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Suiga cast o-glide

Cast-O-Glide is a chromium carbide overlay wear plate that offers unprecedented advantages over traditional quenched and tempered steel plates and weld clad plates. It provides the highest wear resistance, lowest maintenance needs, and highest productivity. Laboratory and field tests show Cast-O-Glide can last 5-6 times longer than quenched and tempered plates and 2-3 times longer than the best weld clad plates. Its extremely smooth surface and negligible dilution provide laminar flow and maximum carbide concentration for superior performance.

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SUIGA Advanced Materials and Technologies Turbocharge Your SAVINGS LeapfrogYour PROFITS
SUIGA Advanced Materials and Technologies “ According to statistics, India loses as much as USD 100 Billion (~ Rs. 6.5 Lakh Cr) every year on account of wear & corrosion ”. - National Metallurgical Laboratory (NML) “India loses around 4-5 % of GDP annually on account of wear and corrosion losses…" - Sunil Duggal, CEO - Hindustan Zinc Ltd (HZL) Reduction in wear thro’ innovatively superior solutions can make significant contribution to the bottom-line of an organisation by enhancing equipment uptime and reducing shutdowns.
SUIGA Advanced Materials and Technologies If you are using…. HARDOX or Similar Smooth Plates For Wear Resistance You can easily enhance…..
SUIGA Advanced Materials and Technologies Direct SAVINGS by ~Rs 60 Lacs For Every 10T of Q&T* Plates Note: This is a very conservative estimate & in reality Savings is higher in most wear situations. * Quench & Tempered Steel viz: Hardox /equivalent products Indirect Savings can be many times more !!
SUIGA Advanced Materials and Technologies AddingCrorestoProfitEveryYear S AV INGS HAV E NEV ER B EEN S O EA S Y !
SUIGA Advanced Materials and Technologies and still…..  Contribute to a Greener Environment  Conserve Resources  Enhance Safety at Workplace  Reduce Downtime  Reduce Labour Costs
SUIGA Advanced Materials and Technologies 1. Smooth Surface 2. Wear Resistance 3. All direction use 4. Fabrication Capability Why Do We Use Quench & Tempered (Q&T) Plates? Yet Q&T is an OLD Technology* If a product can outscore on each of these parameters, it will bring Unprecedented ADVANTAGE to Wear prone Industries *Oldest known example of tempered Martensite is a pick-axe which was found in Galilee, dating around 1200 to 1100 BC
SUIGA Advanced Materials and Technologies Cast -O- Glide Offers Unprecedented ADVANTAGE over existing Wear Plates Highest Productivity Lowest Maintenance Ultra high performance wear liners for today’s high productivity operations
SUIGA Advanced Materials and Technologies Cast -O- Glide Crack free, Even surface & All Direction Use Highest Wear Resistance (Abrasion, Erosion & Impact) Smoothness far Superior than Q&T Plates Delivering Innovation in Smooth Surface Wear Protection Reflection of pen on surface Plasma cut section-view showing sharp ‘line of dilution’ Crack free – even surface All Direction use High density, Hard Chromium Carbide layer Good Fabrication Capability (no loss of hardness)
| SUIGA Advanced Materials and Technologies Your Guarantee Against Wear due to Abrasion, Impact & Erosion Unmatched Wear Resistance Best in Cost- economics Improved Safety Greener Environment Cast –O- Glide CAST-O-GLIDE The Most Effective Solution for Clogging, Hang-ups & Carry backs
| SUIGA Advanced Materials and Technologies Cast-O-Glide Features Max Performance Overlay Smooth Surface Finish Low Co-efficient of Friction (~39% less than SS/Hardox) Reduced hang-ups & carry backs No Weld Beads Works irrespective of direction of flow of materials Laminar flow ensures further reduced wear Single pass alloy deposition from 4mm to 25 mm Packed & Uniform Distribution of Primary Carbides Sharp Fusion Line Means Negligible Dilution Product Type Chromium Carbide Overlay fused on Steel Base Smooth Surface Carbide Overlay Base Plate Weld bead-free Smooth, Even & Crack free surface Sharp Fusion Line Negligible Dilution - unmatched wear resistance Consistent Hardness & Micro-structure Consistent & Predictable wear rates Minimal Surface Cracks Very Low Residual Stress (Overlay & backing plate) Ease in Rolling & Fabrication Smoother flow of materials
| SUIGA Advanced Materials and Technologies Cast-O-Glide vs Other Wear Resistant Plates 20-25 X • 5-6 times (minimum) “Higher Life” than Q&T Plate • 2-3 times “Higher Life” than Best Weld Clad Plate • 3-4 times “Higher Life” than Ordinary Weld Clad Plate Cast-O-Glide * Under abrasive & erosive condition with moderate impact MILD STEEL/ SCRAP Q&T PLATE 12% MN STEEL* ORDINARY WELD CLAD PLATE BEST WELD CLAD PLATE Cast- O-Glide X 3.5 X 4 X 6 X 9 X 20-25 X Performance Beyond the Best
| SUIGA Advanced Materials and Technologies Silica is found associated with most minerals and hence, Q&T plate wears out easily against abrasion due to silica Best in Wear Resistance & Anti-Hang-ups/Anti-Clogging Hang-up & Carry-back Wear Resistance Low High High Quench & Tempered (Q&T) Plate (Used for both Wear Resistance & Hang-up) Conventional Weld Clad Plate (Never to be used as Hang-up solution – Surface Roughness increase hang-ups drastically) Best Wear Resistance & almost NegligibleL Hang-up & Carry- back (39% less Coefficient of Friction than Q&T) 60% of earth’s crust is made up of Silica & Quartz : Hardness ~ 800 Hv Quench & Tempered Carbon Steel : Hardness ~ 300 – 500 Hv Cast-O- Glide Carbide Hardness : Hardness ~ 1600 Hv Cast -O- Glide
| SUIGA Advanced Materials and Technologies Quench & Tempered Plate being Cut with Oxyacetylene Flame. HAZ can be seen around the cut line affecting performance. Q&T Plates – Hardness Reduces When Cutting & Welding Hardness of Cast -O -Glide doesn’t get affected during fabrication Heat Affected Zone
| SUIGA Advanced Materials and Technologies Q&T Plates – Oxidative Wear Cast -O -Glide hard layer packs the maximum density of Chromium Carbide which doesn’t allow formation of Iron oxide and hence causes No Oxidative Wear At the beginning of a wear process, the original oxide film on the metal surface gets removed when hard abrasives rub across the high point of the oxide layer. The fresh underlying metal will quickly react with oxygen in air to form a fresh oxide layer, which will then be scraped off again by abrasives in the following cycle. Such an "oxidation - scrape", or "chemical - mechanical" cycle repeats itself during the ‘Oxidative Wear’ process. During sliding, the high surface temperature induced by frictional heating, and the reduced activation energy of oxide formation caused by plastic deformation, can increase the oxidation rate. Thus, rapid oxidation can be achieved, and the oxide layer can grow thicker during sliding than that under static conditions. This ensures the fresh metal is rapidly covered with a new layer of oxide after the original oxide film was worn away. Mechanism of Oxidative Wear For Q&T steels, the worn surface becomes dark brown (colour of iron oxide) Cast-O-Glide surface doesn’t form Iron oxide Cast -O -Glide No iron oxide formation on the working surface
| SUIGA Advanced Materials and Technologies Industries today, have realized that the largest single factor in most repairs is the installation labour expense. It often outweighs the initial material cost. Here are the remains of an inexpensive Q&T Plates that had to be replaced after it failed prematurely, causing an unplanned breakdown. The initial lower cost quickly turned into a budget-buster. Buy Q&T Plates Cheap & Replace Often ? Crew can always take extra time to do the repetitive work Resources Constantly Reducing Life Cycle Becomes Important No resources available for repetitive work Earlier Now Maintenance Crew - 30 Maintenance Crew - 5
| SUIGA Advanced Materials and Technologies AR 400 often shows a period of good wear resistance followed by a period of rapid wear Cast-O-Glide vs Q&T Steels Q&T Plate is like Oreo Cookie Performance Will outlast Q&T Steel by a Factor > 6:1 La bor ator y & Field Tests show Abrasion Resistant Q&T Steels (AR 400, 500, 600, etc.) AR steels have a harder surface area (averaging 0.020” thick) than the center of the plate The greater the thickness, the lower the hardness is at the center of the plate. • AR plates show initial wear resistance till the 0.020” thick harder surface. • Then it shows more wear in 3 days than it did in 3 months The no. after AR though intended to convey hardness, has become generic and seldom conveys the actual Hardness. Imported AR 400 plates actually may test as low as 302 BHN “Hard on Top – Soft Inside” Cast -O -Glide
| SUIGA Advanced Materials and Technologies Smoothness Goes A Long Way !!! Generally, a rough surface will accelerate wear anywhere from 200 to 600% in comparison to a smooth surface of the same alloy structure and hardness. • Wear around bolt holes show up as comet trails • Corrugations & imperfections show up as cavitation erosion Weld beads in Ordinary Wear Plate generate turbulence leading to premature & costly failure of the wear liner Laminar Flow - Less Wear Turbulent flow - High Wear Cast-O-Glide ensures smoother flow of materials thro hoppers, bins & chutes, dumpers, etc Laminar Flow Cast-O-Glide With no weld beads, Cast- O-Glide allows a laminar flow reducing wear rates Ordinary Weld Clad Plate
| SUIGA Advanced Materials and Technologies Cast-O-Glide Offers Extremely Smooth Surface Wall Material Surface Roughness ‘Ra’ (μm) Remarks Cast-O- Glide (mill finished) 6.0 In service this will get polished to < 2.1 Cast-O- Glide (Polished) 2.1 Bulk Welded Clad Plate 9.5 Abrasion Resistant Q&T Plate 7.6 White Cast Iron 17.0 Ra: Known as the arithmetic mean, this measurement represents the average of all peaks and valleys. Lower numbers indicate a smoother surface Reflection Mill Finish Pre-polished Finish
| SUIGA Advanced Materials and Technologies Condition Dilution (%) Carbon Chromium ASTM G65 (Wt. Loss) Open Arc Wire 5.00 30.0 Open Arc (1st Layer) 40% 3.00 18.0 1.25 Open Arc (2nd Layer) 40% 4.20 25.2 0.40 Sub Arc (1st Layer) 10% 4.30 28.0 0.33 Sub Arc (2nd Layer) 10% 4.55 30.0 0.19 Mild Steel - 1020 Steel – Base plate (for comparison) 2.51 Cast-O-Glide Liners have almost NIL Dilution 20 Why Cast-O-Glide Far Outperforms Weld Clad Plate? Wear Rate increases with WEAR Conventional Weld Clad Wear Plate DILUTION in Conventional Weld Clad Plate reduces conc. of Chromium & Carbon Less Chromium Carbide leads to Increase in Rate of Wear This means that – if the 2nd layer wears out in 3 days, the 1st layer will wear out in 1 day.
