This paper aims to provide an overview of the key industrial applications of ceramic wear plates with CN bonding layer or studs, including ceramic polyurethane wear plates for chutes and hoppers.
Ceramic wear plates with CN bonding layer or studs (including ceramic polyurethane wear plates for chutes and hoppers) have a wide range of applications in power plants, steel industry, ports, mining, cement industry, chemical industry, lithium battery production and other fields due to their excellent wear resistance, high temperature resistance and unique corrosion resistance properties.
Specific applications include:
• Belt conveyor system and block material transfer system in power plants
These include bucket wheel reclaimer body and disk, belt conveyor hopper, raw coal hopper, coal feeder gate, coal mill exits chute and other equipment.
• The ultra-high temperature equipment in power plants
Examples of such equipment include burner square nozzle, W-flame burner cone, tail flue, air preheater baffle, air preheater support rod, and coal mill static ring.
• Wear-resistant ceramic linings for steel industry
1. Feeding system: bucket wheel reclaimer, hopper, etc.
2. Mixing system: mixing hopper, mixing cylinder scraper, etc.
3. Sintering system: ore dressing hopper under vibrating screen, raw material transport chute, etc.
• Ceramic wear plates for ore dock
Ceramic wear plates with CN bonding layer or studs are suitable for use in a variety of applications, including berth fixing hoppers, bucket wheel reclaimer fixing hoppers, belt conveyor station fixing hoppers, ship unloader hoppers, and more.
• Ceramic wear plates for the mining industry
Rubber-backed ceramic liners and ceramic polyurethane wear liners are suitable for a wide range of applications, including those requiring sliding and impact wear.
• Cement industry
The product range includes powder separator guide ceramic composite blades, powder separator cone ceramic linings, cyclone ceramic linings, and so on.
Due to their array of exceptional properties, ceramic wear plates with CN bonding layer or studs are extensively utilized in a multitude of industrial applications. The preceding overview of the applications of wear-resistant ceramic products is but a partial representation of the extensive range of potential applications. For further information on product applications, please consult with industry professionals or supplier.
As a key component of the rotating shaft of the cement mill, the contrarotating ring plays a vital role in preventing large particles of dust from entering the sealing chamber, thereby safeguarding the bearings.
The original process for this cement plant spare parts utilises ST 37-2+HVOF with an HRC of approximately 60.
The contrarotating ring creates friction with another sealing part when the spindle is rotating, which over time accelerates the wear of the surface, leading to a decline in sealing performance. Therefore, the maintenance department of the cement plant needs to replace this part periodically.
Due to the high cost of the contrarotating ring produced by the HVOF process, it is necessary to first accurately machine the ordinary steel plate to an outer diameter of 1200mm, an inner diameter of 1010mm, a thickness of 12mm, and to maintain the surface flatness. These production requirements are very high. Subsequently, tungsten carbide must be sprayed on both sides using high-speed oxy-fuel spraying technology. Finally, the surface roughness of Ra1.6 can be achieved through the processing of a large grinding machine.
The high purchase cost of the HVOF contrarotating ring places significant pressure on the user. Following a technical analysis between our customer and Cafu's technical team, it was decided to replace the original cement plant spare parts with a contrarotating ring made of NM400 wear-resistant steel plate. This is a high-quality wear-resistant steel from China that can be used in a wide range of applications that require resistance to abrasion. It is a good alternative to many composite wear-resistant materials.
Cafu has applied its specialised production process to the manufacture of the contrarotating ring, using high-quality wear-resistant steel plates, which are laser cut, lathed and finely ground, to produce the perfect replacement for the high velocity oxygen fuel (HVOF) technology contrarotating ring. The cost is only about one-third of the original cost, which greatly reduces the maintenance cost and creates a greater value return for our cement plant customers.
Cafu, as a leading supplier of spare parts for cement plants, offers a comprehensive range of wear parts, in addition to providing assistance to customers in improving existing processes. Our mission is to provide the best wear-resistant spare parts solutions for users and their shareholders through the implementation of practical projects.
The wear pipe is a piping system for conveying high-velocity, high-concentration solid particulate media. Its inner wall is specially treated to provide excellent wear resistance and extend the service life of the pipe. Rubber-lined composite steel pipe is a common type of wear-resistant pipe, which consists of an outer steel pipe and an inner rubber lining.
