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Sustainability in heavy industry: beyond materials

In cement, steel, mining, power generation and bulk material handling, “green” does not mean wear-free.
It means:

Extending equipment service life
Reducing replacement frequency
Lowering indirect energy consumption
Cutting lifecycle CO₂ emissions

POP – Powder Overlay Process addresses sustainability through life-cycle thinking, not just raw material selection.

POP technology – the foundation of sustainable wear protection

POP is a hardfacing and overlay technology using engineered metal powders, allowing:

Clear separation between load-bearing substrate and wear-resistant working layer
Precise placement of alloy elements where they are needed
Reduced reliance on full alloy steel components

➡️ Higher material efficiency with superior wear performance.

Green advantages of two-layer D-Plate wear plates

D-Plate consists of:

A structural steel base for strength and fabrication
A POP-applied wear layer for abrasion, erosion and impact resistance

Environmental benefits:

Reduced use of critical alloying elements
Lower metallurgical energy consumption
2–5 times longer service life
Fewer shutdowns and replacements

D-Plate can also be re-overlaid using POP, minimizing waste and supporting a circular economy approach.

Green value of POP-based hardfacing

POP-designed consumables are ideal for:

Localized repair
Hardfacing of heavily worn yet structurally sound components

Typical applications include:

Sinter crusher rotors
Vertical roller mill rollers and tables
Screw conveyors, paddles and wear segments

Sustainability impact:

Repair instead of replacing multi-ton components
Reduced material and energy consumption
Lower transportation-related emissions
Less welding waste and rework

POP Technology and ESG compliance

Through D-Plate and POP hardfacing solutions, companies can:

Reduce Scope 2 and Scope 3 emissions
Improve lifecycle cost efficiency
Strengthen ESG performance and reporting credibility

POP is green not because it is new, but because it eliminates unnecessary consumption.

Conclusion

POP technology delivers practical, measurable sustainability by:

Extending service life
Reducing material use
Lowering emissions
Improving operational efficiency

This is the true “green” value behind D-Plate wear plates and POP-based hardfacing consumables.

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In integrated steel plants, the sinter crusher rotor is one of the most critical components in the sintering process. Operating under extreme conditions—high temperature, heavy impact, and severe abrasion—the rotor and its crushing blades suffer continuous wear.

If not properly maintained, excessive wear can lead to reduced crushing efficiency, unplanned shutdowns, and costly replacement of large components.

Instead of full replacement, professional repair and refurbishment through advanced hardfacing solutions has become the most economical and reliable option for steel producers.

Typical Wear Problems of Sinter Crusher Rotors

During long-term operation, sinter crusher rotors commonly experience:

Severe abrasive wear on crusher blades and rotor surface
Impact damage at blade edges and leading faces
Loss of original geometry, affecting crushing performance
Cracks or material fatigue caused by thermal cycling

These issues significantly shorten service life if conventional repair methods are used.

POP Technology – A Proven Repair & Refurbishment Solution

Our solution is based on POP Technology (Protection – Optimization – Performance), a comprehensive approach combining materials engineering, welding technology, and process control to fully restore and enhance rotor performance.

1. Protection

High-performance hardfacing alloys are applied to protect critical wear zones from abrasion and impact. The deposited layers form a durable protective surface capable of withstanding harsh sintering conditions.

2. Optimization

The rotor geometry and blade profiles are rebuilt precisely according to original design or optimized operating parameters. This ensures balanced rotation, stable operation, and consistent crushing efficiency.

3. Performance

By combining suitable hardfacing materials with controlled welding procedures, the refurbished rotor achieves:

Extended service life
Improved wear resistance
Reduced maintenance frequency
Lower total operating cost

Repair Process Overview

The refurbishment of the sinter crusher rotor typically includes:

Inspection & Assessment
Detailed inspection to evaluate wear level, cracks, and deformation.
Surface Preparation
Removal of worn material and damaged layers by gouging or grinding.
Controlled Hardfacing Welding
Multi-layer welding is applied using selected alloys, ensuring strong metallurgical bonding and controlled heat input.
Dimensional Restoration
Rotor and blade dimensions are rebuilt to specification, ensuring proper balance and alignment.
Final Quality Check
Visual inspection, dimensional verification, and, if required, non-destructive testing.

