Contents
Comprehensive Guide to 100 Consumables Used in Cement Factories: Costs, Changing Intervals, Manufacturers, and Aftermarket Options
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Introduction
Cement factories rely on a vast array of consumables to ensure smooth operation and maintain high efficiency. From grinding media to conveyor belts, these consumables are essential for various processes within the factory. This guide provides a detailed list of consumables used in cement factories, including their manufacturers, aftermarket options, models, expected costs, and changing intervals.
Grinding Media
Steel Balls
- Manufacturer: Magotteaux
- Model: Duromax
- Expected Cost: $900 per ton
- Changing Interval: 8000 hours
- Aftermarket Option: Moly-Cop
- Model: Moly-Cop NG
- Expected Cost: $850 per ton
- Changing Interval: 8000 hours
Cylpebs
- Manufacturer: Magotteaux
- Model: Ecomax
- Expected Cost: $950 per ton
- Changing Interval: 7000 hours
- Aftermarket Option: Grinding Ball Company
- Model: GBC-50
- Expected Cost: $900 per ton
- Changing Interval: 7000 hours
Conveyor Belts
Heat Resistant Belts
- Manufacturer: ContiTech
- Model: Heatline
- Expected Cost: $40 per meter
- Changing Interval: 10000 hours
- Aftermarket Option: Fenner Dunlop
- Model: UsFlex
- Expected Cost: $38 per meter
- Changing Interval: 10000 hours
Oil Resistant Belts
- Manufacturer: ContiTech
- Model: OilLine
- Expected Cost: $45 per meter
- Changing Interval: 9000 hours
- Aftermarket Option: Goodyear
- Model: Pathfinder
- Expected Cost: $42 per meter
- Changing Interval: 9000 hours
Filters
Baghouse Filters
- Manufacturer: Donaldson
- Model: Torit PowerCore
- Expected Cost: $1200 each
- Changing Interval: 5000 hours
- Aftermarket Option: Camfil
- Model: Gold Series
- Expected Cost: $1150 each
- Changing Interval: 5000 hours
Cartridge Filters
- Manufacturer: Donaldson
- Model: Ultra-Web
- Expected Cost: $200 each
- Changing Interval: 4000 hours
- Aftermarket Option: Parker
- Model: ProTura
- Expected Cost: $190 each
- Changing Interval: 4000 hours
Lubricants
Gear Oils
- Manufacturer: Mobil
- Model: SHC 634
- Expected Cost: $150 per gallon
- Changing Interval: 8000 hours
- Aftermarket Option: Shell
- Model: Omala S4 GX
- Expected Cost: $140 per gallon
- Changing Interval: 8000 hours
Hydraulic Oils
- Manufacturer: ExxonMobil
- Model: DTE 10 Excel
- Expected Cost: $130 per gallon
- Changing Interval: 6000 hours
- Aftermarket Option: Chevron
- Model: Rando HDZ
- Expected Cost: $125 per gallon
- Changing Interval: 6000 hours
Bearings
Ball Bearings
- Manufacturer: SKF
- Model: Explorer
- Expected Cost: $30 each
- Changing Interval: 12000 hours
- Aftermarket Option: NTN
- Model: Premium
- Expected Cost: $28 each
- Changing Interval: 12000 hours
Roller Bearings
- Manufacturer: Timken
- Model: Tapered Roller
- Expected Cost: $50 each
- Changing Interval: 10000 hours
- Aftermarket Option: FAG
- Model: X-Life
- Expected Cost: $48 each
- Changing Interval: 10000 hours
Refractories
Fire Bricks
- Manufacturer: HarbisonWalker International
- Model: KRICON
- Expected Cost: $2.50 each
- Changing Interval: 20000 hours
- Aftermarket Option: Vesuvius
- Model: NEOCAST
- Expected Cost: $2.40 each
- Changing Interval: 20000 hours
Castables
- Manufacturer: RHI Magnesita
- Model: Plicast KL 3000
- Expected Cost: $150 per bag
- Changing Interval: 18000 hours
- Aftermarket Option: Saint-Gobain
- Model: Castable 17
- Expected Cost: $145 per bag
- Changing Interval: 18000 hours
Crushers
Jaw Crusher Plates
- Manufacturer: Metso
- Model: C Series
- Expected Cost: $2500 each
- Changing Interval: 8000 hours
- Aftermarket Option: Sandvik
- Model: JAWMASTER
- Expected Cost: $2400 each
- Changing Interval: 8000 hours
Cone Crusher Liners
- Manufacturer: Metso
- Model: GP Series
- Expected Cost: $3000 each
- Changing Interval: 7000 hours
- Aftermarket Option: Terex
- Model: MVPX Series
- Expected Cost: $2900 each
- Changing Interval: 7000 hours
Mills
Vertical Roller Mill Parts
- Manufacturer: FLSmidth
- Model: OK Mill
- Expected Cost: $3500 each
- Changing Interval: 12000 hours
- Aftermarket Option: Loesche
- Model: LM Series
- Expected Cost: $3400 each
- Changing Interval: 12000 hours
Ball Mill Liners
- Manufacturer: Magotteaux
- Model: Xclass
- Expected Cost: $2800 each
- Changing Interval: 10000 hours
- Aftermarket Option: FLSmidth
- Model: PulpMax
- Expected Cost: $2700 each
- Changing Interval: 10000 hours
Kiln Parts
Kiln Seals
- Manufacturer: Metso
- Model: Superdeal
- Expected Cost: $4500 each
- Changing Interval: 15000 hours
- Aftermarket Option: FLSmidth
- Model: AirSeal
- Expected Cost: $4400 each
- Changing Interval: 15000 hours
Kiln Tyres
- Manufacturer: FLSmidth
- Model: Rotary Kiln Tyre
- Expected Cost: $10000 each
- Changing Interval: 20000 hours
- Aftermarket Option: Metso
- Model: PyroShield
- Expected Cost: $9500 each
- Changing Interval: 20000 hours
Dust Collectors
Bag Filters
- Manufacturer: Donaldson
- Model: Downflo Oval
- Expected Cost: $100 each
- Changing Interval: 5000 hours
- Aftermarket Option: Camfil
- Model: Farr Gold Series
- Expected Cost: $95 each
- Changing Interval: 5000 hours
Cartridge Filters
- Manufacturer: Donaldson
- Model: Ultra-Web SB
- Expected Cost: $180 each
- Changing Interval: 4000 hours
- Aftermarket Option: Parker
- Model: BHA ProTura
- Expected Cost: $175 each
- Changing Interval: 4000 hours
Pumps
Slurry Pumps
- Manufacturer: Weir Minerals
- Model: Warman AH
- Expected Cost: $5000 each
- Changing Interval: 10000 hours
- Aftermarket Option: KSB
- Model: LSA-S
- Expected Cost: $4800 each
- Changing Interval: 10000 hours
Water Pumps
- Manufacturer: Grundfos
- Model: CR Series
- Expected Cost: $3500 each
- Changing Interval: 8000 hours
- Aftermarket Option: Wilo
- Model: Helix V
- Expected Cost: $3300 each
- Changing Interval: 8000 hours
Valves
Butterfly Valves
- Manufacturer: Emerson
- Model: Keystone
- Expected Cost: $700 each
- Changing Interval: 12000 hours
- Aftermarket Option: Bray
- Model: Series 30
- Expected Cost: $680 each
- Changing Interval: 12000 hours
Gate Valves
- Manufacturer: Velan
- Model: Securaseal
- Expected Cost: $1500 each
- Changing Interval: 15000 hours
- Aftermarket Option: Kitz
- Model: NPS
- Expected Cost: $1400 each
- Changing Interval: 15000 hours
Motors
Electric Motors
