22 magotteaux
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AEP BRO – FORUM August 2009
MAGOTTEAUXShaping a World of Performance
Xwin®
High Wear Solution
MPS Pu l v e r i ze r s
A L STOM (CE) Pu l v e r i ze r s
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AEP BRO – FORUM August 2009
MAGOTTEAUXShaping a World of Performance
• Gr in d i n g Se gm e n t s • G r i n d i n g Ro l l s a n d …
3 . A L STOM (CE)
• T a b l e Se gm e n t s
• T i r e s a n d … 2 . M PS
Note: Xwin® can also be used for Foster Wheeler MBF Tires and Table Segments
OBJECT I VES
1 . Xw i n ® T e c h n o l o g y
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MAGOTTEAUXShaping a World of Performance
XWIN® is a Metal Matrix Composite composed of High Alloy
Metal and Ceramic
• This combination provides the extreme wear resistance of ceramic withthe mechanical properties of cast alloys.
• This is performed by means of a specialized casting process, thus…
…The Xwin® casting is no more susceptible to breakage than a
solid high chrome casting, thereby providing…
A. The Hardness of Ceramic and…
B. The Reliability of Hi-Cr Metal
XWIN® TECHNOLOGY
XWIN® IS A PATENTED and PROPRIETARY TECHNOLOGY
AEP BRO – FORUM August 2009
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MAGOTTEAUXShaping a World of Performance
XWIN® TECHNOLOGY
• THE CERAMIC IS A FORMED, CUSTOMIZED DESIGN.
• THE POURED METAL COMPLETELY PENETRATES ANDENCAPSULATES THE CERAMIC LAYER FORMING A METAL
MATRIX COMPOSITE. A SOLID XWIN® CASTING IS PRODUCED.
• A THIN METAL LAYER WILL SOLIDIFY ABOVE THE XWIN®LAYER.
• THE XWIN®LAYER THICKNESS AND PLACEMENT IS VARIABLE.
AEP BRO – FORUM August 2009
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MAGOTTEAUXShaping a World of Performance
XWIN® TECHNOLOGY
XWIN® CASTINGS FOR PULVERIZER GRINDING ELEMENTS
• DIRECT REPLACEMENT TO ROLLS, TIRES AND SEGMENTS.
• DIMENSIONALLY IDENTICAL (MPS Standard and Low Profile)
• NO SPECIAL HANDLING, INSTALLATION OR REMOVAL
REQUIREMENTS.• NO SPECIAL MAINTENANCE OR OPERATING REQUIREMENTS.
• FOLLOW NORMAL MAINTENANCE INSTALLATION AND REMOVAL
GUIDELINES FOR HIGH CHROME, NIHARD OR WELDEDCASTINGS AS RECOMMENDED BY THE OEM.
• FOLLOW NORMAL PULVERIZER MAINTENANCE AND OPERATINGPRACTICES AS RECOMMENDED BY THE OEM.
• XWIN®ROLLS/TIRES CAN BE USED WITH STANDARDSEGMENTS AND VICE VERSA.
AEP BRO – FORUM August 2009
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MAGOTTEAUXShaping a World of Performance
•Increased Cycle Life
GENERAL XWIN® ADVANTAGES:
•Improved Grinding Profile Consistency
•Improved Mechanical Reliability
Resulting in…
… Reduced Maintenance Frequency and Cost
… Improved Equipment Runtime… Improved Production Stability
… Improved Pulverizer Performance
XWIN® TECHNOLOGY
AEP BRO – FORUM August 2009
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MAGOTTEAUXShaping a World of Performance
•Elimination of Weld Overlay
SPECIFIC XWIN® ADVANTAGES:
•Assurance of Proper Grinding Profiles
•Elimination of Weld Cracking & Spalling
XWIN® TECHNOLOGY
•Reduce Frequency of Roll-Ring Alignment2
•Extend Maintenance Cycles and Delay or
Skip a Major Maintenance Overhaul1
•Reduce Required Inventory Levels for Spares
2 Alstom Pulverizers
1 B&W MPS Pulverizers; based on existing tire life of 4-6 years and rated bearing life of 11-13 years
AEP BRO – FORUM August 2009
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MAGOTTEAUXShaping a World of Performance
XWIN® TECHNOLOGY
THE GRINDING ELEMENTS ARE NO
LONGER THE CRITICAL PATH FORMAINTENANCE AND PERFORMANCE
AEP BRO – FORUM August 2009
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MAGOTTEAUXShaping a World of Performance
XWIN® WEAR LIFE IMPROVEMENT vs. High Chrome
Xwin® Grinding Rolls and Grinding Segments > 3X
B&W MPS Pulverizers:
Alstom (CE) Pulverizers:
Xwin® Grinding Tires and Table Segments 2.0-2.5X
Note: Individual results may vary based on coal type, pulvervizer settings, etc.
