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Cement Kiln Tube
This tube is used in a proprietary process to feed used tires into a cement kiln. The tube, manufactured in Duraloy's proprietary alloy Super 22H®, is inserted through the outer wall of the rotating kiln.
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HIGH TEMPERATURE CALCINER WITH INTERNAL LIFTERS
Calciners are used for the heating and drying of powdered products. Typical calciner applications include the manufacture of pigments, dyes, and chemicals.
The product is fed into one end of a rotating calciner, which is being heated on the outside
while maintaining a very precise atmosphere inside. As the product moves through the calciner, heat is transferred through the calciner wall to achieve the desired temperature in the product. |
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Duraloy utilizes proprietary casting techniques and unique tools to integrally cast these lifters to the inside of a calciner. The lifters are used to tumble the product inside the calciner during the heating cycle.
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Specialty Radiant Tube Assemblies
Duraloy produces a variety of radiant tube assemblies, like the special fabricated assemblies shown here.
These "inner" tubes are centrifugally cast, then Duraloy welds flanges and spacer bars to the outside of the tube. These tubes are then slid inside of a larger tube, with the spacer bars being used to maintain a consistent spacing between the inner and outer tube. The result is a tube assembly where gas is burned inside the inner tube, travels the length of the inner tube and returns along the outside of the inner tube to the discharge port.
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Nickel Aluminide Furnace Roll
Duraloy is leading the way in the development of cast intermetallic alloys, such as the nickel aluminide roll shown here. Nickel aluminides and iron aluminide are intermetallic alloys developed invented and patented by Oak Ridge National Laboratories in Tennessee.
Nickel Aluminides have shown exceptional strength and resistance to creep at high temperatures as well as good resistance to oxidation and carburization. This roll is for a hydrogen furnace in a steel mill.
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Smelting Pots
These statically cast smelter pots are used for heating
of metals that have low melting temperatures, typically
in the range of 800o-1100o F.(445o-610o C.). The pots are installed in a frame and typically heated with an electric induction coil to melt the metals in the pot. This pot is cast in ASTM A297 Grade HT.
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Large Diameter Centrifugal Tubes
Large, light-walled tubes such as these are often used in a calciner or retort application. These tubes will have a weld-prep bevel machined onto each end then be welded together to form a long cylinder.
In some applications, flights or tumbling bars can be welded along the inside of the tubes prior to installation.
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Grinder Mill Shafts
These shafts, cast with a splined inside surface, are used to drive coal and hard rock grinders. The splined inside diameter, allow a "keying" effect when slipped over the drive motor shaft.
Cast in 400 series stainless steel, the alloy provides hardness to avoid distortion and resist wear.
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Insulator Flange
This one piece statically cast insulator flange is used in the power generation industry. The flat flange is drilled with bolt holes to allow it to be bolted to another flange. The inner tube section is welded to piping carrying hot liquids. The outer, "flared" section is welded to a thin-walled sheathing tube and the space between the two tubes is filled with insulation to reduce the heat loss in the fluid in the main piping.
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Dimetrics "Dual Sync Pulse" TIG Welding
Duraloy uses Dimetrics "Dual Sync Pulse" automatic TIG welding equipment to weld
many of our specialty rolls. This welding technique puts
in a very high quality weld seam, virtually eliminating
repairs. The automatic TIG process is a very efficient
means of producing high quality weld joints.
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Heat Treat Hanger Arms
This hanger arms are actually used to move or lift components within a furnace. The large flanges are pinned to a hydraulic actuator outside the furnace and, when the hydraulic cylinder is moved, the hanger arms pivot to move parts inside the furnace.
These arms are cast in HT alloy.
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Deflector Blocks
These deflector blocks are used in the power generation industry to deflect and diffuse coal powder that is being injected into a steam boiler combustion unit. The blocks are suspended in the end of the injector tubes and allow the coal powder to be more rapidly and thoroughly combusted in the heating chamber.
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Shaft Bearing Housings
These statically cast bearing housings were cast in HK-40 alloy and are to be used in a steel mill application. The upper casting slides inside the upturned flange on the lower housing then the two halves are bolted together. Prior to installation, the inside of the housings will be machined to accept the bearing races.
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Bearing Housing
These statically cast bearing housings are made in ASTM A351 Grade CF-8M. This picture shows both the upper and lower housings. These housings will be drilled to allow the two halves to be bolted together after having the bearings and shafts installed. The cast in holes in the base will be used to bolt the entire assembly to the housing mount.
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Static Housings
These static cast housings are just a smaller version of some of the other housings produced by Duraloy. These parts can be manufactured in any heat resistant or corrosion resistant alloy, depending upon the application.
In this application, there will be an impellor inside the main body of the housing and a shaft will be placed through the side "boss" to drive the impellor.
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Roller Shaft Hubs
These hubs are cast and final machined at Duraloy. These parts are used to hold rotating shafts that are exposed to a very aggressive chemical environment, which can attack the parts in service.
These hubs are statically cast in ASTM A743 Grade CF-3 (304L) alloy.
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Wear Plates
These wear plates are statically cast and shipped for use in a variety of applications, from crusher mills, to log flumes, to coal hoppers. The parts are typically bolted into a frame that allows for easy and quick change-out as the parts wear.
The parts can be made in several different alloys, from abrasion resistant "white iron" to heat and/or corrosion resistant alloys.
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