Key Benefits for Steel Plants

Up to 2–3 times longer service life compared to untreated components
Significant cost savings versus new rotor replacement
Reduced downtime and improved production stability
Proven reliability in heavy-duty sintering applications

Conclusion

With POP Technology, the repair and refurbishment of sinter crusher rotors becomes a strategic maintenance solution rather than a temporary fix. By restoring protection, optimizing design, and enhancing performance, steel plants can maximize equipment availability while minimizing operational costs.

This solution has been successfully applied in steel plants where reliability, durability, and efficiency are critical.

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In modern cement plants, the Vertical Roller Mill (VRM) is a critical piece of equipment for raw material and coal grinding. Key wear components such as grinding rollers and table liners operate under extremely harsh conditions, including abrasion, erosion, impact loading, and elevated temperatures.

Over time, these components experience uneven wear, leading to reduced grinding efficiency, increased power consumption, and unplanned shutdowns. Hardfacing restoration has therefore become a cost-effective and reliable solution to extend service life and maintain stable mill performance.

At BCC, the VRM hardfacing process has been standardized and upgraded through POP – Powder Overlay Process, BCC’s proprietary core technology, enabling precise control of metallurgical properties and wear performance.

POP Philosophy in VRM Hardfacing

POP is not merely a welding method. It is a materials engineering philosophy based on:

Tailored alloy composition for specific wear mechanisms
Controlled ratios of alloying elements (Cr, C, Mo, Nb, V, etc.)
Optimized carbide type, size, and distribution

Each hardfacing layer is designed as a specific “recipe”, matched to actual operating conditions — similar to how different broths are prepared for different types of Phở.

Standard VRM Hardfacing Procedure at BCC

Wear Assessment and Condition Analysis

Measurement of roller and table liner geometry
Identification of wear patterns (uneven wear, ridging, wave wear)
Evaluation of operating parameters: material type, moisture, particle size, grinding pressure

This step is essential to determine the correct POP alloy system.

Surface Preparation

Removal of contaminants (oil, grease, dust)
Machining and removal of worn hardfacing layers
Surface profiling to ensure optimal bonding

According to POP principles, surface preparation directly determines coating longevity.

Preheating – Applied Only When Required

Preheating is NOT universally applied.
It is performed only under the following conditions:

The base material is cast steel
A buffer layer (buttering layer) is required between the base metal and the wear-resistant overlay

Purpose of preheating:

Reduce thermal gradients
Minimize hydrogen-induced cracking
Control residual stresses in cast steel substrates

For rolled steel or fabricated components, preheating is typically not required, provided the correct POP hardfacing system is used.

Buffer Layer Application (When Applicable)

For cast steel components:

A ductile buffer layer is deposited first
The buffer layer acts as a stress-absorbing transition zone
It improves metallurgical compatibility between the base metal and the wear layer

This step is critical for long-term reliability in cast components.

Hardfacing With POP Technology Cored Wire

Application of POP-designed flux-cored wires
Controlled parameters:
- Heat input
- Deposition rate
- Dilution control
- Layer thickness

POP ensures uniform carbide distribution, avoiding brittle clusters or excessive dilution.

Profiling and Shape Restoration

Rebuilding the functional grinding profile
Ensuring optimal material flow and contact pressure
Reducing vibration and uneven wear during operation

Controlled Cooling

Natural or insulated cooling depending on component size
Stress relaxation
Stabilization of microstructure

Inspection and Acceptance

Visual inspection
Hardness measurement
Surface crack inspection
Dimensional verification

Proven Performance in Cement Plants

BCC’s POP-based VRM hardfacing solutions have demonstrated:

Extended maintenance intervals
Reduced localized repair frequency
Improved grinding stability
Lower total lifecycle cost

Conclusion

By integrating POP – Powder Overlay Process into VRM roller and table liner restoration, BCC delivers not just hardfacing, but a controlled, engineered wear solution.

This approach allows cement plants to:

Extend equipment life
Reduce dependency on imported wear parts
Maintain consistent mill performance under demanding conditions

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Industrial equipment operating in mining, cement, steel, and material-handling environments is continuously exposed to abrasion, erosion, impact, and metal fatigue. Replacing worn components is costly and leads to extended downtime. This is why hardfacing electrodes remain one of the most efficient and economical solutions for on-site repair and protective overlay.