| SUIGA Advanced Materials and Technologies 21 Why Cast-O-Glide Outperforms Best Weld Clad Plate? Chromium Carbide Wear Plate Cast-O-Glide: High Density & Ultra-Wear Resisting Hexagonal Carbide System The Sesame Chikki on the right has finer grains and hence can pack more grains needing less matrix than the ‘Badaam’ Chikki. Smaller the size of Carbides, more can be packed in the Matrix (higher VFC) leading to dramatic improvement in performance Cast-O-Glidewith a more dense, consistent and higher % age of carbides lasts much longer Cast-O- Glide offers the Most Optimised Carbide-Matrix System for dealing with Complex Erosive/Abrasion wear even with associated Impact
| SUIGA Advanced Materials and Technologies As the Volume Fraction of Carbides (VFC) increases, the Wear Resistance increases, whilst the Hardness has a Minimal effect on reducing abrasion loss Higher VFC leads to higher Life & Not Hardness Only ‘HARDNESS’ cannot determine Wear Resistance Volume Fraction of Carbides determines Wear Resistance Cast-O- Glide Cast O Glide Different materials with same hardness show widely varied wear rates Higher VFC always Lead to Higher Life
| SUIGA Advanced Materials and Technologies Hadfield 12% Mn Steel Abrasive Application Gouging Abrasion •Large Particles •High Impact or Compression Loads • GOOD Work Hardening Grinding Abrasion •Smaller Particles •High Compression Loads • MODERATE Work Hardening Scratching Abrasion •No Compression Load •Scratching Abrasion - Material is sliding • LOW Work Hardening Mn Steel acquires its working hardness by strain hardening. Original Hardness : 220 BHN With continuous Impact/compression, surface hardens to over 550 BHN Only outer skin hardens and steel stays ductile underneath It is not suited for combating low stress abrasion or erosion
| SUIGA Advanced Materials and Technologies Hadfield 12% Mn Steel Vs Cast-O-Fuse • Low stress or scratching abrasion is the most predominate wear characteristic with the steel being abraded away by the abrading material removing slivers from the wearing steel. • The length of the metal sliver removed varies based upon the microstructure and bulk hardness of the material being abraded Low Stress Abrasion Performance Will outlast 12% Mn Steel by a factor > 5:1 La bor ator y & Fi el d Tests show Manganese Steel is for impact only applications Mn Steel in an abrasion application like this one, will wear away quickly. It requires impact to work-harden the surface Cast O Glide
| SUIGA Advanced Materials and Technologies Overlay thickness (mm) 4 4 6 6 8 9 10 12 17 17 20 20 25 25 Base plate thickness (mm) 4 6 6 8 8 10 10 12 10 12 10 12 10 12 Finished/ Dressed Plate Size (BxL) mm x mm 600 x 2200 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 600 x 2500 600 x 2500 600 x 2500 600 x 2500 600 x 2500 600 x 2500 Overlay Base Plate BASE PLATE • Grade ASTM-A36 or equivalent for normal applications • Stainless Steel 304 Grade for Corrosive environment (on request) • Stainless Steel 310 Grade for High Temp & Corrosive environment (on request) Higher & Other thicknesses are also available on request Cast-O-Glide – Unprecedented Range of Thicknesses Thickness & Dimension details:
| SUIGA Advanced Materials and Technologies Cast-O-Glide – Forming Pipes & Bends Overlay Smallest Dia of Pipe • 8 + 8 = 450 mm • 6 + 6 = 410 mm • 4 + 6 = 410 mm • 4 + 4 = 320 mm Minimum Bend Dia (Overlay on Inside)
| SUIGA Advanced Materials and Technologies    Cast-O-Glide 6 on 6 rolled to 1500 mm OD Weld Repair Grinding of Weld Repair Cast-O-Glide – Forming Pipes (with overlay on OD)    Overlay Minimum Bend Dia (Overlay on Outside) Smallest Dia of Pipe • 12+12 ~ 2000 mm • 10+9 ~ 800 mm • 8 + 8 ~ 800 mm • 6 + 6 ~ 500 mm • 4 + 6 ~ 500 mm • 4 + 4 ~ 400 mm When coating as external diameter, stress crack will occur and expand in long line which can be repaired without affecting wear resistance
| SUIGA Advanced Materials and Technologies Cast-O-Glide - Industrial Applications Major Industries Served Mining Steel Cement Thermal power Non-ferrous Metal Industry Sugar Industry Glass Industry Paper Industry Major Applications Bunker/ Bins Liners Chutes & Hoppers, Cyclones Slurry pipelines & pulverized fuel lines Screw Conveyors Fan blades, Louvres, etc Excavator/Dumper liners Blast Furnace Armor plates & Chutes Screens
| SUIGA Advanced Materials and Technologies Enhances Productivity – Improves Efficiency Dozer with Hang-up Dozer without Hang-up Mining and Earthmoving equipment loses 10-20 % of efficiency due to material hang-up/carry-back (material sticking or binding to a surface) Cast-O-Glide ensures free flow of material, reduced build up and carry-back thereby increasing productivity/efficiency of earthmoving equipments Dumpers with Carry-back Dumpers without Carry-back Bucket with Hang-up Bucket without Hang-up Without Cast-O- Glide Liner With Cast-O-Glide Liner Truck Trays 20% Carry- Back 0% Carry-Back Dipper Buckets 60% Carry- Back 3% Carry - Back Dozer Blades 30% Carry- Back 0% Carry-Back
| SUIGA Advanced Materials and Technologies Reduced Hang-up & Clog free Bin, Hopper & Chutes Efficiency Improvement in Bin/Hopper Increasing Chute angle from 500 to 550 increases Chute Height by 21% and 600 results in a 45% increase Cast-O-Glide ensures smoother flow of materials thro hoppers, bins & chutes. Also, Hoppers & Bins can be designed with shallower wall angles because of lower wall friction and superior abrasion resistance… lowering construction costs. Wall Friction
| SUIGA Advanced Materials and Technologies Performance that is….. Breaking Boundaries Cast -O- Glide
| SUIGA Advanced Materials and Technologies P&H 4100 Shovel Bucket Earlier Used: Q&T Plate - 40 mm thick; Life – 4500 Hrs Cast-O-Glide - 10+9 mm thick Expected Life – in excess of 25,000 Hrs (~ 6 times at 50% thickness) Komatsu 930 Dumper (292 T) Earlier used : Q&T Plate – 40 mm Life – 4200 Hrs. Cast-O-Glide - 10 + 9 mm thick Expected life - 24,000 hrs (~ 6 times life at 50% thickness) Vibratory Feeder 650T/Hr Earlier Used - Conventional best weld clad wear plate - 10+8 mm. Solution : Cast-O-Glide, 10+8 mm Life - Over 10 times 84 % reduction in costs CAT 793 C Dumper (223 T) Earlier Used: Q&T Plate - 40 mm thick; Life – 8200 Hrs Cast-O-Glide plate 10+9 mm Expected life – in excess of 48,000 Hrs ( ~ 6 times with half the thickness) Cast-O-Glide –Renders Dramatic Improvement in Life
| SUIGA Advanced Materials and Technologies Dumpers experiencing a carry-back of 23% can give a return of Rs. 65L /year, just by switching from Q&T steel to Cast-O-Glide. Imagine the savings on a fleet of 200 Dumpers alone. In Savings - Expect the Unexpected !! How much an average Copper Mine Can Save by using Cast-O-Glide ? Copper ore is abrasive and sticky leading to severe wear problems in both mobile and fixed equipments. Performance & reliability of Stockpile feeders, discharge feeders , excavators, dumpers, Dozers, loaders, chutes , hoppers, etc are fundamental to mining success. Generally, 32 mm thick Q&T Liners are used in the stockpile and discharge feeders which give a life of 1900 Hrs (12 weeks approx.) with regular maintenance. Cast-O-Glide 16 mm liners will last 7000 Hours (maintenance free) & 20 mm will last for 10,000 Hrs ( 72 weeks ~ 6 times the 32mm liner in use)
| SUIGA Advanced Materials and Technologies The iron ore companies with an array of load out chutes, can potentially make a saving of Rs. 350 Cr on saved production alone, just by switching from Q&T and Conventional weld overlay plate to Cast-O-Glide In Savings - Expect the Unexpected !! How much an average Iron ore Mine Can Save by using Cast-O-Glide ? Iron ore mineral is hard and abrasive at Mohs 5.5–6.5. The associated silica has Mohs hardness of 7. Both mobile & fixed equipments undergo extreme wear and suffer from problems of hang-ups and carry backs. Wear components: Apron feeders, Pan feeders, crusher liners, conveyor skirt liners, feeder & transfer chutes, cyclones, buckets, train load out chutes, dozer blades, truck bed, bucket & loader liners, hoppers, fan liners, screw conveyors, Q&T Liners & Conventional Weld clad liners used are in sizes from 40 mm to 16 mm for various applications because of initial low cost. Those initial low cost savings with QT steels and weld type overlays are soon eroded through the high cost of down time and productivity losses.
