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    Wear Resistance

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    Muzammil
    The document discusses the application of wear-resistant ceramic coatings in cement production to address issues caused by equipment wear and abrasion. It notes that wear and abrasion account for 50-55% of shutdown time in cement plants. The document then describes a new wear-resistant ceramic coating called Valor series that can be applied to equipment like mills, ducts, cyclones, and valves to reduce shutdown time and maintenance costs. It provides details on appropriate ceramic types for different equipment temperatures and discusses application thickness, curing time, and expected service life.

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    Wear Resistance

    Uploaded by

    Muzammil
    17 views3 pages
    The document discusses the application of wear-resistant ceramic coatings in cement production to address issues caused by equipment wear and abrasion. It notes that wear and abrasion account for 50-55% of shutdown time in cement plants. The document then describes a new wear-resistant ceramic coating called Valor series that can be applied to equipment like mills, ducts, cyclones, and valves to reduce shutdown time and maintenance costs. It provides details on appropriate ceramic types for different equipment temperatures and discusses application thickness, curing time, and expected service life.

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    The document discusses the application of wear-resistant ceramic coatings in cement production to address issues caused by equipment wear and abrasion. It notes that wear and abrasion account for 50-55% of shutdown time in cement plants. The document then describes a new wear-resistant ceramic coating called Valor series that can be applied to equipment like mills, ducts, cyclones, and valves to reduce shutdown time and maintenance costs. It provides details on appropriate ceramic types for different equipment temperatures and discusses application thickness, curing time, and expected service life.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    17 views3 pages

    Wear Resistance

    Uploaded by

    Muzammil
    The document discusses the application of wear-resistant ceramic coatings in cement production to address issues caused by equipment wear and abrasion. It notes that wear and abrasion account for 50-55% of shutdown time in cement plants. The document then describes a new wear-resistant ceramic coating called Valor series that can be applied to equipment like mills, ducts, cyclones, and valves to reduce shutdown time and maintenance costs. It provides details on appropriate ceramic types for different equipment temperatures and discusses application thickness, curing time, and expected service life.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 3

    APPLICATION OF WEAR-RESISTANT CERAMIC

    IN CEMENT INDUSTRY
    Yue Jianmin

    * Xi’an Valor Wear-resistant Engineering Technology Co.,Ltd.

    In recent years, cement industry is growing by leaps and bounds. The matured application of large
    process equipment has provided flying wings for the development of cement industry. In large
    cement projects, production lines with capacity of 5000t/d even 10000t/d have been often seen. The
    continuous highly efficient operation of cement enterprises can’t do without the escort of wear-
    resistant ceramic of new high performance for equipment.

    According to the statistics by authority, the shutdown time caused by wear and abrasion in
    cement industry occupies 50%-55% of the total shutdown time. The maintenance work quantity
    caused by wear and abrasion has increased 60%-65% of the total maintenance work quantity of
    equipment. Wear and abrasion issue of equipment has become one of the critical factors that
    determine the high efficient operation. The successful solution of this issue has geared up the
    development of comprehensive competitiveness of cement enterprises.

    Figure 1 Production line shutdown due to severe wear and abrasion

    1. Function and characteristic

    Valor series wear-resistant ceramic coating is a kind of new wear-resistant ceramic coating. It can
    effectively resolve the issues of wear and erosion of equipment caused by dust, material, smoke
    washing. Owning to its simple and convenient application, as well as applicability for various
    geometric shape and excellent wear-resistant property, it can ensure continuous and economic
    operation of the equipment. Therefore shutdown time, maintenance expense and production
    losses can be greatly reduced.
    Figure 2 application of wear-resistant ceramic on conic hopper

    2. Portions to be applied

    Figure 3 shows the typical process of cement industry. Marks are made where valor series wear-
    resistant ceramic can be applied. For orange portions, low temperature wear-resistant ceramic
    shall be applied. For red portions, high temperature wear-resistant ceramic shall be applied.

    Figure 3 application portions of wear-resistant ceramic on new dry cement production line

    Different wear-resistant ceramic can be selected for cement equipment according to different
    operation temperature. Table 1 shows the operation temperature of typical process equipment and
    selection of wear-resistant ceramic.

    Table 1
    operation temperature of typical process equipment and selection of wear-resistant ceramic
    equipment media Work wear-resistant
    temperature(℃) ceramic selected
    Raw mill, cement mill, raw material/cement/slag Max 120 Valor400
    coal mill powder/coal powder
    Coal powder Coal powder Max 120 Valor400
    conveying bend
    Air duct of dust Smoke/raw Max 120 Valor400
    precipitator, exhaust air material/cement/slag
    duct powder
    Cyclone separator raw material/cement/slag Max 400 Valor400
    powder/coal powder
    Riser/cyclone of Raw material Max 500 Valor700
    Primary preheater riser
    Valve of tertiary pipe High temperature smoke Max1200 Valor1200

    3. Construction method and curing

    According to the variety of abrasive media and washing speed, the application thickness is
    different. For air ducts, bends and cyclone separator, the construction thickness is 20mm. For
    severely worn portions such as discharging conic hopper, chutes of powder separator, the
    thickness shall be increased up to 30mm or 40mm.

    strength

    100 30℃
    %
    20℃
    75% 10℃
    5℃

    50%

    25%

    day
    0 1 2 3 4 5 6 7 s
    figure 5 curve for strength and curing time

    4. Service life

    The service life of wear-resistant ceramic relates to the particle size, concentration, washing speed
    and washing angle of dust and powder. The smaller the particle size and concentration, the lower
    the washing speed, the narrower the washing angle, the longer the service life of the wear-resistant
    ceramic. Usually in air pipe of mineral slag micro-powder production line, when the micro-powder
    to surface area is 420-450㎡ /kg, concentration is 350g/Nm³， washing speed is 30m/s, washing angle
    is 30°， the 20mm thick wear-resistant ceramic coating can serve 8-10 years. As the medium in raw
    mill and clinker mill has better wearing property, for the same thickness, the service life can be
    more than 10 years.

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