分享

ICR article draft
 Best mill practice and protection

2015/09/01 葛大海

Sintered cast grinding rolls are gaining greater prominence by cement
mill maintenance operators, as they do not require intermediate hard facing repair. On the other hand, some producers have been reverting to regular hard facing of mill tyres and table liners, as breakage and abnormal loss of profile is often observed on sintered cast grinding rolls. This can result in a substantial loss of throughput and an increase in power consumption compared to similar output of grinding media by Ni-Hard castings. ......

  Sintered cast grinding rolls are gaining greater prominence by cementmill maintenance operators, asthey do not require intermediate hard facing repair. On the other hand, some producers have been reverting to regular hard facing of mill tyres and table liners, as breakage and abnormal loss of profile is often observed on sintered cast grinding rolls. This can result in a substantial lossof throughput and an increase in power consumption compared to similar output of grinding media by Ni-Hard castings.

  Analysis provided in this article looksat how both types of castings can be intelligently applied, by keeping in mind the basic objective of achieving maximum plant availability and rated mill capacity throughput.

  Myth or fact?

  Sintered cast rolls are non-weldable?

  Myth. Where minimum sinter materialis still visible, a small amount of surface preparation will enable welding to be carried out which could potentially increase working life by 6000-8000h – resulting in substantial savings for the plant. A successful trial at a South African cement plant has already demonstrated such encouraging results. The alternative is to replace the sintered cast table liners.

  Complete hardfacing of sintered castings is not possible?

  Myth. With the use of gauging flux cored wires and air gauging, a clean surface can be almost be achieved, which is suitable for hardfacing. Therefore, a number of welded repairs can be carried out.

  There is no loss of profile in sintered cast?

  Myth. The regular interaction with plant

  Many arguments have been put forward in terms of best practice for maintaining mill grinding components. The two main solutions are hardfacing and sintered cast grinding rolls and table liners. However, it is not always clear when a cement plant should weld or when to simply replace components. By dispelling some common maintenance assumptions, this article how both types of castings can be applied to ensure best mill availability.

  Figure 1: worn-out sintered cast table lines

  WELDING & REPAIR

  Figure 2: repaired by welding for additional life

  operation and maintenance engineers suggest that there is a loss of profile after a year or between 5000-6000 working hours. Plant personnel can be faced with a dilemma since they can neither repair the roller profile to restore optimum

  grinding efficiency nor replace the rolls as they are not worn enough. In such cases, selection on the basis of loss of sinter from the contact surface, hardfacing can be considered by adapting partial gauging onsite and then repairing the castings.

  DECEMBER 2013 ICR XX

  WELDING & REPAIR

  Best practice study

  One collaborative study undertaken by a hardfacing services provider and a cement plant maintenance team found the following measures enabled best mill availabiity:

  Use Ni-Hard casting primarily for slag and clinker grinding, due the higher abrasive nature of both these materials Hi carbon Ni-Hard casting are best.

  The reduction in profile was found to

  be gradual and can be repaired while maximum life and throughput can be achieved with very low wear of less than 1g/t.

  Sinter casts are good for raw mill

  and coal mill grinding components. Throughput should be monitored closely and selective hardfacing be carried out to recover grinding efficiency.

  Before throwing any castings, sintered or Hi carbon cast iron, consideration should be given to the saving resources given the costs involved in making new purchases. Even casting that has been

  About the authors...

  Abhijit Dhodapkar has worked closely with various Indian cement plants during his tenure as managing director of UK–MNC dealing in onsite hardfacing. As chairman of his new venture, FerroClad solutions, he is working with his Chinese counterparts on new collaborations using the latest techniques to repair sinter cast grinding components for cement plants in India, Africa and Middle East.

  Graham Hughes has served 27 years as workshop chief for repairing grinding components. He is now general manager of Chinese Flux Cored Wire Manufacturing and Services Company, Beijing, Open Arc Welding Alloys.

  Sinter casts are good

  for raw mill and coal mill grinding components. However, throughput should be monitored closely and selective hardfacing can be carried out to recover grinding efficiency.

  worn out up to 45mm on radius can be hardfaced with a close study of the best profile during the lifecycle of the casting. ? Losses in power consumption during and after the loss of the roll profile

  need to be monitored closely so that

  an informed decision can be made

  and backed by efficient data collection management.