| SUIGA Advanced Materials and Technologies The cement plants with an array of wear prone components throughput the plant can potentially make a saving of Rs. 5-7 Cr on saved production alone, just by switching from Q&T and Conventional weld overlay plate to Cast-O-Glide In Savings - Expect the Unexpected !! How much an average integrated cement plant Save by using Cast-O-Glide ? Integrated cement has both mine and processing plant. Limestone with containing silica causes extensive wear causes high wear in mining equipments & crusher liners and chutes & hoppers. Wear components: Mining area: Excavator buckets, Loaders, Dozers , Dumpers, Crusher liners Plant areas: Raw Mill, Cement Mill, Clinker section, gypsum line, Packaging section, Q&T Liners & Conventional Weld clad liners used are in sizes from 40 mm to 10 mm for various applications because of initial low cost. Those initial low cost savings with QT steels and weld type overlays are soon eroded through the high cost of down time and productivity losses.
| SUIGA Advanced Materials and Technologies 80% LESS LABOUR COSTS 80% LESS DOWNTIME 600% PERFORMANCE What We Get When We Use Cast-O-Glide ? PRODUCTIVITY is not just about doing more, it is about CREATING more impact with less work Cast -O- Glide
| SUIGA Advanced Materials and Technologies IS GREEN BY SWITCHING TO a single CAT 777 truck with a carry-back of 12.5% Saved carbon emission ~ 31 average sized cars Cast-O-Glide Contributes to a Greener Environment ! OUR PLANET IS WORTH MORE THAN OUR PROFITS Cast -O- Glide Cast -O- Glide
| SUIGA Advanced Materials and Technologies CAST-O-GLIDE DOESN’T COST TO GET GREENER IT ACTUALLY PAYS Contributing to a Greener Environment Year after Year IS GREEN 60 Kgs OF CAN REPLACE 600 Kgs of Q&T PLATE DURING ITS LIFE CYCLE Reducing Carbon Footprint & Conserving Resources Cast-O-Glide Contributes to a Greener Environment ! Cast -O- Glide Cast -O- Glide
| SUIGA Advanced Materials and Technologies Cast-O- Glide Contributes to Safety ENHANCES SAFETY BY Reducing Repair & Maintenance Frequency by OVER 80% IF REPLACING Q&T PLATES Cast -O- Glide
| SUIGA Advanced Materials and Technologies Product - Meets Maintenance Objectives Maintenance Objectives To increase functional reliability of production facilities To maximize the useful life of the equipment To maximize production capacity from the given equipment To minimize the total production cost To minimize the frequency of interruption in production by reducing breakdowns To enhance the safety of the manpower Does Meet ?       Cast -O- Glide
| SUIGA Advanced Materials and Technologies TECHNO- ECONOMICS Cast -O- Glide
| SUIGA Advanced Materials and Technologies Why Cast-O-Glide Doesn’t Cost – It PAYS !!! Q&T Plate (AR 450) Cast-O-Glide Remarks Price (A) Rs. 160/Kg Rs. 550/Kg Prices are approximate Thickness 40 mm 19 mm (10+9) 19 mm Cast-O-Glide can replace 40 mm Q&T Weight considered for an area 100 Kgs 60 Kgs Weight reduction advantages Life Expected X 6X Cast-O-Glide will outlast Q&T by min 6:1 Weight for Same Life (B) 600 Kgs 60 Kgs Cost Rs. 96,000/- Rs. 33,000/- Savings/100 Kgs of Q&T Rs. 63,000/- on every 100 Kgs of Q&T plates used Savings for 10 T Q&T Rs. 63.0 L Only 1 T of Cast-O-Glide will be needed Dragline Buckets, Excavator Buckets, Liners Indirect Savings Dis-assembly & Reassembly Cost Equipment Downtime Reduced Hang-ups & Carry backs Reduced Clogging Reduced Weight benefits Direct Savings
| SUIGA Advanced Materials and Technologies Why Cast-O-Glide Doesn’t Cost – It PAYS !!! Mn Steel Liners Cast-O-Glide Remarks Price (A) Rs. 140/Kg Rs. 520/Kg Prices are approximate Thickness 16 mm 12 mm (6+6) 12 mm Cast-O-Glide is sufficient Weight of plate/segment (80 m2) 10 T 7.7 T Weight reduction advantages Total Qty for 1 Bunker 60 T 46.2 T Life Expected 3 months 15 months Cast-O-Glide will outlast Mn Steel by min 5:1 Weight for Same Life (B) 300 T 46.2 T Cost Rs. 420 L Rs. 240 L Direct Saving per Coke Bunker Rs. 180 L Only 1 T of Cast-O-Glide will be needed Savings on 6 Bunkers Rs. 180 L x 6 = Rs. 10.8 Cr Coke Bunker Liners Indirect Savings Dis-assembly & Reassembly Cost Equipment Downtime Reduced Hang-ups & Carry backs Reduced Clogging Direct Savings
SUIGA Advanced Materials and Technologies Q&T Plates (AR 450) Cast-O-Glide Remarks Price (A) Rs. 160-220/Kg Rs. 500/Kg Thickness 12 mm 12 mm (6+6 mm) Plate thicknesses were kept same Weight on one application 1000 Kgs 1000 Kgs Life Expected (~ 6 times which is minimum) X 6X For same thickness, Cast-O-Glide will generally perform 9-12 times. Weight for Similar Life (B) 6000 Kgs 1000 Kgs Cost per Life Cycle of Cast-O-Glide Rs. 9,60,000/- Rs. 5,00,000/- These are approx. prices and actual savings may be still more. Savings/ Tonne of Q&T Rs. 4,60,000/- Why Cast-O-Glide Doesn’t Cost – It PAYS !!! Liners with same Plate thickness as Q&T Indirect Savings Dis-assembly & Reassembly Cost Equipment Downtime Reduced Hang-ups & Carry backs Reduced Clogging Direct Savings
| SUIGA Advanced Materials and Technologies Why Cast-O- Glide Doesn’t Cost – It PAYS !!! Cost of replacing Hardox (12 m2) for 5 times = Rs. 3.6 L x 5 Times = Rs. 18 L Cost of Cast-O-Glide once for 12 m2 (every 5 times of Hardox) = Rs. 6 L Direct Savings : = Rs. 12 L Loss due to Carry-backs of PC 2000 Excavator Bucket Cost of handling per cu.m of overburden Rs. 8 Cycles per Hour (1 cycle every 60 seconds) 60 Carry over or hang up of 12% for 14 cu.m bucket 1.68 cu.m Cost of Hang up/ Carryover Value in Rs. Per Cycle 13.44 Per hour 806.4 Per day (22 hours) 17,740.8 Per Year (350 days) 62,09,280 Loss on account of carry back per year (‘A’) ~ Rs. 62,00,000/- Savings because of reduced carry back (70% of ‘A’) ~ Rs. 43 L Savings in Komatsu PC 2000 Bucket Other Savings 15 days’ downtime per repair reduced to NIL Original Bucket Life improved (~ lasts for 5 repairs with new life) Damage to pins and booms reduced Reduced Weight if less thick liners used
| SUIGA Advanced Materials and Technologies Why Cast-O-Glide Doesn’t Cost – It PAYS !!! Carry-Back /Hang-up losses (Dumpers) Remarks Fleet Size (Dumpers) - (F) 50 Nos Capacity (C) 100 T Nos. of Trips per Day (N) 14 Avg Hang-ups/Carry backs (H) 10% Cast-O-Glide will outlast Q&T by min 6:1 Working Days in 5 years (W) 1500 (300days X 5 Yrs) Cast-O-Glide will last for 5 years against Q&T lasting for 1 year Loss due to Hang-ups in 5 yrs (L) 10,500,000 T L = (50 F x 100 C x 14 N x 0.1 H x 1500 W) Tonnes Loss (for transportation only) Rs. 26.25 Cr Overburden transport cost @ Rs. 25/T Savings in Fleet of 50 Nos. of 100 T Dumper Cost of replacing Hardox (20 m2) for 5 years = Rs. 6 L x 5 times = Rs. 30 L Cost of Cast-O-Glide once in 5 years for 20 m2 = Rs. 12 L Direct Savings : = Rs. 18 L Other Savings 15 days’ downtime per repair reduced to NIL Original Dump Body Life improved (~ lasts for 5 repairs with new life) Less fuel consumption & Less Tyre Wear Reduced Weight if less thick liners used
