Technical expertise and solutions to solve wear problems in your industry

Choose your Industry

The experience of Innovative Alloys Group allows us to offer customized solutions with its HARDCORED, CLADCORED, NICORED and COBACORED product range for many different industries. From the traditional industrial applications of Steel, Cement, and Mining to the new industrial fields of Thermal Power, Waste and Recycle, customers will profit from increased productivity and efficiency at the plant as well as component level.

Steel Industry

Plant shutdowns can be particularly costly within the steel industry. The major players in steel production rely on continuous operation of facilities to ensure economic viability and, as such, invest significant effort in ensuring that any unscheduled production pauses are kept to a minimum. Innovative Alloys delivers bespoke engineering solutions and products that are designed to optimize runtime and reduce maintenance-related shutdowns within every area of the steel production facility.

Ore Terminal – bunkers, hoppers, chutes, vibro-feeders, bulk materials handling, stacker reclaimers

Sintering plant – Sinter discharge tables/crash decks, sinter crusher spikes and grizzly bars, intensive mixers, drum mixers, hoppers, cyclones, wind boxes, downcomers, dedusting and waste gas fan rotors and casings, etc.

Coking plant – Coke distribution cones, coke crushers, coke cutter, coke pushers, coal pulverizer liners, coke screening etc.

Blast furnace – Skip cars, vibro-feeders, gas scrubbing, hoppers, distribution chutes, bell and hopper assembly, throat amour plates, screening decks etc.

From handling bulk raw materials within the ore terminal through to maintaining the charge chutes used in the blast furnace; from crucial restoration of the rolling mills’ concast rolls to screening and crushing activities at the pellet and sinter plants, Innovative Alloys provides a comprehensive array of robust hardfacing solutions spanning a myriad of areas, including the following:

Cement Industry

It is imperative that fundamental processing apparatus, especially grinding and crushing equipment, are available at all times to facilitate the effective operation of any cement plant. The equipment that is used in this setting is tested to the limit, often handling highly abrasive material. As such, it is particularly prone to wear and tear. Innovative Alloys has a long-established track record of providing engineered anti-wear hardfacing equipment to key players in the cement industry and the associated original equipment manufacturers (OEMs). Our comprehensive solutions have proven time and time again to offer optimal levels of productivity and efficiency at an affordable price tag.

Mining & Crushing – Crushing hammers and cones, apron feeders, shovels/buckets for excavators and loaders, body liners, discs, hoppers etc.

Vertical Mills – Mill body liners, table liners and roller, roller protection guard, classifier blades, cage wheel assembly, grit cone, feed chute, dam ring, nozzle ring, separator fans etc.

Roller Presses – Cheek plates, roller refurbishment and profiling.

Kiln and Coolers – Clinker chutes, bucket elevators, immersion tubes, cooler grate plates, ID fans.

Transport and Storage – ESP ducts, dust collectors, pipes, elbows, bends, fans, silos, hoppers.

Any downtime that is incurred as a result of maintenance and refurbishment activity can incur significant expense for any cement plant. As such, there is an ongoing focus on keeping downtime to a minimum. Innovative Alloys offer an end-to-end refurbishment method to vertical mills (VRMs) that exploits the benefits of high-performance welding, automated welding equipment, and highly skilled team members to deliver the best results in the least amount of time. From grinding systems through to packing operations, Innovative Alloys provides a comprehensive array of hardfacing solutions that cover all aspects of cement production, including the following:

Mining Industry

Engineered hardfacing solutions are required for efficient wear protection and to protect against a myriad of the processes involved in mining, including abrasion, corrosion, impact, and adhesion management. The equipment that is in use in this context varies in scale and complexity, from large-scale earth excavators through to small valves and pumps.

During mining operations, raw materials are extracted on an extensive scale, and the underlying processes incur significant material stresses. Furthermore, there is a requirement to handle the ever more challenging overburden that results from the fact that waste material does not have any commercial value yet makes a significant contribution to the wear and tear caused to the main components of plants.