(责任编辑:陈宗勤)

您可能感兴趣的文章

山东德州发布重污染天气橙色预警 水泥粉磨站停止生产

矿石破碎企业(设施)和水泥粉磨站停止生产,混凝土搅拌站和砂浆搅拌站停止原材料运输。停止室外喷涂、粉刷、切割、护坡喷浆作业。涉及大宗物料运输的电力、有色、钢铁、焦化等行业企业组织做好错峰运输,对达不到超低排放标准的钢铁企业要提前备料,烧结工序执行错峰生产。

2019-04-22 环保 停产 山东省

紧急!重污染天气来袭 这些地区水泥企业将面临停产!

文件要求安阳、鹤壁、新乡、濮阳 4 市于 4 月 21 日 0 时至 25 日 24 时启动重污染天气橙色预警及Ⅱ级响应!同时,4 市所有钢铁企业的烧结(球 团)工序停产;所有涉及水泥、陶瓷行业的涉气企业停产

2019-04-22 停产

成都:淘汰PC32.5MP及以下水泥

日前,成都市工业经济工作领导小组办公室制定了《成都市钢铁、水泥、平板玻璃、烧结砖瓦结构调整方案》(下称“方案”)。方案针对水泥行业提出,淘汰PC32.5MP及以下水泥等要求。

2018-12-13 成都市 32.5

铁铝尖晶石加入量及粒度对镁铁铝尖晶石砖性能的影响

研究了铁铝尖晶石加入量及粒度对镁铁铝尖晶石砖常温性能及抗热震性的影响。结果表明:铁铝尖晶石加入量(w)为 10%、粒度≤3 mm 时,镁铁铝尖晶石砖具有较高的体积密度和常温耐压强度,较低的显气孔率,良好的抗热震性。铁铝尖晶石在烧结过程中形成二次尖晶石,提高晶体间的结合程度而增加强度;由于热失配在材料中存在一定量的微裂纹,其增韧作用改善了材料的抗热震性。

2018-11-01 技术创新
微信关注

文章来源:葛大海 ,如若转载,请注明出处:http://www.ccement.com/

免责声明

① 凡本网注明"来源:水泥网www.ccement.com"的所有文字、图片和音视频稿件,版权均为"水泥网 www.ccement.com"独家所有,任何媒体、网站或个人在转载使用时必须注明来源"水泥网www.ccement.com"。违反者本网将依法追究责任。

② 本网转载并注明其他来源的稿件,是本着为读者传递更多信息之目的,并不意味着赞同其观点或证实其内容的真实性。 其他媒体、网站或个人从本网转载使用时,必须保留本网注明的稿件来源,禁止擅自篡改稿件来源,并自负版权等法律责任。违反者本网也将依法追究责任。

③ 如本网转载稿涉及版权等问题,请作者一周内来电或来函联系。

  • 550+个水泥品牌
  • 31个省市159个地级市
  • 8000+家建筑施工企业正在使用
  • 15年的数据积累
时间 地区 均价
2019-07-17

新疆维吾尔自治区

¥445.55
2019-07-17

宁夏回族自治区

¥309.34
2019-07-17

青海省

¥404.55
2019-07-17

甘肃省

¥355.78
2019-07-17

陕西省

¥450.62
2019-07-17

西藏自治区

¥659.29
2019-07-17

云南省

¥370.83
2019-07-17

贵州省

¥328.19
2019-07-17

四川省

¥509.24
2019-07-17

重庆市

¥443.99
2019-07-17

海南省

¥487.94
2019-07-17

广西壮族自治区

¥381.85
2019-07-17

广东省

¥452.13
2019-07-17

湖南省

¥374.24
2019-07-17

湖北省

¥468.06
2019-07-17

河南省

¥531.35
2019-07-17

山东省

¥479.74
2019-07-17

江西省

¥438.60
2019-07-17

福建省

¥397.57
2019-07-17

安徽省

¥448.62
2019-07-17

浙江省

¥453.77
2019-07-17

江苏省

¥446.12
2019-07-17

上海市

¥472.00
2019-07-17

黑龙江省

¥364.89
2019-07-17

吉林省

¥388.96
2019-07-17

辽宁省

¥342.48
2019-07-17

内蒙古自治区

¥313.63
2019-07-17

山西省

¥385.07
2019-07-17

河北省

¥432.79
2019-07-17

天津市

¥462
2019-07-17

北京市

¥495.56

联系我们

会员咨询:400-8888-870

24小时热线:0571-85999833

杭州总部:0571-85300321

商务合作:0571-85871612

北京信息总部:18969091792

微信服务

水泥网

水泥观察

水泥价格

水泥技术

©1997-2019 水泥网版权所有| 法律顾问:哲鼎律师事务所
2019-07-18 00:24:41