| SUIGA Advanced Materials and Technologies Dam Ring Techno-Economics – Pfeiffer Cement Mill Mild Steel Quench & Tempered (AR 400) Cast-O-Glide Remarks Price (approx.) (A) Rs. 65/Kg Rs. 250/Kg Rs. 500/Kg Cast-O-Glide liners are sold on sq mtr basis and hence per kg prices are derived & approx Thickness (two sizes) 30mm +25 mm (86 kgs +72 Kgs) 30mm +25 mm (86 Kgs +72 Kgs) 24mm (12+12) + 16mm (8+8) 30mm of Q&T plate can be replaced by 24 mm (12+12) of Cast-O-Glide and 25 mm Q&T plate can be replaced by 16mm (8+8) of Cast- O-Glide Weight on one application 1264 Kgs (688+576) 1264 Kgs 976 Kgs (584+392) 8 segments of both thicknesses considered Life Expected X 2.5 X 15 X Cast-O-Glide will outlast Q&T by min 6:1 Weight for Similar Life as Cast-O-Glide (B) 18,960 Kgs 7,584 Kgs 976 kgs Cast-O-Glide helps in conservation and contributes to a greener environment Cost /Life Cycle of Cast-O-Glide (A X B) Rs. 12,32,400/- Rs. 18,96,000/- Rs. 4,88,000/- These are approx. prices and actual savings may still be more. Dis-assembly & Re-assembly Cost Equipment Downtime Enhanced Efficiency Weight Reduction
| SUIGA Advanced Materials and Technologies Techno-Economics for LS Crusher Housing Liners Mn Steel Gr 3 Cast-O-Glide Remarks Price (approx.) (A) Rs. 120/Kg Rs. 540/Kg Cast-O-Glide liners are sold on sq mtr basis and hence per kg prices are derived prices. Thickness 50 mm 10+9 mm UTCL has confirmed replacing the 50 mm Mn Steel Liners with 10+9 mm thick Cast-O-Glide Weight (per m2) 400 Kgs 152 Kgs Total Weight of Liners (approx.) 1,112 Kgs 423 Kgs Life Expected X 4 X Cast-O-Glide will outlast Mn Steel by min 4:1 in application where low angle abrasion and erosion are there with moderate impact. Weight for Similar Life as Cast-O-Glide (B) 4,448 Kgs 423 kgs Cast-O-Glide helps in conservation and contributes to a greener environment Cost /Life Cycle of Cast-O-Glide (A X B) Rs. 5,33,760/- Rs. 2,28,420/- These are approx. prices for plates only and actual savings may still be more. Dis-assembly & Re-assembly Cost Equipment Downtime Enhanced Efficiency Weight Reduction
| SUIGA Advanced Materials and Technologies SCREEN World’s Most Wear Resistant Design to Outlast & Outperform All Q&T and Smooth Surface Screens D e l i v e r i n g I n n o v a t i o n Water Jet Cut Laser Cut OPTIONS Cast-O-Glide 4XP Screen POWER OF  eXtra Performance  eXtra Productivity  eXtra Profitability  eXtra Planet-friendly 4XP DESIGN SUIGA Product Design Philosophy Cast -O- Glide
| IMCO Alloys Limited SAVINGS ! Your Best Return on Investment (ROI) Cast O Glide
| SUIGA Advanced Materials and Technologies Cast -O- Glide Innovative Product Predictableand Consistent Performance Reduced Hang-ups & Carry-back Equipment Weight Reduction Design & Fabrication Capability Customised Solutions Most Cost Effective Wear Solution Reduces Maintenance cost & Downtime, Enhances Productivity Eliminates Carry-back & Hang-ups Enhances Original Life of equipment (Less frequent repairs) Improved Safety at Work Place - thro’ reduced maintenance Contributes to Greener Environment Helps in Optimization of Resources SUIGA Offering…
SUIGA Advanced Materials and Technologies A Global Company engaged in developing & promoting only top line patented, unique and innovative industrial solutions with ”Lower Life Cycle Costs” serving domestic & international markets thro’ a strong pan India & global network. Advanced Materials and Technologies “Designing and implementing transformative wear solutions that help the world’s leading companies build for the future” About SUIGA
| Transformative Wear Solutions SUIGA Advanced Materials and Technologies About SUIGA 53 VALUE PROPOSITION 1 An international company focused on developing and promoting innovative wear solutions & technologies across a wide range of industries in India and globe. GLOBAL COLLABORATION & INNOVATIONS 2 With a team of inventors & innovators and collaboration with internationally renowned institutions viz: IITs, Ceramic Research Institute, Kolkata; CSIR – IICT, Hyderabad; NCL,Pune , SUIGA is well positioned to bring advanced & superior, innovative and patented technologies to serve industries better. FOCUS ON TECHNOLOGIES 3 Promoters & advisors are ex L&T & ex SAIL (USD 18 Bn Co.) with rich experience in engineering, manufacturing & tribology for wear prone industries viz: Steel, Cement, Power, Mining, Sugar, Fertilizer, Oil & Gas, Glass, Paper, Tyre, Agro industries, etc. REACHING THE WORLD 4 With a network of channel partners across India and more than 60 countries, SUIGA offers good knowledge and platform to reach a wide range of industries fast and simultaneously.
| Transformative Wear Solutions SUIGA Advanced Materials and Technologies Global Network….. A strong network in more than 60 countries
SUIGA Advanced Materials and Technologies POWER OF 4XP DESIGN SUIGA’s Product Design Philosophy SUIGA’s R&D and Product Design is driven by its 4XP Core Philosophy 01 02 04 03 eXtra Performance eXtra Productivity eXtra Profitability eXtra Planet-friendly
| SUIGA Advanced Materials and Technologies 0 20 40 60 80 100 120 High Stress Abrasion Rating Relative to ASTM A36 Only Top End Wear Solutions SUIGA Range of High-Performance Wear Solutions Extraordinary SOLUTIONS! Unprecedented SAVINGS !! ONLY COMPANY IN THE WORLD TO OFFER THIS ‘Value Proposition’
| SUIGA Advanced Materials and Technologies Only Company in the World WithProductsToMeet&Exceed BHP Billiton SPEC - 5 Redefining Wear Benchmark Globally
| SUIGA Advanced Materials and Technologies BeingTheBestAgainstWear DIS RUP T ING T HE WORLD OF WEA R GLOBA LLY Advanced Materials and Technologies
| SUIGA Advanced Materials and Technologies SUIGA Wear Solutions TECHNOLOGY DRIVEN. WEAR FOCUSED. Thank You 59 Note: No part of this presentation file may be reproduced, in any form or by any means, without written permission from SUIGA Advanced Materials and Technologies (OPC) Pvt Ltd. Shashi Bhushan Cell +91 9833 698872 Email: SUIGA.advancedtechnologies@gmail.com Contact
| SUIGA Advanced Materials and Technologies
| SUIGA Advanced Materials and Technologies X Cross Hatch CCO Wear Plate COMMON SIZES Cross Hatch AbrasaPlate 4 on 4 4 on 6 6 on 8 9 on 10 12 on 12 COMMON APPLICATIONS Chutes Truck Beds Buckets Ducts Screen Plates Hoppers Pump Casing Transition Segments Crushers Fans Elbows Cross hatch AbrasaPlate®-X is light weight, and outstanding for high impact applications. It is made of mild steel backing, with a weld overlay chrome carbide hardfacing, then a 3mm thick hardfaced cross hatch pattern. The cross hatch pattern enables bulk solids to fill up depressions in the surface, and then selfprotect. It also provides outstanding impact resistance. A general purpose chrome-carbide overlay plate suitable for application in various positions. High impact and abrasion resistance.
| SUIGA Advanced Materials and Technologies Cross hatch Plate has excellent impact resistance Quarry chute wear plates from - X cross hatch

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Suiga cast o-glide

  • 1.
    SUIGA Advanced Materialsand Technologies Turbocharge Your SAVINGS LeapfrogYour PROFITS
  • 2.