Developed by BCC (Bao Chi Company) and manufactured by KOVI, our hardfacing electrodes are engineered using the same metallurgical philosophy behind BCC’s proprietary POP – Powder Overlay Process. This ensures each electrode delivers maximum wear resistance, stable performance, and compatibility with all BCC wear-protection products.

POP Technology – The Foundation of BCC Hardfacing Electrodes

POP (Powder Overlay Process) is BCC’s core technology used to design alloy structures optimized for different wear mechanisms.
Our hardfacing electrodes follow the same engineering logic:

✔ Metallurgical customization

Each electrode type is formulated with a specific blend of alloying elements (Cr, Mn, Nb, Mo, V…) to match the target wear conditions.

✔ Purpose-built carbide engineering

Controlled formation of:

M7C3 carbides for high abrasion
MC carbides for extreme hardness
Austenitic / martensitic matrix for impact absorption

✔ Seamless integration with D-Plate and D-Parts

The same alloy philosophy allows BCC electrodes to work perfectly with:

D-Plate wear plates
D-Parts fabricated components
Hardfacing wires produced under D-Tech
On-site wear protection services

➡ A unified wear-protection ecosystem, from electrode → wire → plate → finished parts.

Product Range – Hardfacing Electrodes for Every Wear Condition

🔹 D100e – Abrasion-Resistant Hardfacing Electrode

Designed for severe abrasive wear without heavy impact.
Ideal for:

Crusher blades
Scraper edges
Feeder chutes
Cement milling components

Key properties:

High chromium carbide content
Smooth weldability
Hardness up to ~58–62 HRC
Perfect match with D-Plate D100 alloy system

🔹 D680Mn – Impact-Resistant Hardfacing Electrode

Developed for environments combining impact and moderate abrasion.

Applications:

Hammer mill hammers
Excavator bucket teeth
Crusher jaws
Conveyor impact components

Features:

High-manganese alloy
Work-hardening surface
Excellent crack resistance
Tough austenitic matrix

Why BCC Hardfacing Electrodes Are Different

1. Engineered by D-Tech using POP principles

Not copied formulas — but scientifically designed alloys based on actual wear conditions.

2. Validated through real industrial applications

Field-tested in:

Vietnam’s largest cement plants
Quarry & mining operations
Steel rolling mills
Sugar factories
Coal-fired power plants

3. Manufactured with strict quality control (KOVI factory)

Ensures:

stable arc performance
consistent deposition
minimal slag interference
reliable hardness

4. Perfect for on-site repair

Works where:

wear plates cannot be installed
hardfacing wires cannot access
components require small-area restoration

5. Cost-effective and highly flexible

A small package that delivers big impact in equipment life extension.

Typical Industrial Applications

BCC hardfacing electrodes are widely used in:

Mining & Quarry

Crusher hammers
Bucket lips
Wear bars
Conveyor components

Cement Industry

Raw mill parts
Rotors and fans
Kiln handling equipment

Steel Production

Slag handling equipment
Scrapers and chutes
Conveyor impact zones

Sugar & Agriculture

Shredder knives
Mill rollers
Feeder conveyors

➡ Extending component lifetime by 2× to 5× compared with standard electrodes.

Conclusion

BCC’s hardfacing electrodes represent the perfect combination of POP-based alloy design, real-world industrial testing, and precision manufacturing. For customers seeking reliable, cost-effective, and durable wear protection, BCC offers a proven, unified solution — from electrodes to plates, to complete D-Tech wear-protection services.

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5. KOVI Catalogue

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In many heavy-industry applications—cement, mining, coal power, and steel—materials with slight moisture content tend to stick, smear, and accumulate on equipment surfaces. This leads to:

Flow obstruction
Bridging and rat-holing
Forced shutdowns for cleaning
Higher energy consumption
Accelerated wear due to clogging

D-Plate S is BCC’s next-generation wear plate designed not only for abrasion resistance but also for exceptional anti-sticking performance.

Built using POP – Powder Overlay Process, D-Plate S features a highly uniform metallurgical surface that prevents particles from attaching, packing, or forming deposits.

Standards & Test Methods for Evaluating Anti-Sticking Performance

While there is no single global standard for “anti-sticking,” the performance of a surface is measured through several recognized industrial tests:

1. Angle of Repose (ASTM C1444 / ISO 4324)

Used to evaluate material flowability and surface interaction.