- Manufacturer: Siemens
- Model: SIMOTICS
- Expected Cost: $6000 each
- Changing Interval: 15000 hours
- Aftermarket Option: ABB
- Model: Baldor-Reliance
- Expected Cost: $5800 each
- Changing Interval: 15000 hours
Hydraulic Motors
- Manufacturer: Bosch Rexroth
- Model: A2FM
- Expected Cost: $4500 each
- Changing Interval: 12000 hours
- Aftermarket Option: Parker Hannifin
- Model: F11
- Expected Cost: $4300 each
- Changing Interval: 12000 hours
Seals
Mechanical Seals
- Manufacturer: John Crane
- Model: Type 5860
- Expected Cost: $300 each
- Changing Interval: 8000 hours
- Aftermarket Option: Flowserve
- Model: ISC2
- Expected Cost: $290 each
- Changing Interval: 8000 hours
Gasket Seals
- Manufacturer: Garlock
- Model: BLUE-GARD
- Expected Cost: $50 each
- Changing Interval: 6000 hours
- Aftermarket Option: Flexitallic
- Model: Flexicarb
- Expected Cost: $45 each
- Changing Interval: 6000 hours
Hoses
Hydraulic Hoses
- Manufacturer: Gates
- Model: MegaSys MXT
- Expected Cost: $200 each
- Changing Interval: 10000 hours
- Aftermarket Option: Eaton
- Model: Aeroquip GH781
- Expected Cost: $190 each
- Changing Interval: 10000 hours
Industrial Hoses
- Manufacturer: Continental
- Model: Fortress 3000
- Expected Cost: $150 each
- Changing Interval: 8000 hours
- Aftermarket Option: Goodyear
- Model: Plicord
- Expected Cost: $140 each
- Changing Interval: 8000 hours
Fans
Axial Fans
- Manufacturer: Howden
- Model: SX Series
- Expected Cost: $5000 each
- Changing Interval: 12000 hours
- Aftermarket Option: FläktGroup
- Model: JM Aerofoil
- Expected Cost: $4800 each
- Changing Interval: 12000 hours
Centrifugal Fans
- Manufacturer: Greenheck
- Model: SWSI
- Expected Cost: $4500 each
- Changing Interval: 10000 hours
- Aftermarket Option: Twin City Fan
- Model: BCSW
- Expected Cost: $4300 each
- Changing Interval: 10000 hours
Compressors
Rotary Screw Compressors
- Manufacturer: Atlas Copco
- Model: GA Series
- Expected Cost: $15000 each
- Changing Interval: 15000 hours
- Aftermarket Option: Ingersoll Rand
- Model: R Series
- Expected Cost: $14500 each
- Changing Interval: 15000 hours
Reciprocating Compressors
- Manufacturer: Kaeser
- Model: K Series
- Expected Cost: $12000 each
- Changing Interval: 12000 hours
- Aftermarket Option: Sullair
- Model: LS Series
- Expected Cost: $11500 each
- Changing Interval: 12000 hours
Sensors
Temperature Sensors
- Manufacturer: Honeywell
- Model: SmartLine
- Expected Cost: $200 each
- Changing Interval: 8000 hours
- Aftermarket Option: Emerson
- Model: Rosemount 214C
- Expected Cost: $190 each
- Changing Interval: 8000 hours
Pressure Sensors
- Manufacturer: Endress+Hauser
- Model: Cerabar S
- Expected Cost: $250 each
- Changing Interval: 8000 hours
- Aftermarket Option: ABB
- Model: 2600T Series
- Expected Cost: $240 each
- Changing Interval: 8000 hours
Belts
V-Belts
- Manufacturer: Gates
- Model: Predator
- Expected Cost: $50 each
- Changing Interval: 6000 hours
- Aftermarket Option: Continental
- Model: ContiTech
- Expected Cost: $48 each
- Changing Interval: 6000 hours
Timing Belts
- Manufacturer: Mitsuboshi
- Model: GT4
- Expected Cost: $70 each
- Changing Interval: 7000 hours
- Aftermarket Option: Bando
- Model: Synchro-Link
- Expected Cost: $68 each
- Changing Interval: 7000 hours
Clutches
Industrial Clutches
- Manufacturer: Eaton
- Model: Airflex
- Expected Cost: $2500 each
- Changing Interval: 10000 hours
- Aftermarket Option: Altra Industrial Motion
- Model: Wichita Clutch
- Expected Cost: $2400 each
- Changing Interval: 10000 hours
Chains
Roller Chains
- Manufacturer: Renold
- Model: Synergy
- Expected Cost: $200 each
- Changing Interval: 8000 hours
- Aftermarket Option: Tsubaki
- Model: GT4 Winner
- Expected Cost: $190 each
- Changing Interval: 8000 hours
Actuators
Electric Actuators
- Manufacturer: Rotork
- Model: IQ3
- Expected Cost: $3500 each
- Changing Interval: 12000 hours
- Aftermarket Option: AUMA
- Model: SA Series
- Expected Cost: $3400 each
- Changing Interval: 12000 hours
Pneumatic Actuators
- Manufacturer: Festo
- Model: DFPD
- Expected Cost: $1500 each
- Changing Interval: 10000 hours
- Aftermarket Option: SMC
- Model: NCA1
- Expected Cost: $1450 each
- Changing Interval: 10000 hours
Nozzles
Spray Nozzles
- Manufacturer: Spraying Systems Co.
- Model: VeeJet
- Expected Cost: $50 each
- Changing Interval: 6000 hours
- Aftermarket Option: Lechler
- Model: Series 460
- Expected Cost: $48 each
- Changing Interval: 6000 hours
Gears
Spur Gears
- Manufacturer: Boston Gear
- Model: Y Series
- Expected Cost: $150 each
- Changing Interval: 12000 hours
- Aftermarket Option: Martin Sprocket & Gear
- Model: PS Series
- Expected Cost: $145 each
- Changing Interval: 12000 hours
Helical Gears
- Manufacturer: SEW-Eurodrive
- Model: R Series
- Expected Cost: $200 each
- Changing Interval: 12000 hours
- Aftermarket Option: Nord
- Model: UNICASE
- Expected Cost: $195 each
- Changing Interval: 12000 hours
Instrumentation
Flow Meters
- Manufacturer: Endress+Hauser
- Model: Proline Promag
- Expected Cost: $1200 each
- Changing Interval: 15000 hours
- Aftermarket Option: Yokogawa
- Model: ADMAG AXF
- Expected Cost: $1150 each
- Changing Interval: 15000 hours
Level Sensors
- Manufacturer: Vega
- Model: VEGAPULS
- Expected Cost: $900 each
- Changing Interval: 10000 hours
- Aftermarket Option: Siemens
- Model: SITRANS
- Expected Cost: $850 each
- Changing Interval: 10000 hours
Heat Exchangers
Shell and Tube Heat Exchangers
- Manufacturer: Alfa Laval
- Model: Aalborg
- Expected Cost: $5000 each
- Changing Interval: 20000 hours
- Aftermarket Option: Kelvion
- Model: K Series
- Expected Cost: $4800 each
- Changing Interval: 20000 hours
Plate Heat Exchangers
- Manufacturer: GEA
- Model: NT Series
- Expected Cost: $4500 each
- Changing Interval: 15000 hours
- Aftermarket Option: Tranter
- Model: SUPERMAX
- Expected Cost: $4300 each
- Changing Interval: 15000 hours
Mixers
Batch Mixers
- Manufacturer: Eirich
- Model: RV19
- Expected Cost: $25000 each
- Changing Interval: 12000 hours
- Aftermarket Option: BHS-Sonthofen – Model: DKX – Expected Cost: $24000 each – Changing Interval: 12000 hours
TO Download this post and all the books and excel sheets and my personal notes and presentations I collected about cement industry in the last 30 years click the below paypal link