    SUIGA Advanced Materialsand Technologies “ According to statistics, India loses as much as USD 100 Billion (~ Rs. 6.5 Lakh Cr) every year on account of wear & corrosion ”. - National Metallurgical Laboratory (NML) “India loses around 4-5 % of GDP annually on account of wear and corrosion losses…" - Sunil Duggal, CEO - Hindustan Zinc Ltd (HZL) Reduction in wear thro’ innovatively superior solutions can make significant contribution to the bottom-line of an organisation by enhancing equipment uptime and reducing shutdowns.
  • 3.
    SUIGA Advanced Materialsand Technologies If you are using…. HARDOX or Similar Smooth Plates For Wear Resistance You can easily enhance…..
  • 4.
    SUIGA Advanced Materialsand Technologies Direct SAVINGS by ~Rs 60 Lacs For Every 10T of Q&T* Plates Note: This is a very conservative estimate & in reality Savings is higher in most wear situations. * Quench & Tempered Steel viz: Hardox /equivalent products Indirect Savings can be many times more !!
  • 5.
    SUIGA Advanced Materialsand Technologies AddingCrorestoProfitEveryYear S AV INGS HAV E NEV ER B EEN S O EA S Y !
  • 6.
    SUIGA Advanced Materialsand Technologies and still…..  Contribute to a Greener Environment  Conserve Resources  Enhance Safety at Workplace  Reduce Downtime  Reduce Labour Costs
  • 7.
    SUIGA Advanced Materialsand Technologies 1. Smooth Surface 2. Wear Resistance 3. All direction use 4. Fabrication Capability Why Do We Use Quench & Tempered (Q&T) Plates? Yet Q&T is an OLD Technology* If a product can outscore on each of these parameters, it will bring Unprecedented ADVANTAGE to Wear prone Industries *Oldest known example of tempered Martensite is a pick-axe which was found in Galilee, dating around 1200 to 1100 BC
  • 8.
    SUIGA Advanced Materialsand Technologies Cast -O- Glide Offers Unprecedented ADVANTAGE over existing Wear Plates Highest Productivity Lowest Maintenance Ultra high performance wear liners for today’s high productivity operations
  • 9.
    SUIGA Advanced Materialsand Technologies Cast -O- Glide Crack free, Even surface & All Direction Use Highest Wear Resistance (Abrasion, Erosion & Impact) Smoothness far Superior than Q&T Plates Delivering Innovation in Smooth Surface Wear Protection Reflection of pen on surface Plasma cut section-view showing sharp ‘line of dilution’ Crack free – even surface All Direction use High density, Hard Chromium Carbide layer Good Fabrication Capability (no loss of hardness)
  • 10.
    | SUIGA Advanced Materialsand Technologies Your Guarantee Against Wear due to Abrasion, Impact & Erosion Unmatched Wear Resistance Best in Cost- economics Improved Safety Greener Environment Cast –O- Glide CAST-O-GLIDE The Most Effective Solution for Clogging, Hang-ups & Carry backs
  • 11.
    | SUIGA Advanced Materialsand Technologies Cast-O-Glide Features Max Performance Overlay Smooth Surface Finish Low Co-efficient of Friction (~39% less than SS/Hardox) Reduced hang-ups & carry backs No Weld Beads Works irrespective of direction of flow of materials Laminar flow ensures further reduced wear Single pass alloy deposition from 4mm to 25 mm Packed & Uniform Distribution of Primary Carbides Sharp Fusion Line Means Negligible Dilution Product Type Chromium Carbide Overlay fused on Steel Base Smooth Surface Carbide Overlay Base Plate Weld bead-free Smooth, Even & Crack free surface Sharp Fusion Line Negligible Dilution - unmatched wear resistance Consistent Hardness & Micro-structure Consistent & Predictable wear rates Minimal Surface Cracks Very Low Residual Stress (Overlay & backing plate) Ease in Rolling & Fabrication Smoother flow of materials
  • 12.
    | SUIGA Advanced Materialsand Technologies Cast-O-Glide vs Other Wear Resistant Plates 20-25 X • 5-6 times (minimum) “Higher Life” than Q&T Plate • 2-3 times “Higher Life” than Best Weld Clad Plate • 3-4 times “Higher Life” than Ordinary Weld Clad Plate Cast-O-Glide * Under abrasive & erosive condition with moderate impact MILD STEEL/ SCRAP Q&T PLATE 12% MN STEEL* ORDINARY WELD CLAD PLATE BEST WELD CLAD PLATE Cast- O-Glide X 3.5 X 4 X 6 X 9 X 20-25 X Performance Beyond the Best
  • 13.
    | SUIGA Advanced Materialsand Technologies Silica is found associated with most minerals and hence, Q&T plate wears out easily against abrasion due to silica Best in Wear Resistance & Anti-Hang-ups/Anti-Clogging Hang-up & Carry-back Wear Resistance Low High High Quench & Tempered (Q&T) Plate (Used for both Wear Resistance & Hang-up) Conventional Weld Clad Plate (Never to be used as Hang-up solution – Surface Roughness increase hang-ups drastically) Best Wear Resistance & almost NegligibleL Hang-up & Carry- back (39% less Coefficient of Friction than Q&T) 60% of earth’s crust is made up of Silica & Quartz : Hardness ~ 800 Hv Quench & Tempered Carbon Steel : Hardness ~ 300 – 500 Hv Cast-O- Glide Carbide Hardness : Hardness ~ 1600 Hv Cast -O- Glide
  • 14.
    | SUIGA Advanced Materialsand Technologies Quench & Tempered Plate being Cut with Oxyacetylene Flame. HAZ can be seen around the cut line affecting performance. Q&T Plates – Hardness Reduces When Cutting & Welding Hardness of Cast -O -Glide doesn’t get affected during fabrication Heat Affected Zone
  • 15.
    | SUIGA Advanced Materialsand Technologies Q&T Plates – Oxidative Wear Cast -O -Glide hard layer packs the maximum density of Chromium Carbide which doesn’t allow formation of Iron oxide and hence causes No Oxidative Wear At the beginning of a wear process, the original oxide film on the metal surface gets removed when hard abrasives rub across the high point of the oxide layer. The fresh underlying metal will quickly react with oxygen in air to form a fresh oxide layer, which will then be scraped off again by abrasives in the following cycle. Such an "oxidation - scrape", or "chemical - mechanical" cycle repeats itself during the ‘Oxidative Wear’ process. During sliding, the high surface temperature induced by frictional heating, and the reduced activation energy of oxide formation caused by plastic deformation, can increase the oxidation rate. Thus, rapid oxidation can be achieved, and the oxide layer can grow thicker during sliding than that under static conditions. This ensures the fresh metal is rapidly covered with a new layer of oxide after the original oxide film was worn away. Mechanism of Oxidative Wear For Q&T steels, the worn surface becomes dark brown (colour of iron oxide) Cast-O-Glide surface doesn’t form Iron oxide Cast -O -Glide No iron oxide formation on the working surface
  • 16.
    | SUIGA Advanced Materialsand Technologies Industries today, have realized that the largest single factor in most repairs is the installation labour expense. It often outweighs the initial material cost. Here are the remains of an inexpensive Q&T Plates that had to be replaced after it failed prematurely, causing an unplanned breakdown. The initial lower cost quickly turned into a budget-buster. Buy Q&T Plates Cheap & Replace Often ? Crew can always take extra time to do the repetitive work Resources Constantly Reducing Life Cycle Becomes Important No resources available for repetitive work Earlier Now Maintenance Crew - 30 Maintenance Crew - 5
  • 17.
    | SUIGA Advanced Materialsand Technologies AR 400 often shows a period of good wear resistance followed by a period of rapid wear Cast-O-Glide vs Q&T Steels Q&T Plate is like Oreo Cookie Performance Will outlast Q&T Steel by a Factor > 6:1 La bor ator y & Field Tests show Abrasion Resistant Q&T Steels (AR 400, 500, 600, etc.) AR steels have a harder surface area (averaging 0.020” thick) than the center of the plate The greater the thickness, the lower the hardness is at the center of the plate. • AR plates show initial wear resistance till the 0.020” thick harder surface. • Then it shows more wear in 3 days than it did in 3 months The no. after AR though intended to convey hardness, has become generic and seldom conveys the actual Hardness. Imported AR 400 plates actually may test as low as 302 BHN “Hard on Top – Soft Inside” Cast -O -Glide
  • 18.
    | SUIGA Advanced Materialsand Technologies Smoothness Goes A Long Way !!! Generally, a rough surface will accelerate wear anywhere from 200 to 600% in comparison to a smooth surface of the same alloy structure and hardness. • Wear around bolt holes show up as comet trails • Corrugations & imperfections show up as cavitation erosion Weld beads in Ordinary Wear Plate generate turbulence leading to premature & costly failure of the wear liner Laminar Flow - Less Wear Turbulent flow - High Wear Cast-O-Glide ensures smoother flow of materials thro hoppers, bins & chutes, dumpers, etc Laminar Flow Cast-O-Glide With no weld beads, Cast- O-Glide allows a laminar flow reducing wear rates Ordinary Weld Clad Plate
  • 19.
