Extending the Life of Roller Screens Used in Pelletization by 3-6X using HybriComp-W104 Tungsten Carbide Coatings

Steel Mills using HybriComp-W104 tungsten carbide coatings on pelletizer roller screens save an average of $1M through reduced capital costs, and generate $1M in additional revenues through reduced downtime, maintenance, and replacement cost.

Case Study
A roller screen coated with HybriComp-W104 coating was installed in the pelletizing line and was inspected for 9 months and compared with rolls coated with conventional tungsten carbide coatings which were installed at the same time. After 9 months, HybriComp-W104 coated roller screens looked as good as new and showed no signs of abrasion or dimensional loss compared to competitor’s coatings which were wornout, and showed a dimensional loss of 6-15mm and hence had to be replaced. The same HybriComp coated roller when evaluated again after 14 months had still shown no signs of abrasion whereas the rolls coated with conventional tungsten carbide coatings were again worn-out and hence the rolls had to be replaced; it is expected that roller screens coated with HybriComp-W coatings should last for 18 to 24 months and significantly reduce downtime and maintenance costs associated with early failure of coatings of roller screens.