DJM ceramic composite vertical mill spare parts (roller and pan) technology introduction
Due to vertical mill low energy consumption, the newly built large-scale cement production line adopts vertical mill as basic raw material/coal grinding, even cement mill, the largest vertical mill output can reach 600-600 tons/hour, while the roller is required with reliable against fracture and abbrasive wheel wear resistance.Usually adopt four types alloy: Mn steel, NihardIV alloy, high Cr alloy, Hardfacing (surface overlaying).Although Mn steel to surface overlaying, the material hardness is more and more big, the wear resistance improved, but its brittleness has been greatly increased at the same time, the risk of fracture is also growing. So how to choose the material with high resistance to wear and can prevent fracture become the important determinants of vertical mill spare parts materials.
Generally, LM and CKP vertical roller as a whole setting, so if using high Cr alloy, the fracture risk is bigger, so the general original equipment manufacturers are using good plasticity Mn steel roller, but its abrasion resistant life maturely is low. Aimed at this situation, DJM choose iron base ceramic composite materials, which is the roller basement with plasticity iron, it has 4% elongation, thus has completely safety of resistance to fracture and embed high wear resistance of ceramic reinforcement into the iron basement, to get great improvement wear resistance. Due to its complete rupture of resistance, weight can even get 30%-40% of original roller after wear , the weight of the Mn steel or alloy NihardIV generally 50-60%, and the reinforcement design makes even in the process causes cracks to appear on the stiffener, won't be extended to the basement , thus completely does not affect the service life of the wear resistant. In addition, this design also makes the wear is more uniform, more stable production in the whole life period, to avoid the typical Mn steel roller wear big ripple and the Angle formed on large diameter end. The life of the ceramic composite roller, compared with common Mn steel roller life can reach more than 1.5-2 times.
On MPS, ATOX and RM vertical mill ceramic composite technology and high Cr materials, general MPS, ATOX and RM vertical mill roller consists of several blocks. This kind of roller fracture risk is not big, the main factors for its abrasion wear life, generally, original equipment manufacturers adopt NihardIV alloy or high Cr alloy. To further increase its wear life, DJM selects high Cr ceramic composite materials, which forms the ceramic metal composite reinforcement through injection of ceramic particles into the high-Cr material , the composite layer wear-resisting property is than high Cr material 3-4 times, at the same time, the composite layer thickness can be made to a third of the thickness of the original spare parts, and can make the targeted composite material according to original wear curve. Even if some particles crack, also are limited its own, can’t expand the basement. Ceramic composites roller life is more than 2 times than NihardIV alloy and high Cr alloy.
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