Heavy-duty opencast mining equipment: Material slides, conveyor belts, buckets, shovel loaders, discharge chutes.

Mining equipment – Earth-moving machines, stackers, front loaders, loader shovels, surface excavators, bucket chain excavators, dragline bucket liners etc.

Conveyors – Material slides, screw feeders, linings of chain conveyors, sides and scrapers of belt conveyors.

Crushing & screening – Hammers, cone crushers, hopper liners, crusher body liners, chute liners, screening deck plates, vibro-feeders, breaker plates.

Significant effort is invested in addressing issues that result from key aspects of equipment failing to function as required or needing replacement. The mining industry has found itself facing increased economic pressure over the last few years. Key players must implement a strategic and sustainable approach to operations management at the lowest possible cost. Innovative Alloys offers a range of proven anti-wear hardfacing solutions that span all aspects of earthmoving and mining activities. Just some of the examples on offer are as follows:

Thermal Power Industry

Operators and designers of coalfired power plants throughout the world face a myriad of challenges including abrasive and erosive wear and tear of the main aspects of the systems used in the handling and firing systems and the boiler. Coal contains exceptionally hard mineral matter, especially pyrite and quartz, that is tougher than conventional steel. During the processes involved in the operation of coalfired power plants, including crushing, grinding, storage, burning, and separation, it is imperative that the core systems are protected against the large quantities of materials that are handled.

Coal handling – Hoppers, wagon tippler, distributors, inlet and discharge chutes, transfer points, pulverized coal pipe line, coal compartment assembly, screens and breaker plates.

Mill maintenance – Journal housing liners, inner cone, body liners, deflector plate, vane wheel assembly, scraper, hot air duct, beater mill plates, classifier parts, grinding roller and tables.

Boiler maintenance – Dampers, burner tips and nozzles, ID fan rotors and casings, duct deflector guide vanes, ESP/Economiser hopper, flue gas ducts.

Ash handling – Ash discharge pipes, bottom ash feeder side plates, ash mixing blades and linings.

Otherwise, they will rapidly become damaged and require replacement or repair. Innovative Alloys has developed a comprehensive range of effective anti-wear hardfacing offerings that span all aspects of coal-based thermal power production. A few examples of the systems we have available are as follows:

Oil & Gas Industry

Operators in the petrochemical, gas, and oil industry encounter a set of unique challenges due to the environment in which they operate. The parts that are in use need to be reliable, robust, and able to endure the intense pressure, corrosion, and wear associated with the harsh subsea conditions. It can be cost-prohibitive and difficult to service and maintain equipment that is used at the deep-sea level. As such, it is imperative that hardwearing parts, such as drill bits, motors, and other components, are in use that can reliably withstand hostile operating conditions.

Wear sleeves and stabilizers: Hardfacing of new as well as refurbishment of old wear sleeves and stabilizers for steerable drilling systems, logging systems, MWD tools, LWD tools, drilling motor sleeves.

Tool joints – Hardbanding with casing friendly materials.

Hole openers and drill bits

Innovative Allows offers a comprehensive range of ultra-high performance engineered hardfacing solutions that meet executives’ needs for reliable, hardwearing equipment. These, in combination with our proven expertise in preserving against corrosion, wear, abrasion, and extreme pressure, ensure we are well placed to offer components and solutions you can rely on. A few examples of the solutions we have available are as follows:

Foundry & Ceramic Industry

Innovative Alloys has a long-established track record of collaborating with prominent players in the foundry and ceramic industry to deliver expertly engineered anti-wear hardfacing solutions. As production facilities in this industry are required to process highly abrasive raw materials, an exceptionally high level of wear and tear is frequently detected. Specialized solutions must be put in place to keep this wear and tear to a minimum.

