High Chrome Liner Plates & Diaphragms
SBMI was established during 2017 for manufacturing of Wear Resistant Castings. Our integrated unit has latest globally accepted modern state of art technology for manufacturing of such castings. We have a team of sincerely dedicated skilled professionals for providing most economical grinding solutions to user industry. We are a leading composite solution provider for Grinding Media and Mill Internals.
We are an ISO: 9001-2008 approved company and are offering following services to cement, minerals, fertilizers, chemicals and thermal power sectors of the country and abroad.
Mill Internals: Complete designing and manufacturing of mill liners, flow control and other type of diaphragms in High Chrome as well as Mn Steel compositions and supply of Hardware items like Liner Bolts and EPDM Rubber Sheets.
We do not intend to supply these items merely on commodity basis but provide complete services required for optimizing wear economics, power consumption and performance level of the mills by giving consideration and proper weightage to important factors like Mill dimensions, Grinding Circuit, characteristics of feed material (like size, grindeability, hardness and moisture contents etc.)
Economics
- We guarantee for the following advantage from our products-
- Low Specific Energy Consumption and Wear Rate due to Guaranteed Micro-Structural Features with optimum carbide quota and high reliability against breakage.
- No chipping in the process of grinding due to perfectly sound castings poured on optimum pouring temperature. Casting yield maintained by us is approx. 10% lower compared to other products in the market. Our manufacturing cost is comparatively higher which is offset much more in terms of low wear feature.
- Completely free of all type of casting defects due to closely monitored manufacturing process.
- Full Functionality during whole lifetime retaining spherical shape for long time.
- Long maintenance free life time
Advantages Of Adopting Our High Chrome Liners And Economics
Users are normally mentioning only chemical composition and hardness of High Chrome Liners in their enquiry which is not sufficient for assessing/ comparing quality level of these items from different manufacturers. The metallurgy involved in High Chrome Alloys is highly complex and also the manufacturing technology adopted by different manufacturers which necessitates full understanding of alloy characteristics and production technologies for developing full confidence in the manufacturer and the product. It is an established fact that Mertensite phase and chromium carbides have maximum wear/ abrasion resistant properties and as such microstructure evaluation should be given maximum weightage at the time of comparing quality from different manufacturers. An ideal High Chrome Alloy should reflect following micro-structural characteristics.
- Proper contents of Chromium Carbides (Cr7 C3) should be at least 25-30% of volume.
- These carbides should be well disconnected and properly distributed in Martensitic Matrix which is possible only by proper balancing of chromium and carbon contents in the alloy.
- Occurrence of austenite, Pearlites and ferrites should be as low as possible which is only possible by designing proper heat treatment cycle.
- All these micro-structural features are observed on High Magnification Metallurgical Microscope and are absolutely necessary for providing proper wear resistant characteristics in high chrome alloys.
- We guarantee for the following advantage from our High Chrome Liners.
- Consistent Quality: Although all manufacturers are now equipped with spectrometer but due to constraint of time factor because of Heat cycles of 45-60 minutes, it is not practically possible to analyze chemical composition of bath samples of each heat. It is, therefore, most important to use only consistent quality of inputs. We have, therefore, restricted commercial grade of scrap in our factory and are using only selected qualities of scrap with known composition for getting consistent quality of these items well within specifications.
- Excellent Surface Finish: Unlike other manufacturers, we are using facing sand with 100% of fresh silica sand for getting good surface finish. Our fresh sand consumption is 2-3times compared to others. Perfect Sound Castings: Yield is known as ratio of net casting weight v/s gross weight e.g. if 70kg of casting is manufactured from 100 kg liquid metal poured, Yield becomes 70%. Manufacturing cost reduces with increase in yield percentage but still we are normally maintaining yield percentage of 60 – 65% for getting perfect sound castings from High Chrome Alloys.
- Properly Designed Heat Treatment Cycle: For achieving desired physical properties and microstructure level, High Chrome Casting have to pass through properly designed heat treatment cycle consisting of heating to specific temperature, soaking for certain period depending on thickness of castings and Cr percentage followed by proper air quenching and then tempering in electric furnace for relieving stresses developed during Heat treatment. Heat treatment cost can be drastically reduced if only hardness is to be provided but we are spending more on heat treatment of liners for improving micro-structural features which are necessary for achieving low wear rate.
- Low Specific Energy Consumption and Wear Rate due to Guaranteed Micro-Structural Features with optimum carbide quota and high reliability against breakage.
- Completely free from all type of casting defects due to closely monitored manufacturing process.
- Full Functionality during whole lifetime due to feature of retaining the shape for long time.
Specifications
High Chrome Grinding Liners are manufactured by us confirming to following specifications as per BS : 4844 as well as against specific requirements of customers.