A lower angle means better sliding and reduced sticking.
Comparing the angle of repose on different surfaces indicates anti-sticking performance.

Expected performance of D-Plate S:
→ Reduction of 10–25% compared to regular steel or CCO plates.

2. Static & Dynamic Coefficient of Friction – COF (ASTM D1894 / ISO 8295)

Measures the sliding resistance of bulk materials on a surface.

Lower COF = smoother surface, fewer adhesion points.

D-Plate S surface properties:
→ Typically 20–40% lower COF than conventional hardfaced CCO plates.

3. Flowability Test – Jenike Shear Test (ASTM D6773)

Determines:

Cohesion
Adhesion stress
Flow factor

A direct indicator of how much material sticks under pressure and motion.

D-Plate S performance:
→ Reduction of 15–35% in adhesion stress.

4. Inclined Plane Test – Minimum Slip Angle

Evaluates the minimum angle at which material starts sliding.

Lower slip angle = better anti-sticking.

Typical improvement:
→ D-Plate S reduces slip angle by 4–10 degrees compared to conventional CCO plates.

5. Moisture Adhesion Test (for wet materials)

Measures:

Remaining material (%) after discharge
Cleaning energy (force required to detach stuck materials)

D-Plate S advantage:
→ Reduces residual buildup by 40–70%.

Why D-Plate S Works: POP Metallurgical Advantage

The anti-sticking performance of D-Plate S comes from:

1. Smooth, uniform surface with no weld beads

Conventional CCO plates have ridges and weld patterns that trap wet or fine materials.
D-Plate S eliminates these mechanical anchors.

2. Optimized micro-roughness

POP technology produces a surface with extremely fine and controlled micro-texture, reducing:

Adhesive bonding
Cohesive packing
Micro-interlocking

3. Even carbide distribution

Carbides are uniformly dispersed within the alloy layer → smooth wear pattern over long service life.

4. Moisture-resistant metallurgy

The POP matrix limits capillary adhesion, reducing “wet sticking” caused by thin moisture films.

Performance Example: Material 1–3 mm, Moisture < 8%

Below is a typical comparative evaluation:

These improvements translate to major operational gains.

Key Industrial Benefits

✔ 1. Reduced clogging & bridging

Ideal for hoppers, transfer chutes, cyclone outlets, feed pipes.

✔ 2. Less downtime for cleaning

Higher OEE and reduced labor cost.

✔ 3. Lower energy consumption

Material flows freely → reducing frictional drag.

✔ 4. Extended equipment life

Less surface packing → less abrasive regrinding and compaction.

✔ 5. Higher throughput & stable process

Better material flow → higher processing consistency.

Recommended Applications

D-Plate S is ideal for:

Cement Industry

Cyclone dip tubes
Clinker pipes
Raw meal chutes
Preheater discharge

Mining & Aggregates

Fine ore chutes
Wet material hoppers
Feeder lining

Coal Power Plants

Coal feeders
Wet ash handling systems

Steel Plants

Lime handling
Pellet return lines

Wherever materials tend to stick, D-Plate S is a superior replacement for:

Rubber lining
Standard hardfacing CCO plates
Stainless lining
Ceramic tile lagging in wet zones

Conclusion

D-Plate S represents a new generation of wear plate technology:

Abrasion-resistant like traditional D-Plate
Anti-sticking engineered for wet, fine, cohesive materials
POP-based metallurgical precision enabling superior flow performance
Designed for modern high-efficiency plants

It helps industries reduce downtime, increase productivity, and achieve long-term cost efficiency.

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In modern industrial wear-protection systems, Flux-Cored Wire (FCW) is the most advanced and versatile material for creating high-performance hardfacing layers. It is widely used to extend the lifetime of equipment exposed to abrasion, erosion, impact, corrosion, thermal wear, or high-pressure conditions.

With POP (Powder Overlay Process) technology, BCC/KOVI is the only manufacturer in Vietnam fully mastering the entire process:
from alloy design → powder formulation → strip rolling → wire forming → finished flux-cored wire.
This enables complete material independence, customized solutions, and precise control over performance.