MPS & ALSTOM PULVERIZERS
TYPICAL XWIN® WEAR LIFE IMPROVEMENT:
AEP BRO – FORUM August 2009
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MAGOTTEAUXShaping a World of Performance
MPS PULVERIZERS
XWIN® RESULTS
AEP BRO – FORUM August 2009
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MAGOTTEAUXShaping a World of Performance
Eastern Sub Bituminous (80%) / PRB (20%)
AEP Cardinal – 30 Months
MPS PULVERIZERS
XWIN® RESULTS
ACHIEVING 2x+
SUPERIORITY vs. Hi-Cr
AEP BRO – FORUM August 2009
WEAR: MINIMAL
XWIN®
TIRE
XWIN® TABLE
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MAGOTTEAUXShaping a World of Performance
Texas LigniteSouthwest Location – 23,000 Hours (3 years)
MPS PULVERIZERS
XWIN® RESULTS
AEP BRO – FORUM August 2009
XWIN® TABLE
XWIN® TIRE
XWIN® TABLE
Maximum wear: ~3/8"(10 mm)
1 YEAR 2 YEARS
Maximum wear: ~5/8"(16 mm)
3 YEARS(23,117 hours)
Maximum wear: ~1" (25 mm)
TIRE LIFETIME (Xwin vs. High Chrome)
0
10
20
30
40
50
60
70
80
0 1 2 3 4 5 6
Operational Lifetime (Years)
T i r e W
e a r ( m m )
0.0
0.5
1.0
1.5
2.0
2.5
3.0
T i r e W e a r ( i n )
High Chrome Tires (Historical Lifetime)Xwin Tires (Projected Wear and Lifetime)Xwin Tires (Actual Wear)
Historical Hi-Cr Tire Life:~3 Yrs
Projected Xwin®Tire Life:6 Yrs
Projected Xwin®Superiority:2x
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MAGOTTEAUXShaping a World of Performance
ALSTOM PULVERIZERS
XWIN® RESULTS
AEP BRO – FORUM August 2009
Alstom 1003 Shallow Bowl Mill – Texas LigniteWELDED HI-CR ROLLS
14 Months / 687,000 Tons
Xwin®ROLLS
END OF LIFE PROJ ECTED LIFETIME – 2,000,000+ TONS
PROJ ECTED SUPERIORITY – 3x
661,000 Tons
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MAGOTTEAUXShaping a World of Performance
… Alstom - Grinding Rolls and Segments
… MPS - Tires and Table Segments
Note: Xwin® can also be used for Foster Wheeler MBF Tires and Table Segments
SUMMARY
Xwin® Technology for …
Increases Wear Life by 2x - +3x …… vs. Hi-Chrome
Resulting in…… Increased Cycle Life
… Improved Grinding Profile Consistency
… Improved Mechanical Reliability
AEP BRO – FORUM August 2009
… Ability to Extend or Skip a Major Mill Overhaul
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MAGOTTEAUXShaping a World of Performance
CONTACT
INFORMAT ION
MAGOTTEAUX
725 Cool Springs Blvd.
Franklin, TN 37067615 385 3055
AEP BRO – FORUM August 2009