The wear resistance of AR-type plates in shot blast furnaces is a well-known issue in steel manufacturing. These plates typically last only five weeks, leading to frequent maintenance and operational disruptions.
But what if there was a way to extend the lifespan of these plates and increase efficiency?
Enter Kennametal KenCast plates. These precision-engineered plates boast six times the durability of traditional AR-type plates. Discover how a multinational steel manufacturer with a facility in Vanderbijlpark, South Africa, used KenCast shot blast furnaces to improve their steel production.
Shot blasting is a technique that employs pellets — usually steel, aluminum, or copper — to clean and prepare metal surfaces for the next stage of manufacturing. These pellets are propelled against a target surface at high velocity using centrifugal or mechanical force.
Conditions inside the furnaces are extreme. Temperatures exceed 600° C, and the high-impact abrasions caused by shot blasting lead to frequent wear and replacement of AR 400 plates used inside furnaces. Typically, these plates last only five weeks.
Seeking to find a solution that could reduce downtime, maintenance costs, and overall operational inefficiencies caused by frequent wear-related interruptions, the manufacturer turned to Kennametal.
By joining forces with EPTOCAP Consulting and CSS Engineering, we were able to conduct a trial that proved the enhanced durability of our KenCast™ plates.
In one shot blast furnace, existing AR 400 plates were swapped out and replaced with KenCast plates. Lasting up to six times longer than standard wear solution depending upon the application and site conditions, KenCast is renowned for its exceptional wear and abrasion resistance, combining an embedded tungsten carbide grit layer on the wear surface cast into a steel base material. This unique composition enabled the KenCast plates to endure the harsh conditions found at this site's blast furnace, which was far better than the AR 400 standard plates used there.
After six months of service, the KenCast plates continue to perform effectively. Wear and tear is minimal, and the plates still look new. Additionally, their enhanced durability provides the steel manufacturer with significant benefits:
| Other Methods | KenCast |
| Brazed-on solid carbide tiles | Tougher |
| Hardfacing | |
| Standard or AR-type steels, chocky blocks, and chromium-carbide plates | Longer lasting More wear resistant Better steel protection |
| Embedded weld overlays |
Engineered to withstand severe wear and abrasion, KenCast is ideal for demanding applications like shot blast furnaces. Its implementation at the steel mill in Vanderbijlpark has proven to be a game-changer
for the client. By dramatically extending the lifespan of the shot blast furnace's AR 400 wear plates from five weeks to beyond five months, KenCast plates deliver measurable improvements in maintenance efficiency, cost savings, and overall productivity.
The information contained in this case study is intended for comparative purposes only and is based upon a limited test sample. The information is no guarantee of actual future results. The information is provided “as is” without warranty of any kind, whether expressed or implied.
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