Vertical roller mill grinding table liner segment - curved arc shape high chromium steel casting with red protective coating for VRM mill table assembly - ZHILI foundry

Vertical Roller Mill Grinding Table / Vertical Mill Liner ISO 9001:2015 SSAB Hardox Authorized

Vertical Roller Mill Grinding Table / Vertical Mill Liner

VRM Grinding Table Segments & Table Liners — Ni-Hard IV / High Chrome Alloy (Cr20 / Cr26 / Cr27Mo2) / Hardfaced Composite — For Loesche / Pfeiffer / FLSmidth Atox / Polysius

Material Ni-Hard IV / High Chrome Cast Iron (Cr20 / Cr26 / Cr27Mo2) / Hardfaced Composite / Manganese Steel (Mn13Cr2)

Hardness HRC 58-65 (Ni-Hard/High Cr As-Cast) / HRC 63-68 (Hardfaced Surface) / HB 200-250 (Mn Steel As-Cast)

Compatibility Loesche LM Series / Pfeiffer MPS / FLSmidth Atox / Polysius RM / UBE / Sinoma / Citic / NHI / Chaeng

Certification ISO 9001:2015 Certified, EN 10204 3.1 Mill Test Certificate, NDT Report (UT/MT)

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Vertical Roller Mill Grinding Table / Vertical Mill Liner — Material Specifications | ZHILI

Parameter	Ni-Hard IV	High Cr Cr15	High Cr Cr20	High Cr Cr26	Cr27Mo2
Standard	ASTM A532 I-D	ASTM A532 II	ASTM A532 II	II-E / GB/T 8263	GB/T 8263 / EN 12513
C%	2.8-3.6	2.4-3.2	2.4-3.2	2.3-3.0	2.3-2.9
Cr%	7.0-11.0	14.0-17.0	18.0-22.0	23.0-28.0	26.0-29.0
Mo% / Ni%	Mo 0-1.0 / Ni 3.5-5.0	Mo 0.5-1.5	Mo 0.5-2.0	Mo 0-1.5	Mo 1.5-2.5
Hardness	55-60 HRC	56-60 HRC	58-62 HRC	58-63 HRC	58-65 HRC
Carbide Vol.	20-28%	22-30%	25-33%	28-38%	30-42%
Matrix	Martensite+Austenite	Martensite+Austenite	Martensite+Austenite	Martensite+fine carbides	Tempered Martensite
Impact (J/cm2)	3-5	4-6	4-7	5-8	6-9
Life Factor	1.0x	1.1-1.2x	1.3-1.5x	1.5-1.8x	1.8-2.2x
Max Temp	250 C	300 C	350 C	400 C	450 C
Max Segment	5,000 kg	8,000 kg	10,000 kg	12,000 kg	15,000 kg

Parameter	Standard HF	Heavy-Duty HF	Premium HF	Bi-Metallic
Base Material	Cr20 Casting	Cr26 Casting	Cr27Mo2 Casting	Mn13Cr2 + Cr HF
Overlay Process	Single-layer open arc	Double-layer open arc	Multi-layer (3-5x)	Cast-in-place + overlay
Weld Wire	Fe-Cr-C (Cr28-33%)	Fe-Cr-C-Nb (Nb4-7%)	Fe-Cr-C-Nb-W-V	WC-reinforced NiCrBSi
Thickness	3-5 mm	5-8 mm	8-15 mm	6-10 mm
Hardness	58-62 HRC	60-64 HRC	63-68 HRC	62-67 HRC
Carbide HV	1200-1400	1400-1600	1600-2000	1800-2400 (WC)
Coverage	Top face only	Top + inner groove	Full coverage	Top (bi-metal bond)
Re-Hardenable	2-3 times	3-4 times	3-5 times	Replace overlay only
HF Interval	2,000-2,500 hrs	2,500-3,500 hrs	3,500-5,000 hrs	2,500-4,000 hrs