    | SUIGA Advanced Materialsand Technologies Cast-O-Glide Offers Extremely Smooth Surface Wall Material Surface Roughness ‘Ra’ (μm) Remarks Cast-O- Glide (mill finished) 6.0 In service this will get polished to < 2.1 Cast-O- Glide (Polished) 2.1 Bulk Welded Clad Plate 9.5 Abrasion Resistant Q&T Plate 7.6 White Cast Iron 17.0 Ra: Known as the arithmetic mean, this measurement represents the average of all peaks and valleys. Lower numbers indicate a smoother surface Reflection Mill Finish Pre-polished Finish
  • 20.
    | SUIGA Advanced Materialsand Technologies Condition Dilution (%) Carbon Chromium ASTM G65 (Wt. Loss) Open Arc Wire 5.00 30.0 Open Arc (1st Layer) 40% 3.00 18.0 1.25 Open Arc (2nd Layer) 40% 4.20 25.2 0.40 Sub Arc (1st Layer) 10% 4.30 28.0 0.33 Sub Arc (2nd Layer) 10% 4.55 30.0 0.19 Mild Steel - 1020 Steel – Base plate (for comparison) 2.51 Cast-O-Glide Liners have almost NIL Dilution 20 Why Cast-O-Glide Far Outperforms Weld Clad Plate? Wear Rate increases with WEAR Conventional Weld Clad Wear Plate DILUTION in Conventional Weld Clad Plate reduces conc. of Chromium & Carbon Less Chromium Carbide leads to Increase in Rate of Wear This means that – if the 2nd layer wears out in 3 days, the 1st layer will wear out in 1 day.
  • 21.
    | SUIGA Advanced Materialsand Technologies 21 Why Cast-O-Glide Outperforms Best Weld Clad Plate? Chromium Carbide Wear Plate Cast-O-Glide: High Density & Ultra-Wear Resisting Hexagonal Carbide System The Sesame Chikki on the right has finer grains and hence can pack more grains needing less matrix than the ‘Badaam’ Chikki. Smaller the size of Carbides, more can be packed in the Matrix (higher VFC) leading to dramatic improvement in performance Cast-O-Glidewith a more dense, consistent and higher % age of carbides lasts much longer Cast-O- Glide offers the Most Optimised Carbide-Matrix System for dealing with Complex Erosive/Abrasion wear even with associated Impact
  • 22.
    | SUIGA Advanced Materialsand Technologies As the Volume Fraction of Carbides (VFC) increases, the Wear Resistance increases, whilst the Hardness has a Minimal effect on reducing abrasion loss Higher VFC leads to higher Life & Not Hardness Only ‘HARDNESS’ cannot determine Wear Resistance Volume Fraction of Carbides determines Wear Resistance Cast-O- Glide Cast O Glide Different materials with same hardness show widely varied wear rates Higher VFC always Lead to Higher Life
  • 23.
    | SUIGA Advanced Materialsand Technologies Hadfield 12% Mn Steel Abrasive Application Gouging Abrasion •Large Particles •High Impact or Compression Loads • GOOD Work Hardening Grinding Abrasion •Smaller Particles •High Compression Loads • MODERATE Work Hardening Scratching Abrasion •No Compression Load •Scratching Abrasion - Material is sliding • LOW Work Hardening Mn Steel acquires its working hardness by strain hardening. Original Hardness : 220 BHN With continuous Impact/compression, surface hardens to over 550 BHN Only outer skin hardens and steel stays ductile underneath It is not suited for combating low stress abrasion or erosion
  • 24.
    | SUIGA Advanced Materialsand Technologies Hadfield 12% Mn Steel Vs Cast-O-Fuse • Low stress or scratching abrasion is the most predominate wear characteristic with the steel being abraded away by the abrading material removing slivers from the wearing steel. • The length of the metal sliver removed varies based upon the microstructure and bulk hardness of the material being abraded Low Stress Abrasion Performance Will outlast 12% Mn Steel by a factor > 5:1 La bor ator y & Fi el d Tests show Manganese Steel is for impact only applications Mn Steel in an abrasion application like this one, will wear away quickly. It requires impact to work-harden the surface Cast O Glide
  • 25.
    | SUIGA Advanced Materialsand Technologies Overlay thickness (mm) 4 4 6 6 8 9 10 12 17 17 20 20 25 25 Base plate thickness (mm) 4 6 6 8 8 10 10 12 10 12 10 12 10 12 Finished/ Dressed Plate Size (BxL) mm x mm 600 x 2200 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 1000 x 3000 ; 1200 x 3000 600 x 2500 600 x 2500 600 x 2500 600 x 2500 600 x 2500 600 x 2500 Overlay Base Plate BASE PLATE • Grade ASTM-A36 or equivalent for normal applications • Stainless Steel 304 Grade for Corrosive environment (on request) • Stainless Steel 310 Grade for High Temp & Corrosive environment (on request) Higher & Other thicknesses are also available on request Cast-O-Glide – Unprecedented Range of Thicknesses Thickness & Dimension details:
  • 26.
    | SUIGA Advanced Materialsand Technologies Cast-O-Glide – Forming Pipes & Bends Overlay Smallest Dia of Pipe • 8 + 8 = 450 mm • 6 + 6 = 410 mm • 4 + 6 = 410 mm • 4 + 4 = 320 mm Minimum Bend Dia (Overlay on Inside)
  • 27.
    | SUIGA Advanced Materialsand Technologies    Cast-O-Glide 6 on 6 rolled to 1500 mm OD Weld Repair Grinding of Weld Repair Cast-O-Glide – Forming Pipes (with overlay on OD)    Overlay Minimum Bend Dia (Overlay on Outside) Smallest Dia of Pipe • 12+12 ~ 2000 mm • 10+9 ~ 800 mm • 8 + 8 ~ 800 mm • 6 + 6 ~ 500 mm • 4 + 6 ~ 500 mm • 4 + 4 ~ 400 mm When coating as external diameter, stress crack will occur and expand in long line which can be repaired without affecting wear resistance
  • 28.
    | SUIGA Advanced Materialsand Technologies Cast-O-Glide - Industrial Applications Major Industries Served Mining Steel Cement Thermal power Non-ferrous Metal Industry Sugar Industry Glass Industry Paper Industry Major Applications Bunker/ Bins Liners Chutes & Hoppers, Cyclones Slurry pipelines & pulverized fuel lines Screw Conveyors Fan blades, Louvres, etc Excavator/Dumper liners Blast Furnace Armor plates & Chutes Screens
  • 29.
    | SUIGA Advanced Materialsand Technologies Enhances Productivity – Improves Efficiency Dozer with Hang-up Dozer without Hang-up Mining and Earthmoving equipment loses 10-20 % of efficiency due to material hang-up/carry-back (material sticking or binding to a surface) Cast-O-Glide ensures free flow of material, reduced build up and carry-back thereby increasing productivity/efficiency of earthmoving equipments Dumpers with Carry-back Dumpers without Carry-back Bucket with Hang-up Bucket without Hang-up Without Cast-O- Glide Liner With Cast-O-Glide Liner Truck Trays 20% Carry- Back 0% Carry-Back Dipper Buckets 60% Carry- Back 3% Carry - Back Dozer Blades 30% Carry- Back 0% Carry-Back
  • 30.
    | SUIGA Advanced Materialsand Technologies Reduced Hang-up & Clog free Bin, Hopper & Chutes Efficiency Improvement in Bin/Hopper Increasing Chute angle from 500 to 550 increases Chute Height by 21% and 600 results in a 45% increase Cast-O-Glide ensures smoother flow of materials thro hoppers, bins & chutes. Also, Hoppers & Bins can be designed with shallower wall angles because of lower wall friction and superior abrasion resistance… lowering construction costs. Wall Friction
  • 31.
    | SUIGA Advanced Materialsand Technologies Performance that is….. Breaking Boundaries Cast -O- Glide
  • 32.
    | SUIGA Advanced Materialsand Technologies P&H 4100 Shovel Bucket Earlier Used: Q&T Plate - 40 mm thick; Life – 4500 Hrs Cast-O-Glide - 10+9 mm thick Expected Life – in excess of 25,000 Hrs (~ 6 times at 50% thickness) Komatsu 930 Dumper (292 T) Earlier used : Q&T Plate – 40 mm Life – 4200 Hrs. Cast-O-Glide - 10 + 9 mm thick Expected life - 24,000 hrs (~ 6 times life at 50% thickness) Vibratory Feeder 650T/Hr Earlier Used - Conventional best weld clad wear plate - 10+8 mm. Solution : Cast-O-Glide, 10+8 mm Life - Over 10 times 84 % reduction in costs CAT 793 C Dumper (223 T) Earlier Used: Q&T Plate - 40 mm thick; Life – 8200 Hrs Cast-O-Glide plate 10+9 mm Expected life – in excess of 48,000 Hrs ( ~ 6 times with half the thickness) Cast-O-Glide –Renders Dramatic Improvement in Life
  • 33.
