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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.

Documents:

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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.

Documents:

5. D-Plate Pulley lagging

6. KOVI Catalogue for powder specifications[/tintuc]

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In heavy industries—cement, mining, steel production, and coal-fired power—conveyor systems are the backbone of material handling. When the conveyor stops, the entire plant stops. And among all components, the pulley is one of the most critical yet most frequently compromised parts.

For decades, rubber lagging has been the default solution for protecting pulleys and improving friction. But in today’s high-abrasion environments, traditional rubber lagging is no longer able to keep up.

A new solution has emerged:
Wear-plate lagging, engineered from high-chromium, carbide-rich overlay materials such as D-Plate.
This technology is now rapidly replacing rubber lagging across the world.

This article explains why the shift is happening—and what advantages wear-plate lagging brings to modern industrial operations.

1. Why Rubber Lagging Fails in Modern Industrial Environments

Rubber lagging was sufficient in the past for moderate abrasion and predictable operating conditions. But today’s plants face:

higher material throughput
harder and more abrasive minerals
hotter operating temperatures
more frequent impact loading
stricter uptime requirements

Rubber simply cannot withstand these conditions. The most common failure modes include:

1.1 Abrasive Wear

Sharp clinker, iron ore, limestone, or coal particles grind and cut the rubber surface.
Wear accelerates with:

high belt tension
misalignment
high loading points
fine abrasive dust

1.2 Delamination

Because rubber relies on adhesives, heat and vibration eventually weaken the bonding layer.
One crack → moisture enters → the entire sheet detaches.

1.3 Thermal Degradation

Drive pulleys generate heat due to:

torque transfer
belt slippage
friction under load

Rubber hardens, cracks, and loses friction.

1.4 Chemical and Oil Damage

Common in steel and mining environments, chemicals penetrate the rubber matrix and compromise structural integrity.

The result:
Rubber lagging requires replacement every 6–12 months, causing downtime that costs far more than the lagging itself.

This is why industries are shifting to a stronger, more durable solution.

2. What Is Wear-Plate Lagging?

Wear-plate lagging uses hardfaced chromium-carbide overlay plates, welded or bolted directly onto the pulley shell.
The plates are engineered with:

a metallurgical bond
hardness up to 58–65 HRC
high carbide density
cross-hatch traction patterns
excellent heat resistance
minimal wear rate

Instead of a soft surface (rubber), the pulley is protected by a rigid, abrasion-proof armor layer.

Compared with rubber lagging, this solution lasts 5–10 times longer, depending on application.

3. Technical Advantages of Wear-Plate Lagging

3.1 Superior Abrasion Resistance

The hardfaced surface contains M₇C₃ carbides, among the hardest structures used in wear protection.
These carbides resist:

cutting
scratching
gouging
grinding

Even under continuous abrasive flow.

3.2 Zero Delamination

Wear plates bond through welding or bolting, eliminating adhesive layers.
No glue → no peeling.

3.3 High-Temperature Performance

Wear plates maintain integrity even at 400–600°C, making them ideal for:

clinker conveyors
sinter plants
steelmaking lines
hot-material transfer systems

Rubber cannot operate in these conditions.

3.4 Stable Traction Performance

Textured patterns (cross-grid or diamond pattern) maintain:

stable friction
consistent belt grip
reduced slippage

This improves energy efficiency and reduces belt wear.

3.5 Lower Life-Cycle Cost

Although initial cost is higher than rubber, wear plates last significantly longer and reduce:

downtime
re-lagging frequency
maintenance labor
emergency repairs

Total lifecycle cost can be reduced by up to 60–70% over a 4-year cycle.

4. Comparing Rubber Lagging vs Wear-Plate Lagging

5. Applications Across Industries

Wear-plate lagging is now widely used in:

5.1 Cement Industry

Raw material conveyors
Clinker cooler conveyors
Kiln feed systems

Cement plants report 3–5× longer pulley life after switching from rubber.

5.2 Mining & Quarrying

Ore transfer conveyors
Limestone and granite handling
High-impact feed chutes

In mining, rubber often tears early; wear plates remain stable.

5.3 Steelmaking

Coke conveyors
Sinter handling systems
Heat-intensive pulleys

Wear plates endure both abrasion and temperature.

5.4 Coal-Fired Power Plants

Fly ash conveyors
Coal handling systems
Bottom-ash transfer lines

Where fine ash rapidly grinds rubber away, wear plates excel.