Brand	Model	Table Dia.	Segments	Seg. Wt (kg)	Material	kW	tph
Loesche	LM 28.3D	2,800	12	380-500	Cr20	1,200	150-180
Loesche	LM 46.4	4,600	12	1,600-2,200	Cr26	3,300	340-400
Loesche	LM 56.3+3 CS	5,600	12	3,500-5,000	Cr27Mo2	5,400	500-600
Pfeiffer	MPS 3750 B	3,020	8	600-850	Cr20	1,500	160-200
Pfeiffer	MPS 4750 B	3,750	12	1,200-1,800	Cr26	2,800	280-340
Pfeiffer	MPS 5600 BC	4,400	12	2,000-3,000	Cr27Mo2	5,400	450-540
FLSmidth	Atox 35	3,000	8	550-800	Cr20	1,600	180-220
FLSmidth	Atox 50	4,250	12	1,800-2,800	Cr26	3,600	370-440
FLSmidth	OK 42-4	3,600	8	1,000-1,500	Cr26	3,200	220-280
Polysius	RM 41/19	3,300	12	800-1,200	Cr20	2,000	200-250
Polysius	RM 54/27	4,350	12	2,200-3,500	Cr26	4,500	380-460
UBE	UM 38.4	3,800	12	1,200-1,800	Cr26	2,600	240-300
UBE	UM 50.4	5,000	12	3,500-5,500	Cr27Mo2	5,000	430-520
Sinoma	TRM 38.4	3,800	12	1,100-1,700	Cr20/Cr26	2,600	220-280
Sinoma	TRM 53.4	5,300	12	3,000-4,800	Cr27Mo2	5,000	430-520
Citic	CLM 3630	3,630	12	950-1,400	Cr20/Cr26	2,250	200-260

Selection Quick Reference

Coal mill grinding table (lower abrasion, moderate temp): Ni-Hard IV or Cr15 — most economical, segments 200-1,500 kg, service life 15,000-22,000 hrs
Raw meal grinding (limestone + clay, standard abrasion): Cr20 standard; upgrade to Cr26 for hard limestone with chert/flint nodules, table 2.8-5.6m, segments 1,000-6,000 kg
Slag grinding / GGBFS (high silica, 30-35% SiO2): Cr26 minimum, Cr27Mo2 preferred for >200 tph, requires hardfacing rebuild every 2,000-3,000 hrs
Cement finish grinding (250-350 C, clinker + gypsum): Cr27Mo2 with multi-layer hardfacing — Mo content >1.5% essential for hot hardness retention at elevated temps
Mineral / ore grinding (quartz, iron ore, extreme abrasion): Cr27Mo2 + WC-reinforced hardfacing mandatory, NDT inspection every 1,000 hrs, life 5,000-8,000 hrs

Certifications & Authorizations

Quality you can verify. Partners you can trust.

National Invention Patent Certificate — Multi-hammer Sand Mold Casting Process — Luoyang Zhili ZL 2016 1 0056588.5

ISO 9001:2015 Quality Management System Certificate — Luoyang Zhili New Materials — GICG UK Certified IAF Accredited Valid until 2027

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VRM Grinding Table / Vertical Mill Liner — FAQ | ZHILI

Frequently Asked Questions

1 How long do VRM grinding table segments and table liners last, and what factors affect service life?

VRM grinding table segment service life depends primarily on feed material abrasiveness, operating hours, and material grade selection. Here are the typical service life ranges by application:

Coal Mill

15,000-22,000 hrs

Raw Meal (Standard)

12,000-18,000 hrs

Slag (GGBFS)

8,000-12,000 hrs

Cement Finish

10,000-15,000 hrs

Key factors affecting service life:

Silica content (SiO₂): The single most critical factor. Slag with 30-35% SiO₂ wears segments 2-3x faster than raw meal with 5-8% SiO₂.
Feed size distribution: Oversized particles (>5% above 30mm) cause uneven wear and localized gouging.
Operating pressure: Higher grinding pressure accelerates wear; each +1 MPa above design specification reduces life by approximately 8-12%.
Material grade: Upgrading from Ni-Hard IV to Cr27Mo2 typically extends life by 1.8-2.2x. Adding multi-layer hardfacing extends intervals by an additional 40-60%.
Table maintenance: Uneven bed depth or worn dam ring accelerates localized wear. Inspect bed profile every 500 operating hours.
Temperature cycling: Frequent start/stop cycles cause thermal fatigue cracking. Continuous operation yields 15-20% longer life.

ZHILI recommendation: We help clients optimize material selection based on your specific feed analysis and operational data. Contact us with a feed sample and we will provide a detailed wear rate projection and material recommendation free of charge.

2 What hardfacing and rebuild options does ZHILI offer for worn grinding table segments? Can you do on-site repair?

Yes. ZHILI offers three rebuild service levels to minimize your downtime and maximize segment utilization:

1. On-Site Hardfacing (Mobile Service)

Our mobile team deploys to your plant with complete welding equipment within 7-10 days of order confirmation.
Hardfacing is performed inside the mill without removing the grinding table — zero segment removal downtime.
Flux-cored open-arc welding, deposition rate 10-15 kg/hr. Standard Fe-Cr-C or premium Nb/WC-reinforced wire available.
Overlay thickness: 3-8mm per pass. Multi-pass available up to 15mm total buildup.
Typical on-site rebuild time: 24-48 hours for a 12-segment table (depending on wear depth).

2. Workshop Rebuild (Full Restoration)

Segments are removed, shipped to our facility, and fully rebuilt under controlled factory conditions.
Process: incoming UT/MT inspection, crack gouging and repair welding, preheat to 300-400 C, multi-layer automated robotic overlay (6-axis robot, +/-0.3mm uniformity), post-weld heat treatment for stress relief, final CMM dimensional verification.
Returns segment to original OEM profile within +/- 1.5mm.
Includes full documentation: NDT report, chemical analysis of overlay, dimensional report, EN 10204 3.1 certificate.

3. New Segment with Pre-Hardfacing (Factory Option)

New Cr20/Cr26/Cr27Mo2 casting + factory-applied hardfacing overlay before first installation.
Eliminates the initial wear-in period. Reduces first-year wear by 35-40%.
Approximately +15% cost premium vs un-treated segment, but typically pays back within the first 12 months through reduced maintenance downtime.

Which option is right for you? On-site = fastest, Workshop = highest quality, Pre-hardfaced new = longest initial interval. Our engineers can help you evaluate based on your remaining segment thickness, production schedule, and budget. Contact us for a site assessment.

3 How do I choose between Ni-Hard IV, High Chrome (Cr20/Cr26), and Hardfaced Composite for my VRM grinding table?

The right material grade depends on feed type, abrasiveness, and operating temperature. Here is a simplified decision framework:

Coal / Petcoke

Ni-Hard IV

Standard Raw Meal

Cr20

Hard / Siliceous Raw Meal

Cr26

Slag / Cement Clinker

Cr27Mo2 + Hardfacing

Decision logic:

Start with feed SiO₂ content: <5% SiO₂ -> Ni-Hard IV or Cr20; 5-15% -> Cr26; >15% -> Cr27Mo2 + hardfacing.
Consider operating temperature: Above 300 C, Mo content becomes critical for hot hardness. Ni-Hard IV softens above 250 C; Cr27Mo2 retains hardness to 450 C.
Factor in tramp metal risk: If your feed contains occasional tramp iron (from upstream crushing or handling), choose Mn13Cr2 bi-metallic composite for impact toughness rather than brittle high-Cr grades.
Evaluate total cost of ownership (TCO): Although Cr27Mo2 + premium hardfacing costs 2.0-2.5x more upfront than Ni-Hard IV, the 1.8-2.2x longer service life and reduced shutdown frequency typically yield 30-40% lower TCO over 5 years for slag or cement applications.
Match to mill size: Larger mills (>4,000kW motor) benefit disproportionately from premium materials because each shutdown costs more in lost production. For example, an LM 56.3 shutdown costs approximately $80,000-120,000/day in lost cement output.

ZHILI recommendation flow: Send us your (1) feed material analysis (SiO₂%, moisture, particle size), (2) current segment material and wear rate (mm/1,000 hours), and (3) annual production target. Our metallurgists will provide a 3-option recommendation with service life projections and ROI comparison within 48 hours.