    | SUIGA Advanced Materialsand Technologies Dumpers experiencing a carry-back of 23% can give a return of Rs. 65L /year, just by switching from Q&T steel to Cast-O-Glide. Imagine the savings on a fleet of 200 Dumpers alone. In Savings - Expect the Unexpected !! How much an average Copper Mine Can Save by using Cast-O-Glide ? Copper ore is abrasive and sticky leading to severe wear problems in both mobile and fixed equipments. Performance & reliability of Stockpile feeders, discharge feeders , excavators, dumpers, Dozers, loaders, chutes , hoppers, etc are fundamental to mining success. Generally, 32 mm thick Q&T Liners are used in the stockpile and discharge feeders which give a life of 1900 Hrs (12 weeks approx.) with regular maintenance. Cast-O-Glide 16 mm liners will last 7000 Hours (maintenance free) & 20 mm will last for 10,000 Hrs ( 72 weeks ~ 6 times the 32mm liner in use)
  • 34.
    | SUIGA Advanced Materialsand Technologies The iron ore companies with an array of load out chutes, can potentially make a saving of Rs. 350 Cr on saved production alone, just by switching from Q&T and Conventional weld overlay plate to Cast-O-Glide In Savings - Expect the Unexpected !! How much an average Iron ore Mine Can Save by using Cast-O-Glide ? Iron ore mineral is hard and abrasive at Mohs 5.5–6.5. The associated silica has Mohs hardness of 7. Both mobile & fixed equipments undergo extreme wear and suffer from problems of hang-ups and carry backs. Wear components: Apron feeders, Pan feeders, crusher liners, conveyor skirt liners, feeder & transfer chutes, cyclones, buckets, train load out chutes, dozer blades, truck bed, bucket & loader liners, hoppers, fan liners, screw conveyors, Q&T Liners & Conventional Weld clad liners used are in sizes from 40 mm to 16 mm for various applications because of initial low cost. Those initial low cost savings with QT steels and weld type overlays are soon eroded through the high cost of down time and productivity losses.
  • 35.
    | SUIGA Advanced Materialsand Technologies The cement plants with an array of wear prone components throughput the plant can potentially make a saving of Rs. 5-7 Cr on saved production alone, just by switching from Q&T and Conventional weld overlay plate to Cast-O-Glide In Savings - Expect the Unexpected !! How much an average integrated cement plant Save by using Cast-O-Glide ? Integrated cement has both mine and processing plant. Limestone with containing silica causes extensive wear causes high wear in mining equipments & crusher liners and chutes & hoppers. Wear components: Mining area: Excavator buckets, Loaders, Dozers , Dumpers, Crusher liners Plant areas: Raw Mill, Cement Mill, Clinker section, gypsum line, Packaging section, Q&T Liners & Conventional Weld clad liners used are in sizes from 40 mm to 10 mm for various applications because of initial low cost. Those initial low cost savings with QT steels and weld type overlays are soon eroded through the high cost of down time and productivity losses.
  • 36.
    | SUIGA Advanced Materialsand Technologies 80% LESS LABOUR COSTS 80% LESS DOWNTIME 600% PERFORMANCE What We Get When We Use Cast-O-Glide ? PRODUCTIVITY is not just about doing more, it is about CREATING more impact with less work Cast -O- Glide
  • 37.
    | SUIGA Advanced Materialsand Technologies IS GREEN BY SWITCHING TO a single CAT 777 truck with a carry-back of 12.5% Saved carbon emission ~ 31 average sized cars Cast-O-Glide Contributes to a Greener Environment ! OUR PLANET IS WORTH MORE THAN OUR PROFITS Cast -O- Glide Cast -O- Glide
  • 38.
    | SUIGA Advanced Materialsand Technologies CAST-O-GLIDE DOESN’T COST TO GET GREENER IT ACTUALLY PAYS Contributing to a Greener Environment Year after Year IS GREEN 60 Kgs OF CAN REPLACE 600 Kgs of Q&T PLATE DURING ITS LIFE CYCLE Reducing Carbon Footprint & Conserving Resources Cast-O-Glide Contributes to a Greener Environment ! Cast -O- Glide Cast -O- Glide
  • 39.
    | SUIGA Advanced Materialsand Technologies Cast-O- Glide Contributes to Safety ENHANCES SAFETY BY Reducing Repair & Maintenance Frequency by OVER 80% IF REPLACING Q&T PLATES Cast -O- Glide
  • 40.
    | SUIGA Advanced Materialsand Technologies Product - Meets Maintenance Objectives Maintenance Objectives To increase functional reliability of production facilities To maximize the useful life of the equipment To maximize production capacity from the given equipment To minimize the total production cost To minimize the frequency of interruption in production by reducing breakdowns To enhance the safety of the manpower Does Meet ?       Cast -O- Glide
  • 41.
    | SUIGA Advanced Materialsand Technologies TECHNO- ECONOMICS Cast -O- Glide
  • 42.
    | SUIGA Advanced Materialsand Technologies Why Cast-O-Glide Doesn’t Cost – It PAYS !!! Q&T Plate (AR 450) Cast-O-Glide Remarks Price (A) Rs. 160/Kg Rs. 550/Kg Prices are approximate Thickness 40 mm 19 mm (10+9) 19 mm Cast-O-Glide can replace 40 mm Q&T Weight considered for an area 100 Kgs 60 Kgs Weight reduction advantages Life Expected X 6X Cast-O-Glide will outlast Q&T by min 6:1 Weight for Same Life (B) 600 Kgs 60 Kgs Cost Rs. 96,000/- Rs. 33,000/- Savings/100 Kgs of Q&T Rs. 63,000/- on every 100 Kgs of Q&T plates used Savings for 10 T Q&T Rs. 63.0 L Only 1 T of Cast-O-Glide will be needed Dragline Buckets, Excavator Buckets, Liners Indirect Savings Dis-assembly & Reassembly Cost Equipment Downtime Reduced Hang-ups & Carry backs Reduced Clogging Reduced Weight benefits Direct Savings
  • 43.
    | SUIGA Advanced Materialsand Technologies Why Cast-O-Glide Doesn’t Cost – It PAYS !!! Mn Steel Liners Cast-O-Glide Remarks Price (A) Rs. 140/Kg Rs. 520/Kg Prices are approximate Thickness 16 mm 12 mm (6+6) 12 mm Cast-O-Glide is sufficient Weight of plate/segment (80 m2) 10 T 7.7 T Weight reduction advantages Total Qty for 1 Bunker 60 T 46.2 T Life Expected 3 months 15 months Cast-O-Glide will outlast Mn Steel by min 5:1 Weight for Same Life (B) 300 T 46.2 T Cost Rs. 420 L Rs. 240 L Direct Saving per Coke Bunker Rs. 180 L Only 1 T of Cast-O-Glide will be needed Savings on 6 Bunkers Rs. 180 L x 6 = Rs. 10.8 Cr Coke Bunker Liners Indirect Savings Dis-assembly & Reassembly Cost Equipment Downtime Reduced Hang-ups & Carry backs Reduced Clogging Direct Savings
  • 44.
    SUIGA Advanced Materialsand Technologies Q&T Plates (AR 450) Cast-O-Glide Remarks Price (A) Rs. 160-220/Kg Rs. 500/Kg Thickness 12 mm 12 mm (6+6 mm) Plate thicknesses were kept same Weight on one application 1000 Kgs 1000 Kgs Life Expected (~ 6 times which is minimum) X 6X For same thickness, Cast-O-Glide will generally perform 9-12 times. Weight for Similar Life (B) 6000 Kgs 1000 Kgs Cost per Life Cycle of Cast-O-Glide Rs. 9,60,000/- Rs. 5,00,000/- These are approx. prices and actual savings may be still more. Savings/ Tonne of Q&T Rs. 4,60,000/- Why Cast-O-Glide Doesn’t Cost – It PAYS !!! Liners with same Plate thickness as Q&T Indirect Savings Dis-assembly & Reassembly Cost Equipment Downtime Reduced Hang-ups & Carry backs Reduced Clogging Direct Savings
  • 45.
    | SUIGA Advanced Materialsand Technologies Why Cast-O- Glide Doesn’t Cost – It PAYS !!! Cost of replacing Hardox (12 m2) for 5 times = Rs. 3.6 L x 5 Times = Rs. 18 L Cost of Cast-O-Glide once for 12 m2 (every 5 times of Hardox) = Rs. 6 L Direct Savings : = Rs. 12 L Loss due to Carry-backs of PC 2000 Excavator Bucket Cost of handling per cu.m of overburden Rs. 8 Cycles per Hour (1 cycle every 60 seconds) 60 Carry over or hang up of 12% for 14 cu.m bucket 1.68 cu.m Cost of Hang up/ Carryover Value in Rs. Per Cycle 13.44 Per hour 806.4 Per day (22 hours) 17,740.8 Per Year (350 days) 62,09,280 Loss on account of carry back per year (‘A’) ~ Rs. 62,00,000/- Savings because of reduced carry back (70% of ‘A’) ~ Rs. 43 L Savings in Komatsu PC 2000 Bucket Other Savings 15 days’ downtime per repair reduced to NIL Original Bucket Life improved (~ lasts for 5 repairs with new life) Damage to pins and booms reduced Reduced Weight if less thick liners used
  • 46.