WHAT IS FLUX-CORED WIRE? – THE MATERIAL BEHIND HIGH-PERFORMANCE HARDFACING

Flux-cored wire is a specialized welding wire consisting of:

A steel alloy strip (outer sheath)
A core filled with alloy powders formulated for specific wear mechanisms
Adjustable ratios between strip thickness and powder composition

This structure allows BCC/KOVI to engineer hundreds of wire types—something impossible with conventional electrodes.

Key Advantages of Flux-Cored Wires

✔ 2–5× higher deposition rate than stick electrodes
✔ Accurate alloy composition and consistent metallurgical structure
✔ Produces specialized hardfacing layers (high-carbide, self-hardening, extreme erosion resistance)
✔ Compatible with MIG, FCAW, SAW, and gas-shielded or self-shielded processes
✔ Fully customizable under POP alloy-design framework

POP TECHNOLOGY – THE CORE PLATFORM THAT ENABLES BCC TO MANUFACTURE ADVANCED FCW

POP (Powder Overlay Process) is the technological foundation that allows BCC to:

▪ Design customized alloy compositions

BCC adjusts:

Alloy ratios
Powder particle size
Carbide types (CrC, NbC, VC, WC…)
Work-hardening behavior (Mn-series)

▪ Produce wire tailored for each industry and wear mechanism

Because BCC is not dependent on imports, the company can:

Develop industry-specific or even equipment-specific FCW
Localize formulas for Vietnam’s operating conditions
Respond quickly to urgent maintenance demands

▪ Integrate materials – welding technology – wear-surface engineering

POP unifies powders, electrodes, flux-cored wires, wear plates, and surface-engineering technologies into one system.

As a result, BCC/KOVI hardfacing layers ensure:

Precise hardness as designed
Correct microstructure
Minimal defects
2–10× longer service life, depending on application

INDUSTRIAL APPLICATIONS OF BCC/KOVI FLUX-CORED WIRES

BCC’s FCW is used widely in:

🟥 Cement Industry

VRM rollers & tables
Buckets & elevator systems
Pump housings & impellers
Feed chutes & liners

🟥 Thermal Power Plants

Coal rollers & grinding components
Fans, ducts, and high-temperature surfaces
Wear protection at 400–900°C

🟥 Mining & Quarrying

Bucket teeth & lips
Screen plates & liners
Conveyor pulleys & rollers

🟥 Steel & Metallurgy

Steel-mill rollers
Draw rolls and guide pulleys
Guide rails and sheaves

🟥 Chemical & Petrochemical

Corrosion-resistant hardfacing
High-temperature components

🟥 Other Industries

Hydropower
Ceramics & construction materials
Agricultural processing equipment

BCC/KOVI'S KEY FLUX-CORED WIRE SERIES

▪ Mn-Series – Work-Hardening (Heavy Impact)

D2546, D4048, D8547

▪ Low–Medium Alloy (Friction & Pressure Wear)

D3056, D5062

▪ Tool-Steel Based (Abrasion – Heat – Erosion)

D5553, D6550

▪ High-Carbide Series (Severe Abrasion & Erosion)

D4063, D6565, D6566

▪ Corrosion & Heat-Resistant (410–430 Stainless Series)

D4101, D4142, D4203, D4304

▪ Nickel-Based (Inconel / Superalloy Applications)

D11036

▪ Cobalt-Based (Extreme Heat & Thermal Shock)

D8047

▪ Cast Iron Repair

D2018

ADVANTAGES OF USING BCC/KOVI FLUX-CORED WIRES

1. 2–10× Longer Service Life

Optimized alloy design ensures layers engineered for each wear mechanism.

2. 20–40% Lower Maintenance Cost

Reduced shutdown frequency and improved asset reliability.

3. 2–5× Higher Welding Productivity

Higher deposition rate compared with SMAW.

4. European–AWS Standard Quality Control

Consistent metallurgy and operational reliability.

5. Local Manufacturing – Fast Delivery

No import dependency → ideal for urgent repairs.

CONCLUSION

Flux-cored wire is the central material in modern hardfacing, rebuilding, surface restoration, and wear-resistant engineering.
Combined with POP technology, BCC/KOVI delivers a truly integrated solution—from alloy development to finished hardfacing performance.

This enables industries to:

Increase equipment lifetime
Reduce maintenance costs
Improve operational continuity
Handle extreme wear conditions reliably

BCC/KOVI proudly stands as Vietnam’s only full-cycle manufacturer capable of designing, producing, and deploying advanced flux-cored wires for heavy industry.