6. Why D-Plate Wear Lagging Stands Out

D-Plate is engineered using BCC’s proprietary POP – Powder Overlay Process, which delivers:

highly controlled carbide formation
uniform hardness
low dilution (<8%)
excellent bonding strength
predictable wear performance

POP technology allows BCC to tailor:

alloy composition
layer thickness
surface pattern
impact resistance
thermal stability

This customization makes D-Plate suitable for a wide variety of pulley sizes and operating conditions.

7. Installation Options

7.1 Weld-On Lagging

Permanent bonding
Highest durability
Ideal for extreme environments

7.2 Bolt-On Modular Lagging

Faster installation
Replace only worn modules
Ideal for remote sites or limited downtime

8. Conclusion: A Modern Upgrade for Modern Heavy Industry

Rubber lagging was the right solution in the past—but industrial demands have changed.

Wear-plate lagging, especially with advanced technology like D-Plate, offers:

dramatically longer lifespan
consistent performance
reduced downtime
stronger ROI
safer operation

For plants facing high abrasion, high temperature, or heavy impact, switching to wear-plate lagging isn’t just an upgrade—it’s a new standard.

Below is fabrication procedure that BCC did for steel making plant.

Documents:

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Coal-fired power plants operate under extreme erosive and thermal conditions. Coal dust, ash particles and high-temperature gas flows rapidly wear down steel components, leading to performance loss and production instability.

D-Plate provides a dependable and long-lasting wear protection solution across all coal processing and boiler systems.

Applications in Power Plants

Boiler System

ID fan / PA fan housings
Coal mill wear plates
Venturi liners
Mill cones & orifices
Ash pump impellers and casings

Coal Handling System

Crusher starter plates
Coal mill rings
Transfer chute liners
Bulldozer bucket edges & tips

Why Power Plants Trust D-Plate

Strong resistance to coal and ash erosion
Excellent heat stability for boiler and duct applications
Reduces risk of fan imbalance and mill vibration
Extends lifecycle of critical systems
Can be repaired using D-Tech 3R onsite refurbishment

D-Plate enhances reliability, reduces failures, and supports cleaner, more efficient power generation.

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Mining environments are defined by high impact, aggressive abrasion, uneven material loading and heavy shock. Wear components must withstand continuous rock flow, sharp edges, and high drop heights.

D-Plate, produced by BCC’s POP overlay technology, is engineered to outperform traditional wear plates in every critical mining application.

Common Mining Applications

Hopper and chute liners
Transfer points for conveyors
Crusher liners and breaker plates
Cyclone feed pipes
Vibratory feeder plates
Washer pipework bends, reducers & spools
Screen plates and deck liners
Reclaimer bucket liners and dozer blade edges

Why Mining Operations Prefer D-Plate

Outstanding abrasion resistance for ore, sand, coal and aggregates
Handles heavy impact and rock drop
Long service life even in high-velocity material flow
Decreases shutdown frequency and maintenance cost
Custom designs available for specialized equipment
Can be refurbished on-site with D-Tech 3R

D-Plate ensures safer, more stable and more efficient mining operations with superior long-term performance.

Documents:

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Steel manufacturing involves severe operating conditions: high temperatures, thermal shock, abrasive sinter and ore, and constant mechanical impact. Standard steel components fail quickly in such environments.

D-Plate provides a high-strength, metallurgically bonded wear surface designed specifically for the harsh realities of steel production.

Applications Across the Steel Production Chain

1. Sinter Plant

Ore loading systems
Sinter conveyor rollers
Suction boxes
Hot screening systems
Sinter cooler components

2. Gas Cleaning Systems

Bischof gas cleaning cones
Dust ducts and cracking units

3. Blast Furnace Operations

Coke sinter screening chutes
Skip hoist liners
Burden bunkers
Top bell and protection shells

4. Converter (BOF) & Refining Lines

Charging chutes
Slag handling liners
Alloy feeding funnels

Advantages for Steel Manufacturers

Superior resistance to abrasion and thermal shock
Suitable for areas with repeated temperature cycling
Stronger than cast white iron and traditional chrome carbide plates
Custom-made parts available through D-Parts program
Onsite hardfacing repair with D-Tech 3R

With D-Plate, steel plants achieve higher equipment performance, reduced downtime, and predictable operational stability.

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