Foundries frequently encounter issues with the organic materials that act as sand binders; for instance, clay and soot. These materials can cause a significant amount of damage that is costly to repair. Also, plant productivity can fall if frequent repair and maintenance operations are required. To reduce the risk of loss, it is imperative that effective advanced wear-protection materials and anti-wear hardfacing solutions are put in place.

Sand mixer blades, linings

Scraper arms

Rotary screens

Mixer feed screws and feed chutes

Pulverizer mill scrapers

Extrusion dies

Ceramic raw materials, such as clay, feldspar, and quartz, are both abrasive and sticky. During the operation of mixers and agitators, the tools are subject to significant wear, which is associated with a reduction in plant efficiency and high maintenance costs. Thankfully, it is possible to increase the lifecycle of critical components through the use of Innovative Alloys’ expert engineered offerings. Some of the examples of the hard metals and hardfacing consumables we have on offer are as follows:

Paper & Pulp Industry

Paper is manufactured via a process that involves the use of chemicals or friction to pulp woody or fibrous material into its basic cellulose elements. As a result of the presence of pressure, high temperatures, abrasive materials, and corrosion, the basic components involved in the production process can exhibit extensive wear and tear. To reduce the risk of wear, it is imperative that robust anti-wear constituents, such as tungsten carbides in a corrosion-resistant nickel matrix, are employed.

Raw material handling – Chipping teeth, debarking teeth, grinding hammers, screw feeders.

Pulp mill – Pulper, detrashing, disc sorters and coarse screening.

De-watering – Centrifuge scroll tiles.

Co-generation – Feed injection fans, hammers.

Innovative Alloys offers a range of solutions that can help to optimize the processes in use in paper and pulp production and ensure equipment is used to its full potential with minimum outages. Our proven Carbide solutions can be used within a variety of settings, from griding wood feed through to pulping, dewatering, co-generation, and rolling out the final product. A few examples of the offers we have available are as follows:

Waste & Recycle Industry

Waste recycling is becoming increasingly important in the modern era amid concerns of global warming and natural resource depletion. Recycling materials involves a range of processes, including crushing, reforming, and shredding, all of which can lead to wear of fundamental components. Municipal solid wastes, including refuse-derived fuels, are commonly used as a source of fuel in waste-to-energy plants, while biomass power generation plants are typically fueled using agricultural waste, sewage, and wooden waste that is collected from areas located close to the plant.

Crushing, shredding – Impact mills, impact plates, hammer mills, twin-shaft shredders, rapid-rotating crusher rolls, etc.

Materials handling – Spiral conveyors, scraping conveyors, compaction spirals, grapples, feed gates, funnels etc.

Waste treatment – Boilers, bunkers, rotary kilns, screens, classifiers, dischargers, mixer paddle, drum beaters, heavy-duty slicing mills, mixer equipment wall, turning paddles, etc

Furthermore, companies process a vast array of materials including glass, metal, plastics, electrical products, and building waste. This entails that the fuel and boiler conditions vary from plant to plant in accordance with the region or country in which it operates. To ensure plants run at the optimal efficiency level, there is a need to use highly erosion-corrosion-resistant engineered hardfacing components. Innovative Solutions offers reliable solutions that span all the key processes involved in waste recycling, including the following:

Sugar Industry

The profitability of major players in the sugar industry relies on optimized production processes and reliable supply of raw materials. As the end-to-end process is completed within just a few months, any outages or unplanned maintenance activities can negatively impact the yield and profitability of the refinery. To reduce the risk of incidents and ensure maximum uptime, strategic, specially engineered hardfacing solutions must be put in place.

Sugar rolls

Trash plates

Shredder components

Fibrizer hammers and cutting, levelling knives

Grippers, pumps, fans, conveyors

As part of the sugarcane harvesting process, abrasive materials, such as sand, are harvested that corrode and scratch the equipment. Innovative Alloys provides an array of robust anti-wear hardfacing solutions that are suitable at all stages of the production process, from planting and harvesting through to crushing and shredding. Some examples of the products we have on offer are as follows: