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耐磨耐热材料厂

       合肥水泥研究设计院耐磨耐热材料厂已从事耐磨耐热材料的研发、制造与售后服务三十余年,拥有教授级高级工程师和高级工程师3人,工程师7人,其中硕士研究生3人,本科7人;获得了10项省部级科技成果和科技进步奖。

  在提供优质耐磨材料的同时,经验丰富的粉磨工艺专家可为用户提供衬板、隔仓板和篦板的结构优化设计和钢球级配等粉磨系统工艺调试的技术服务,提高磨机产量,降低粉磨电耗和提高水泥比表面积。为国内外近千家客户提供的耐磨耐热材料产品结合工艺调试的技术服务,获得了用户的广泛赞誉。

科研成果 Scientific Research Achievements

新型磨机衬板——沟槽板 

New Pattern Mill Liner——Grooved Liner

建材行业部级科学技术进步三等奖

Third Prize of Building Industry Ministry

Science and Technology Progress

大中型磨机中碳多元合金钢衬板

Medium Carbon Multi-component Alloy Steel Liner in Large-scale Mill

高碳奥氏体锰    High Carbon Austenite Manganese Steel

SR-I型铬镍耐热钢  

SR-I type Cr-Ni Heat-resistant Steel

湿式磨机新材质衬  New Material Liner in Wet Ball Mill

安徽省科学技术二等奖

Second Prize of Anhui Province 

高碳中铬合金  High Carbon Medium Chromium Alloy Steel

安徽省科学技术进步三等奖

Third Prize of Anhui Province 

双螺旋型段分级衬   Double Spiral Classifying Liner for Cylpebs

安徽省科技成果

Anhui Province Scientific Research Achievements

熟料破碎机高韧性耐磨锤头

High Toughness Wear-resistant Hammer in Clinker Crusher

TU-I型高铬铸铁    TU-I type High-Cr Cast Iron

低碳多元合金钢    Low Carbon Multi-component Alloy Steel

  一、衬板类 Liner Sort

  1. 材质及性能  Materials and Properties


  根据耐磨件应用工况和用户对使用寿命的要求,提供材质的优选,实现低投入、高回报。
  We provide optimal selection of materials according to used conditions of wearing parts and service lifetime demand of customer, to achieve low investment and high return。


  2。1 沟槽衬板Grooved liner
  沟槽衬板将球与衬板之间的点接触变为120° 弧线接触,增大了研磨面积;沟槽内始终存有料垫,提高了研磨效率,并减轻了球与衬板的直接金属磨损;活化衬板、环沟衬板、螺旋沟槽衬板、锥面衬板、挡料环等多型式的组合,可使钢球产生正分级,与物料的粉磨进程相吻合;安装方式可用螺栓固定,亦可镶砌。同等筛余细度下,提高水泥比表面积~15m2/kg;同等材质下,降低钢球磨耗,延长衬板寿命。

   Grooved liner transform point contact of balls and liners to 120°curved contact which enlarges the grinding area; Material bed laid in groove enhance the grinding efficiency and reduce direct metal abrasion between balls and liners; Combination of active liner, ring grooved liner, spiral grooved liner, cone liner and damming ring make balls positive classified and conform to the grinding process of materials; Liners can be fixed with bolts or inlayed.
  Technical Index: Output increased by 5%. Power consumption reduced by 8%. With same residue of sieve, specific surface area of cement is raised by 15m2/kg. Other things being equal, the ball abrasion wear is reduced and the service lifetime of liners is extended.

  
沟槽衬板Grooved liner                                              普通衬板Ordinary liner


  2。2 双螺旋型段分级衬板 Double spiral classifying liner for Cylpebs
  适用于研磨体为段的各种磨机细磨仓,依靠多边形截面的旋转排列和倾斜凸棱的疏密排列,构成双螺旋,可使钢段产生良好的正分级,提高磨机的粉磨效率和水泥的比表面积。

  They are applicable to mill fine grinding chamber. Double spiral is formed by rotary arrangement of polygonal sections and spacing arrangement of oblique rib, so that good positive classification of cylpebs to increase the grinding efficiency of mill and specific surface area of cement.


  双螺旋型段分级衬板示意图
  Schematic diagram of Double Spiral Classifying Liner for Cylpebs

  2。3 控制流内筛分隔仓板 Control Flow Inner- Screening Diaphragm
  开路磨中采用控制流内筛分隔仓板,筛分出2mm以上的颗粒返回一仓继续破碎,细磨仓安装挡料环或挡料圈,控制物料流速、搅动滞留区研磨体,增加剪切、搓磨作用,采用Φ8×8~Φ16×16的微段充分细研磨。在比表面积要求>380m2/kg的闭路水泥磨中以及粉磨超细粉煤灰和矿渣的磨机中,均可采用筛分隔仓板。筛分隔仓板的应用需与仓长比例、衬板结构、出料篦板、研磨体级配等相结合。
  Control Flow Screening Diaphragm used in open-circuit mill screen out grains of more than 2mm, which are sent back to the first chamber for future grinding. Damming rings are installed in the fine grinding chamber to control flow velocity of materials, stir grinding media in the retention section, increase cutting and rubbing. Φ8×8~Φ16×16 micro-cylpebs can be used for fine grinding fully. Then the production can be increased by 20%. Control Flow Screening Diaphragm can also be used in closed-circuit mills whose specific surface area is required to exceed 380 m2/kg and mills for grinding ultra-fine fly ash and slag. The chamber length, liner structure, outlet grate plates, gradation of grinding media must be considered together.


控制流内筛分隔仓板示意图
Schematic diagram of Control Flow Inner-Screening Diaphragm
  根据用户的粉磨系统参数,提供沟槽衬板、双螺旋段分级衬板及控制流筛分隔仓板的结构设计、系统参数优化和增产调试服务。
We provide structure design for Grooved Liner, Double-spiral Classifying Liner and Control Flow Screening Diaphragm, process parameters optimization and commissioning for production increase according to the parameters of grinding system.


   

Ф5×15m水泥磨沟槽衬板使用1.5年后形貌                Ф3.8×13m水泥磨沟槽衬板与锥面衬板组合
Grooved liner appearance after 1.5 years in Ф5×15m        Combined grooved liners in 2nd chamber Ф3.8×13m

3. 代表性业绩  Representative achievements
  ·CEMAX泰国Saraburi两台Ф3×11m闭路水泥磨,原三仓改为两仓,同时更换沟槽衬板,粉磨P I 52。5水泥,台产提高7t/h,38μm筛余下降7%,一天强度提高20kg/cm2,得到泰方总经理的嘉奖。

  For CEMAX Thailand Saraburi Cement Co. Ltd 2 sets of Φ3×11m closed-circuit cement mills, three chambers changed into two chambers, grooved liners instead. To grind P I 52.5 cement, output increased by 7t/h, 38?m residue reduced by 7%, and one day strength increased by 20kg/cm2. The best effect has been commended by the general manager.


  ·句容台泥Ф4。2×13。5m闭路水泥磨,RP-Z-170/180B辊压机+VSK112/24-3750分级机+通仓沟槽衬板,PⅡ52。5水泥,比表面积350m2/kg,台产240t/h;PⅠ52。5水泥,比表面积420m2/kg,台产160t/h。高铬铸铁材质,使用寿命>60,000小时。

  For Jurong Taiwan Cement Corporation Φ4.2×13.5m closed-circuit cement mill, fitted with RPZ170/180B Roller Press and VSK112/24-3750 Classifier, one chamber of grooved liners instead. To grind PⅡ52.5 cement, specific surface being 350 m2/kg, output being 240 t/h. To grind P I 52.5 cement, specific surface being 420 m2/kg, output being 160 t/h. The service lifetime of high-Cr cast iron is more than 60,000hrs.


  ·Heidelberg越堡Ф4。2×14m闭路水泥磨2台(双仓沟槽衬板),PC32。5R水泥,比表面积380m2/kg,台产145t/h。Ф4。2×14m开路水泥磨3台(控制流筛分隔仓板),比表面积370m2/kg,PⅡ52。5R水泥,台产95t/h;PO42。5R水泥,台产120t/h。中碳铬钼镍合金钢材质,使用寿命>15,000小时。

  For Guangzhou Heidelberg Cement Co. Ltd. 2 sets of Φ4.2×14m closed-circuit cement mills (fitted with grooved liner), to grind PC32.5R cement, specific surface being 380 m2/kg, output being 145 t/h. 3 sets of Φ4.2×14m open-circuit cement mills (fitted with Control Flow Screening Diaphragm), specific surface being 370 m2/kg, to grind PⅡ52.5 cement, output being 95 t/h, to grind PO42.5R cement, output being 120 t/h. The service lifetime of medium-carbon Cr-Mo-Ni alloy steel is more than 15,000hrs.


  ·沙特Najran Ф5×15m闭路水泥磨2台,双仓沟槽衬板和控制流筛分隔仓板,PⅠ52.5水泥,比表面积330m2/kg,台产160t/h。中碳多元合金钢材质,使用寿命>15,000小时。

  For Saudi Najran Cement Co. Ltd. 2 sets of Φ5×15m closed-circuit cement mills, fitted with Grooved Liners and Control Flow Screening Diaphragm. To grind P I 52.5 cement, specific surface being 330 m2/kg, output being 160 t/h. The service lifetime of medium-carbon multi-component alloy steel is more than 15,000hrs.


