring is available for all materials and even for combined linings. KALDETECT electric is a good prerequisite for the smooth replacement of the wear protection lining in green pipes. KALDETECT mechanical Support structure and wear protection lining are fitted with a removable pin installed in a threaded hole. Upon removal, the length of the pin indicates the thickness and condition

KALCRET is a wear-resistant, high-performance concrete made of high-strength hard aggregates in an extremely strong cement matrix. The improved compound provides maximum resistance to erosion and abrasion. KALCRET is a wear-resistant, high-performance concrete made of high-strength hard aggregates in an extremely strong cement matrix. The improved compound is matched to the specific requirements and provides maximum resistance to erosion and abrasion. KALCRET is the leading cement-bonded hard aggregate compound on the market. KALCRET combines excellent wear protection properties with ease of use. The specific advantage of all compound materials is their flexibility in practice. Large surfaces can be coated quickly and reliably to restore plant availability rapidly. KALCRET is suitable for lining plant components and pipe systems, including in environmental engineering applications such as air and water filtration plants, in waste incineration plants, in power plants, in plants that produce construction materials, in cement works, and in the steel industry. KALCRET complies with strict international erosion resistance wear testing requirements according to ASTM-C704-15

Green pipes are wear resistant pipes where the worn cylinder can be replaced without the need for a new steel shell. Green pipes and pipe bends have a wear-resistant lining that can be removed and recycled at the end of their service life. The wear-resistant lining’s special mounting concept makes it possible to remove the old lining without destroying the steel shell. The existing steel pipes are subsequently relined with new material cylinders. The method used gives the lining the same service life as conventionally lined pipes and pipe bends. Returning the worn pipes and pipe bends to Kalenborn eliminates disposal costs and no expenses are incurred to manufacture new steel pipes. Companies reduce their CO2 load on the environment. With fused cast basalt and ceramics, Kalenborn relies on natural materials that are renewable. After the worn lining has been removed, its materials are recycled and fed back into the process for manufacturing new wear-resistant materials. Green pipes and pipe bends are available as product variants: * ABRESIST fused cast basalt pipes

Kalenborn celebrated an anniversary party in Vettelschoß, Germany and in Vespasiano/MG, Brazil for employees with their families and other guests. Kalenborn celebrated an anniversary party in Vettelschoß. In various demonstrations Kalenborn Germany showed what can be done with the materials. Glowing cast basalt poured out of a crucible, the hard compound KALCRET formed smiling faces and ceramic materials were cut precisely with 6200 bar waterpower. The mobile ComboCombo Band, which accompanied the guests between the show acts and the festival hall with a wide range of live music, provided the right atmosphere. At both locations the smaller guests enjoyed the children’s program with hand tattoos, goal wall shooting, bouncy castle and football table. International buffets convey tastily the importance of cooperation as a global group and the cultural togetherness at Kalenborn. Films and slide shows in Germany and Brazil showed the beginnings of the company up to the present day and conveyed the shared "Spirit of Kalenborn." At the end, great prizes awaited the participants of the raffles. "The employees

A thermal power plant wished to prevent wear in their trough chain conveyor. These units are used to collect and transport away ash and slag from the combustion of e.g. coal under the boiler. A municipal thermal power plant wished to prevent progressive wear in their trough chain conveyor. These units are used to collect and transport away ash and slag from the combustion of e.g. coal under the boiler. The hard material often causes rapid abrasion of the floor and side walls. The operator of the thermal power plant was looking for a wear protection solution to avoid the costly repairs and shutdowns of the plant. Kalenborn received the order to line the trough chain conveyor with ABRESIST cast basalt plates. The product is characterised by a very hard but smooth surface that reliably protects against abrasive wear and the build-up of material being conveyed. ABRESIST is resistant to corrosion, insensitive to chemical substances and at the same time temperature resistant up to 350°C. Kalenborn lined the component in only three days. The simple and quick installation, plus the cost-effective wear-resistant material ABRESIST. An economical solution