The natural rubber (NR) lining is characterized by its high abrasion resistance and corrosion resistance, rendering it well-suited for the conveyance of general solid particles of media, such as ore and coal. The styrene-butadiene rubber (SBR) lining, on the other hand, exhibits high abrasion resistance and strength, rendering it suitable for the conveyance of abrasive media, such as coal mill dust, powder, and dust.
The CR (neoprene rubber) lining exhibits superior oil resistance and ozone resistance, rendering it well-suited for conveying oil-containing media, chemical media, and ultraviolet radiation environments.
The EPDM (ethylene-propylene rubber) lining boasts exceptional abrasion resistance, corrosion resistance, and high-temperature resistance, rendering it an optimal choice for transportation in high-temperature environments, such as flue gas discharge systems and high-temperature ash transportation.
Rubber-lined composite steel pipes are employed in a number of fields and contexts, including:
The chemical industry is one of the primary applications of rubber-lined composite steel pipes. These pipes are particularly suited to the handling of corrosive media, high-temperature media, and high-pressure media. They can be used to convey acids, alkalis, solvents, salts, and various chemicals, including those that are corrosive to metals.
The oil and gas industry is another area in which rubber-lined composite steel pipes are extensively utilized. These pipes are employed in the extraction, transportation, and storage of oil and gas. They are utilized for the transportation of corrosive media, reservoir water, and natural gas, as well as in oil wells to enhance the efficiency of oil recovery.
The power industry employs rubber-lined composite steel pipes for the conveyance of cooling water, circulating water, and wastewater. These pipes are also utilized for the conveyance of coal ash, coal mill emissions, and other solid particulate matter, as well as coal and oil fuels in thermal power plants.
The mining industry is another area in which rubber-lined composite steel pipes are extensively utilized. These pipes are employed in the conveyance of ores, coal, and tailings. In order to withstand the rigors of the mining environment, which includes the potential for abrasion and corrosion, as well as the impact of high-velocity fluids and solid particles, the pipes must be constructed from materials that are resistant to these ills.
In brief, rubber-lined composite steel pipe are employed in a multitude of industrial sectors, including the chemical, petroleum, natural gas, food, pharmaceutical, electric power, and mining industries. This is due to their exceptional corrosion, abrasion, and high-temperature resistance.
1. SHS Ceramic Composite Pipe:
Characteristics:
- SHS ceramic composite pipe refers to a self-spreading high temperature synthetic ceramic lined pipe with self-spreading high temperature synthetic (SHS) technology, which can be divided into centrifugal SHS coating technology and SHS coating technology for gas transmission. The structure consists of three layers: corundum ceramic, transition layer and steel pipe from inside to outside.
- It has very high abrasion resistance and corrosion resistance, and can effectively resist abrasion, corrosion and high temperature erosion.
- Smooth inner wall reduces friction resistance and improves material conveying efficiency.
Applicable:
- SHS ceramic composite pipe is suitable for conveying high hardness, granular or abrasive materials, such as coal powder, ores, abrasive materials, ash, and so on.
Main application industries:
- Mining industry: used for conveying coal, metal ores and other mineral particles.
- Electric power industry: used for conveying coal powder, limestone powder, etc. in thermal power plants.
- Metallurgical industry: for conveying slag, metallurgical slag, etc.
2. Ceramic Patch Pipe:
Characteristics:
- Ceramic patch pipe is a wear pipe made of high hardness ceramic patch attached to the inner wall of the pipe.
- It has excellent abrasion resistance and erosion resistance, which can effectively prevent the wear and corrosion of the inner wall of the pipe.
- Patch structure makes the pipe more flexible, suitable for complex curved and shaped pipes.
Applicable:
- Ceramic patch pipe is suitable for conveying materials containing granular, high hardness or corrosive materials, such as gangue.
Main application industries:
- Mining industry: used for conveying coal gangue, etc.
- Environmental protection industry: used for conveying dust and other waste materials containing solid particles.
3. Ceramic Armored Pipe:
Characteristics:
- Ceramic armored pipe is a wear pipe with high hardness ceramic armored on the inner surface of steel pipe.
- It has excellent abrasion resistance, corrosion resistance and impact resistance, and can protect the steel pipe from abrasion and corrosion.
- The armored structure makes the pipe not only have the wear-resistant characteristics of ceramic, but also have the mechanical strength of steel pipe.
Applicable:
- Ceramic armored pipe is suitable for conveying materials that require high abrasion and corrosion performance of the pipe, such as coal ash, cement, slag and so on.
Main application industries:
- Thermal power industry: for conveying coal ash, coal ash, etc.
