The Project
A customer in the glass recycling sector was looking to us to help reduce rates of abrasion rates in the plant handling cullet (broken glass). They wanted to reduce downtime for refitting and improve production plant availability, thus reducing overall operating costs. We had previously helped with lining kits for the sites cyclones with great success.
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Need/Requirement
A better material grade was required to be identified to form liners on to the sides of the transfer chutes where sliding and impact conditions existed for powdered cullet. The cullet material is then fed into cyclones prior to being fed into furnaces' to form cullet balls prior to end use processing.
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Specialist Skills
Sourcing the correct grade of material for wear and impact resistance was critical.
Accurate CAD,profiling and forming capability was an important consideration to ensure the new lining components fitted perfectly for ease of assembly, perfect plant operation and minimal downtime.
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Capability
Brown McFarlane's access to material and skills required to perfectly execute such projects are known around the world. Our latest technology includes the Infinity Skew Head Plasma Bevel Plasma Cutter, and demonstrates Brown McFarlane's long held strategy of being the industry leader in technology and innovation.
Brown McFarlane's 100,000sqft facility is capable of storing, handling and processing massive tonnages of steel plate. A mixture of more traditional and state of the art Oxy and Plasma equipment means we have the capacity as well as the skills, experience and quality standards to meet the customers requirement.
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The Agreed Solution Scope
Brown McFarlane would use its extensive experience of high wear application material to source and supply the right material. In this case CRC60 was selected, a chrome carbide faced steel plate with the optimal characteristics in the correct sizes for processing with minimal scrap.
Lining kits would be profiled and weld inserts added to suit the fitting bolt sizes for ease of installation and replacement.
The material would be profiled to exact size at Brown McFarlane’s first class profiling facility in Stoke on Trent UK. Delivery would be to the customer’s site to fit in with the scheduled maintenance routine.
We quickly established a gas profiling solution that would give the appropriate tolerances and the appropriate Quality Control processes required at all process stages.
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Additional Customer Requirements
Special attention was also paid to providing a value for money solution for the customer. Not only in reducing down time but ease of installation and further maintenance of the lining kit as they intended to perform the installation and ongoing maintenance themselves. Heat from the furnace process may also cause issues at times so a product capable of prolonged exposure to high temperatures (up to 600 degrees celcius) such as CRC60, made it an ideal choice
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The Steel Solution
The material was supplied quickly from our extensive range of CRC60 wear material stocks. Worn liners were supplied to us and customers CAD drawings prepared for sign off prior to production.
CRC60 Chrome Carbide steel plate was profiled and processed into the finished lining components to schedule and supplied to fit the maintenance schedule.
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The Delivery
Due to Brown McFarlane’s own, extensive know how, coupled with our extensive Western European sourced steel stocks; we were able to provide a materials solution to the customer that completely met with the required specification. On top of this, we were able to provide accurate, cut to size parts, which were delivered to the customers exacting requirement saving the customer time and money
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The Conclusion
Another satisfied customer! Our customer experienced almost 600% improvement in wear characteristics of the cullet chutes.
Brown McFarlane supplied profiled and processed parts hat could be fixed directly in to place in the gullet chutes, with minimal plant downtime and to fit in with the customer’s maintenance schedule. The Chrome Carbide product used proved to be longer lasting in use meaning the customer had lass downtime and increased productivity – with up to 50% improvement in life cycle costs.”
With increasing skills shortages and leaner workforces, the ability to bring traditional or sophisticated processing to the highest quality standard on demand is something our customers understand and recognise as a vital part of solution provision and maintenance planning.
All this is another example of our commitment to our customers and demonstrable proof of our ability to assist in the delivery of innovative solutions in full and on time. Other recycling applications we regularly assist with include crushers, cyclones, screeners, shakeout and shredders.