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Efficient pulley lagging is essential to maintain belt traction, extend pulley life, and ensure stable conveyor operation. Today, industries typically choose among three main solutions:

Rubber lagging
Ceramic lagging
Wear-plate lagging (e.g., D-Plate)

Each technology has specific benefits, limitations, and ideal application conditions.
Below is a thorough engineering comparison.

1. Rubber Lagging

✔ Advantages

Low initial cost
Good flexibility – absorbs small impacts
Good friction coefficient when new
Lightweight → Easy installation
Works for light to medium duty conveyors

✘ Limitations

Very poor abrasion resistance
Wears quickly with sharp, abrasive materials (clinker, iron ore, limestone)
Delamination risk is high due to adhesives (glue failure)
Sensitive to heat, oil, chemical attack
Loses friction rapidly → belt slippage increases energy consumption
Requires frequent re-lagging (6–12 months)

👍 Best For

Low-abrasion industries
Light material handling
Non-critical conveyors

👎 Not Suitable For

Cement industry (clinker, hot zones)
Mining (ore, rock impact)
Steelmaking (coke, sinter)
Power plants (fly ash, bottom ash)
Any system with high abrasion or high temperature

2. Ceramic Lagging (Rubber Backing + Embedded Ceramic Tiles)

✔ Advantages

Much higher wear resistance than rubber
Ceramic tile surface provides exceptionally high friction
Good performance for wet conditions
Reduces belt slippage effectively

✘ Limitations

Tiles can crack under impact from large rocks
Tiles may debond from the rubber matrix
Still relies on adhesives → delamination remains a risk
High local friction may cause belt surface wear
Not designed for very high temperature applications
More expensive than rubber

👍 Best For

Wet environments
Slippage control
Medium to high abrasion (not extreme)
Conditions where traction is the main concern

👎 Not Suitable For

Very high impact
Extreme abrasion
High-temperature pulleys
Environments where adhesive failure is common

3. Wear-Plate Lagging (Hardfaced Chromium-Carbide Overlay Plates)

(E.g., D-Plate Wear Lagging Using POP Technology)

✔ Advantages

Outstanding abrasion resistance (5–10× rubber)
Metallurgical bond → Zero delamination
Works in very high temperatures (400–600°C)
Resistant to:

abrasion
erosion
corrosion
impact
thermal cycling

Stable traction with cross-grid patterns
Extremely long service life (3–5+ years)
Low maintenance cost
High reliability in critical operations
Customizable alloy composition for specific wear conditions

✘ Limitations

Higher initial cost than rubber
Heavier → requires proper welding or bolting
Installation requires skilled technicians
Not designed to provide elastic cushioning (like rubber)

👍 Best For

Cement (clinker handling, high heat zones)
Mining (ore, rock, impact zones)
Steel mills (sinter, coke, slag)
Coal power plants (fly ash, coal handling)
Any 24/7, high-load, high-abrasion industrial conveyor

👎 Not Suitable For

Light-duty conveyors
Applications where elasticity or noise reduction is important

⭐ Overall Evaluation

Rubber Lagging

Suitable for light-duty, low-abrasion scenarios. Cheap at first—but expensive in the long term.

Ceramic Lagging

A good intermediate solution, especially for wet or slippery conditions.
Better traction than rubber but still limited by tile cracking and delamination.

Wear-Plate Lagging (D-Plate Type)

The most durable and reliable solution for medium to extreme conditions:

no delamination
excellent against abrasion and heat
predictable long-term performance
longest lifespan
lowest lifecycle cost

For industries facing continuous heavy wear, wear-plate lagging is the clear winner.

⭐ Conclusion: The Future of Pulley Lagging

Due to the increasing abrasion levels, higher production loads, and stricter uptime requirements, many plants have started phasing out rubber and ceramic lagging. Wear-plate lagging—especially advanced hardfaced products like D-Plate—is becoming the new global standard for pulley protection in high-duty operations.

It offers:

superior durability
predictable maintenance
significant cost savings
improved conveyor reliability
higher plant productivity

For mission-critical conveyors, the choice is no longer about cost per meter—it is about total cost of ownership (TCO), safety, and reliability.
And in all these aspects, wear-plate lagging stands clearly ahead.

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