- Building materials industry: used for conveying cement, concrete, etc.
- Metallurgical industry: used for conveying slag, metal slag, etc. in the smelting process.
It should be noted that the specific application also needs to be evaluated and selected according to the specific needs of the plant and industry.
In the process of cement production, coal mill, as one of the important equipment, is responsible for grinding and conveying coal powder, and its stable performance is directly related to the quality and efficiency of cement production.
However, after a period of time, the gap of the grate plate of the coal mill usually closes gradually, resulting in problems such as poor ventilation, accumulation of coal powder, and unqualified fineness, which in turn leads to the emergence of unfavorable factors such as the decrease of coal mill output and the increase of system wear.
In order to solve these problems, the new grate plate after structural improvement is applied in the improvement process of coal mill in cement plant. The improved grate plate of the coal mill adopts a horizontal slit structure, which has some significant features and advantages compared with the original vertical arrangement.
Firstly, the transverse slit structure can effectively improve the ventilation, and by changing the relative angle between the grate plate slit and the direction of movement of the coal mill, it improves the ventilation performance inside the coal mill, maintains good air flow, and reduces the pressure loss in the system.
Secondly, the transverse slit structure can effectively reduce the closing phenomenon of the grate plate slit, making the operation of the grate plate more stable, reducing the problem of coal powder accumulation brought about by the closed slit, and ensuring the normal transportation and grinding process of coal powder.
In addition, the lateral arrangement structure can also effectively reduce the degree of wear of the coal mill and extend the service life of the equipment.
The improved coal mill grate plate structure is applicable to various types of coal mills in cement plants, and has shown excellent adaptability in several coal mill retrofit projects in cement plants.
Cement plants are one of the industries where the improved coal mill grate plate gap structure process is mainly applied. In cement production, coal mills undertake important work tasks, and their stable operation is crucial to the efficiency and quality of the cement production process. By improving the grate plate gap structure, the cement plant can effectively solve the problems caused by the closed gap, improve the performance and service life of the coal mill, and thus improve the quality and productivity of cement production.
The wear resistant hard-faced plates are commonly used in wear engineering for the purpose of providing protection wherever wear and corrosion resistance is required. wear resistant hard-faced plates are prepared by overlaying a high hardness alloy onto a substrate to form a composite material with excellent wear resistance. composite material with excellent abrasion resistance.
The following are some common overlay materials for wear-resistant hard-faced plates and their properties:
1. High-chromium cast iron alloy: High-chromium cast iron alloy has excellent wear resistance and corrosion resistance, commonly used alloy composition is Cr-Ni-Mo-W-V and so on. Its hardness is generally between HRC55-65, with high strength and wear resistance. It is mainly used in coal mines, iron mines, cement and other industries.
2. High-chromium white iron alloy: High-chromium white iron alloy is a kind of material with very high wear resistance, and its alloy composition is mainly Cr and C. Its hardness can reach HRC60-65, and it has very high wear resistance and anti-impact performance. It is mainly used in grinding ball mills, mining hoppers and other high wear-resistant occasions.
3. High manganese steel alloy: high manganese steel alloy is a common surfacing wear-resistant material, with excellent wear resistance, impact resistance and good plasticity. Its hardness is generally between HB200-250 with high strength. It is mainly used in crusher, screening equipment and other grinding and sorting fields.
Selection of suitable surfacing wear-resistant alloy materials should be considered according to specific application scenarios, the following points are important factors in selecting surfacing wear-resistant alloy materials:
1. Wear resistance requirements: Different occasions have different requirements for wear resistance, some occasions need to resist heavy impact and wear, while other occasions may only need to resist light wear. According to the actual wear resistance requirements to select the appropriate surfacing wear-resistant alloy materials.
2. Working conditions: Consider the temperature, humidity, and wear patterns of the working environment. For example, on some occasions there may be high temperatures or corrosion and other special working conditions, you need to choose the alloy material that can withstand these conditions.
3. Processability: Consider the processability of the alloy material, including cutting, welding and installation. Select the appropriate material according to the specific process requirements.
4. Economy: According to the budget constraints and performance requirements to select economically reasonable cladding wear-resistant alloy materials, in order to maximize the cost-effective.
In summary, the selection of suitable wear resistant hard-faced plates should fully consider the wear resistance requirements, working conditions, processability and economy to meet the needs of specific applications. For actual selection, professional technicians or suppliers can be consulted for more detailed advice and guidance.
IPv6 network supported