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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





• 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




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





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.





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.





•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





•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





XWIN® TECHNOLOGY

THE GRINDING ELEMENTS ARE NO

LONGER THE CRITICAL PATH FORMAINTENANCE AND 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:





MPS PULVERIZERS

XWIN® RESULTS





Eastern Sub Bituminous (80%) / PRB (20%)

AEP Cardinal – 30 Months

MPS PULVERIZERS

XWIN® RESULTS

ACHIEVING 2x+

SUPERIORITY vs. Hi-Cr


WEAR: MINIMAL

XWIN®

TIRE

XWIN® TABLE




Texas LigniteSouthwest Location – 23,000 Hours (3 years)

MPS PULVERIZERS

XWIN® RESULTS


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




ALSTOM PULVERIZERS

XWIN® RESULTS


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




… 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


… Ability to Extend or Skip a Major Mill Overhaul




CONTACT

INFORMAT ION

MAGOTTEAUX

725 Cool Springs Blvd.

Franklin, TN 37067615 385 3055

[email protected]


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