In our latest success story, we showcase how ESSER’s TWIN 900 pipe performed exceptionally well and achieved outstanding results, exceeding the client’s expectations.
Our client, a cement plant in the EU, had issues with conveying Refuse Derived Fuels (RDF) to the kiln at the speed of 35-40 m/s, under pressure of 0,6-2,0 bar. Before 2016, the customer used a fuel injection pipe made of non-hardened material. It was located at the end of the feed line and exposed to the kiln’s high temperatures of around 800°C (approx. 1450°F). The customer was searching for another solution to the injection component that would last for two years, reduce downtime, and require less maintenance.
They contacted ESSER for a consultation. Our team suggested the installation of a custom-made pipe from our ESSER TWIN 900. Products in this series have a wear layer of CCI cast iron, which is far less sensitive to high temperatures and provides exceptional wear protection of the component even under the heat exposure.
The pipe outlet (bevelled end) was suffering the most under the high temperatures of the kiln; the steel structure was negatively affected, losing its previously developed hardness. Despite the continuous fuel supply that provided some cooling for the pipe, it would heat up significantly, causing wear to increase proportionally. ESSER suggested making the pipe outlet from hardened composite steel 4+4 in order to protect it from the kiln’s high temperatures.
According to the customer’s feedback, the first component of this type was installed in 2016, two years later the replacement of the injection pipe followed. From 2018 to 2024 the pipe outlet made of composite steel 4+4 has been repaired or patched multiple times, while the inlet with ESSER TWIN 900 components has remained stable during the whole period. The customer is very satisfied with the ESSER solution. A new pipe, which you can see on the photo below, was ordered in 2024.
This success story once again proves ESSER to be a reliable partner for the conveyance industry. Our solutions are designed to exceed the client’s expectations. Contact us for more information!
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