    | SUIGA Advanced Materialsand Technologies Why Cast-O-Glide Doesn’t Cost – It PAYS !!! Carry-Back /Hang-up losses (Dumpers) Remarks Fleet Size (Dumpers) - (F) 50 Nos Capacity (C) 100 T Nos. of Trips per Day (N) 14 Avg Hang-ups/Carry backs (H) 10% Cast-O-Glide will outlast Q&T by min 6:1 Working Days in 5 years (W) 1500 (300days X 5 Yrs) Cast-O-Glide will last for 5 years against Q&T lasting for 1 year Loss due to Hang-ups in 5 yrs (L) 10,500,000 T L = (50 F x 100 C x 14 N x 0.1 H x 1500 W) Tonnes Loss (for transportation only) Rs. 26.25 Cr Overburden transport cost @ Rs. 25/T Savings in Fleet of 50 Nos. of 100 T Dumper Cost of replacing Hardox (20 m2) for 5 years = Rs. 6 L x 5 times = Rs. 30 L Cost of Cast-O-Glide once in 5 years for 20 m2 = Rs. 12 L Direct Savings : = Rs. 18 L Other Savings 15 days’ downtime per repair reduced to NIL Original Dump Body Life improved (~ lasts for 5 repairs with new life) Less fuel consumption & Less Tyre Wear Reduced Weight if less thick liners used
  • 47.
    | SUIGA Advanced Materialsand Technologies Dam Ring Techno-Economics – Pfeiffer Cement Mill Mild Steel Quench & Tempered (AR 400) Cast-O-Glide Remarks Price (approx.) (A) Rs. 65/Kg Rs. 250/Kg Rs. 500/Kg Cast-O-Glide liners are sold on sq mtr basis and hence per kg prices are derived & approx Thickness (two sizes) 30mm +25 mm (86 kgs +72 Kgs) 30mm +25 mm (86 Kgs +72 Kgs) 24mm (12+12) + 16mm (8+8) 30mm of Q&T plate can be replaced by 24 mm (12+12) of Cast-O-Glide and 25 mm Q&T plate can be replaced by 16mm (8+8) of Cast- O-Glide Weight on one application 1264 Kgs (688+576) 1264 Kgs 976 Kgs (584+392) 8 segments of both thicknesses considered Life Expected X 2.5 X 15 X Cast-O-Glide will outlast Q&T by min 6:1 Weight for Similar Life as Cast-O-Glide (B) 18,960 Kgs 7,584 Kgs 976 kgs Cast-O-Glide helps in conservation and contributes to a greener environment Cost /Life Cycle of Cast-O-Glide (A X B) Rs. 12,32,400/- Rs. 18,96,000/- Rs. 4,88,000/- These are approx. prices and actual savings may still be more. Dis-assembly & Re-assembly Cost Equipment Downtime Enhanced Efficiency Weight Reduction
  • 48.
    | SUIGA Advanced Materialsand Technologies Techno-Economics for LS Crusher Housing Liners Mn Steel Gr 3 Cast-O-Glide Remarks Price (approx.) (A) Rs. 120/Kg Rs. 540/Kg Cast-O-Glide liners are sold on sq mtr basis and hence per kg prices are derived prices. Thickness 50 mm 10+9 mm UTCL has confirmed replacing the 50 mm Mn Steel Liners with 10+9 mm thick Cast-O-Glide Weight (per m2) 400 Kgs 152 Kgs Total Weight of Liners (approx.) 1,112 Kgs 423 Kgs Life Expected X 4 X Cast-O-Glide will outlast Mn Steel by min 4:1 in application where low angle abrasion and erosion are there with moderate impact. Weight for Similar Life as Cast-O-Glide (B) 4,448 Kgs 423 kgs Cast-O-Glide helps in conservation and contributes to a greener environment Cost /Life Cycle of Cast-O-Glide (A X B) Rs. 5,33,760/- Rs. 2,28,420/- These are approx. prices for plates only and actual savings may still be more. Dis-assembly & Re-assembly Cost Equipment Downtime Enhanced Efficiency Weight Reduction
  • 49.
    | SUIGA Advanced Materialsand Technologies SCREEN World’s Most Wear Resistant Design to Outlast & Outperform All Q&T and Smooth Surface Screens D e l i v e r i n g I n n o v a t i o n Water Jet Cut Laser Cut OPTIONS Cast-O-Glide 4XP Screen POWER OF  eXtra Performance  eXtra Productivity  eXtra Profitability  eXtra Planet-friendly 4XP DESIGN SUIGA Product Design Philosophy Cast -O- Glide
  • 50.
    | IMCO Alloys Limited SAVINGS! Your Best Return on Investment (ROI) Cast O Glide
  • 51.
    | SUIGA Advanced Materialsand Technologies Cast -O- Glide Innovative Product Predictableand Consistent Performance Reduced Hang-ups & Carry-back Equipment Weight Reduction Design & Fabrication Capability Customised Solutions Most Cost Effective Wear Solution Reduces Maintenance cost & Downtime, Enhances Productivity Eliminates Carry-back & Hang-ups Enhances Original Life of equipment (Less frequent repairs) Improved Safety at Work Place - thro’ reduced maintenance Contributes to Greener Environment Helps in Optimization of Resources SUIGA Offering…
  • 52.
    SUIGA Advanced Materialsand Technologies A Global Company engaged in developing & promoting only top line patented, unique and innovative industrial solutions with ”Lower Life Cycle Costs” serving domestic & international markets thro’ a strong pan India & global network. Advanced Materials and Technologies “Designing and implementing transformative wear solutions that help the world’s leading companies build for the future” About SUIGA
  • 53.
    | Transformative Wear Solutions SUIGAAdvanced Materials and Technologies About SUIGA 53 VALUE PROPOSITION 1 An international company focused on developing and promoting innovative wear solutions & technologies across a wide range of industries in India and globe. GLOBAL COLLABORATION & INNOVATIONS 2 With a team of inventors & innovators and collaboration with internationally renowned institutions viz: IITs, Ceramic Research Institute, Kolkata; CSIR – IICT, Hyderabad; NCL,Pune , SUIGA is well positioned to bring advanced & superior, innovative and patented technologies to serve industries better. FOCUS ON TECHNOLOGIES 3 Promoters & advisors are ex L&T & ex SAIL (USD 18 Bn Co.) with rich experience in engineering, manufacturing & tribology for wear prone industries viz: Steel, Cement, Power, Mining, Sugar, Fertilizer, Oil & Gas, Glass, Paper, Tyre, Agro industries, etc. REACHING THE WORLD 4 With a network of channel partners across India and more than 60 countries, SUIGA offers good knowledge and platform to reach a wide range of industries fast and simultaneously.
  • 54.
    | Transformative Wear Solutions SUIGAAdvanced Materials and Technologies Global Network….. A strong network in more than 60 countries
  • 55.
    SUIGA Advanced Materialsand Technologies POWER OF 4XP DESIGN SUIGA’s Product Design Philosophy SUIGA’s R&D and Product Design is driven by its 4XP Core Philosophy 01 02 04 03 eXtra Performance eXtra Productivity eXtra Profitability eXtra Planet-friendly
  • 56.
    | SUIGA Advanced Materialsand Technologies 0 20 40 60 80 100 120 High Stress Abrasion Rating Relative to ASTM A36 Only Top End Wear Solutions SUIGA Range of High-Performance Wear Solutions Extraordinary SOLUTIONS! Unprecedented SAVINGS !! ONLY COMPANY IN THE WORLD TO OFFER THIS ‘Value Proposition’
  • 57.
    | SUIGA Advanced Materialsand Technologies Only Company in the World WithProductsToMeet&Exceed BHP Billiton SPEC - 5 Redefining Wear Benchmark Globally
  • 58.
    | SUIGA Advanced Materialsand Technologies BeingTheBestAgainstWear DIS RUP T ING T HE WORLD OF WEA R GLOBA LLY Advanced Materials and Technologies
  • 59.
    | SUIGA Advanced Materialsand Technologies SUIGA Wear Solutions TECHNOLOGY DRIVEN. WEAR FOCUSED. Thank You 59 Note: No part of this presentation file may be reproduced, in any form or by any means, without written permission from SUIGA Advanced Materials and Technologies (OPC) Pvt Ltd. Shashi Bhushan Cell +91 9833 698872 Email: SUIGA.advancedtechnologies@gmail.com Contact
  • 60.
  • 61.
    | SUIGA Advanced Materialsand Technologies X Cross Hatch CCO Wear Plate COMMON SIZES Cross Hatch AbrasaPlate 4 on 4 4 on 6 6 on 8 9 on 10 12 on 12 COMMON APPLICATIONS Chutes Truck Beds Buckets Ducts Screen Plates Hoppers Pump Casing Transition Segments Crushers Fans Elbows Cross hatch AbrasaPlate®-X is light weight, and outstanding for high impact applications. It is made of mild steel backing, with a weld overlay chrome carbide hardfacing, then a 3mm thick hardfaced cross hatch pattern. The cross hatch pattern enables bulk solids to fill up depressions in the surface, and then selfprotect. It also provides outstanding impact resistance. A general purpose chrome-carbide overlay plate suitable for application in various positions. High impact and abrasion resistance.
  • 62.
    | SUIGA Advanced Materialsand Technologies Cross hatch Plate has excellent impact resistance Quarry chute wear plates from - X cross hatch