  ·沙特Najran粉磨站Ф4。2×13m闭路水泥磨2台,HFCG1400/800辊压机+SF6000打散分级机+双仓沟槽衬板+控制流筛分隔仓板,PⅠ52。5水泥,比表面积330m2/kg,台产150t/h。中碳多元合金钢材质,使用寿命>30,000小时。

  For Saudi Najran grinding station 2 sets of Φ4.2×13m closed-circuit cement mills, fitted with HFCG1400/800 Roller Press, SF6000 Breaking Classifier, Grooved Liners and Control Flow Screening Diaphragm. To grind P I 52.5 cement, specific surface being 330 m2/kg, output being 150 t/h. The service lifetime of medium-carbon multi-component alloy steel is more than 30,000hrs.


  ·Larfage智利Puerto粉磨站Ф3.4×12m闭路水泥磨,采用了磨内通热风烘干的特殊工艺,比表面积460m2/kg,台产36t/h。高铬铸铁材质,使用寿命>30,000小时。

  For Larfage Chile Puerto grinding station Φ3.4×12m closed-circuit cement mill. Owing to pozzolana mixed proportion 30% and its moisture 10%, hot-air sucked in mill barrel to dry moist material. Specific surface being 460 m2/kg, output being 36 t/h. The service lifetime of high-Cr cast iron is more than 30,000 hrs.


  ·Larfage乌干达Hima Ф4.2×14m闭路水泥磨,双仓沟槽衬板和控制流筛分隔仓板,掺入的火山灰水分高达,比表面积≥500m2/kg,台产65t/h。中碳铬钼镍合金钢材质,使用寿命>20,000小时。

  For Larfage Uganda Hima Cement Co. Ltd. Φ4.2×14m closed-circuit cement mill, fitted with Grooved Liners and Control Flow Screening Diaphragm. Pozzolana mixed proportion 32% and its moisture 13%, specific surface being 500 m2/kg, output being 65 t/h. The service lifetime of medium-carbon Cr-Mo-Ni alloy steel is more than 20,000hrs.


  ·Lafarge赞比亚 Chilanga Φ4.6×15.3m水泥磨,Φ4.6×8.5+3m原料磨,Φ2.8×5.75+2.25m 煤磨,3套衬板、端衬板、隔仓板、篦板均采用中碳多元合金钢材质,使用寿命>21,000小时。

  For Lafarge Zambia Chilanga Cement Co. Ltd. Φ4.6×15.3m cement mill, Φ4.6×8.5+3m raw mill and Φ2.8×5.75+2.25m coal mill, 3 sets of liner, end liner, diaphragm and grate, the service lifetime of medium-carbon multi-component alloy steel is more than 21,000hrs.


  ·埃塞俄比亚Messebo Ф4。2×13m闭路水泥磨2台,HFCG1600/1200辊压机+SF6000打散分级机+沟槽衬板+控制流筛分隔仓板,PⅡ52。5水泥,比表面积320m2/kg,台产≥150t/h。中碳多元合金钢材质,使用寿命>30,000小时。

  For Ethiopia Messebo Cement Co. Ltd. 2 sets of Φ4.2×13m closed-circuit cement mills, fitted with HFCG1600/1200 Roller Press, SF6000 Breaking Classifier, Grooved Liners and Control Flow Screening Diaphragm. To grind PⅡ52.5 cement, specific surface being 340 m2/kg, output being more than 150 t/h. The service lifetime of medium-carbon multi-component alloy steel is more than 30,000hrs.


  ·苏丹Atbara Φ4.6×13.5m闭路水泥磨3台,双仓沟槽衬板和控制流筛分隔仓板,PⅠ52.5水泥,比表面积330m2/kg,台产120t/h。中碳多元合金钢材质,使用寿命>15,000小时。

  For Sudan Atbara Cement Co. Ltd. 3 sets of Φ4.6×13.5m closed-circuit cement mills, fitted with Grooved Liners and Control Flow Screening Diaphragm. To grind P I 52.5 cement, specific surface being 330 m2/kg, output being 120 t/h. The service lifetime of medium-carbon multi-component alloy steel is more than 15,000hrs.


  ·巴西POLIMIX、 MARE、CIMPOR三个公司Φ3.0×11m和Φ3.5×11m水泥磨,Φ3.2×9m生料磨,Φ3.4×7.2+1.8m煤磨,衬板、隔仓板、篦板均采用中碳多元合金钢。

  For Brazil POLIMIX, MARE and CIMPOR companies’ Φ3.0×11m and Φ3.5×11m cement mill, Φ3.2×9m raw mill and Φ3.4×7.2+1.8m coal mill, all of liner, diaphragm and grate are made of medium-carbon multi-component alloy steel.


  ·台泥贵港水泥公司Ф4.2×13m水泥磨2台,辊压机+V型选粉机,高铬铸铁衬板使用寿命>60,000小时。

  For Guigang Taiwan Cement Corporation 2 sets of Ф4.2×13m cement mills, fitted with Roller Press and V-Classifier. The service lifetime of high-Cr cast iron is more than 60,000 hrs.


  ·越南LUXS Φ3.4×7.2+1.8m和Φ3.2×7.2+1.8m原料磨,Φ3.0×11m水泥磨,Φ2.4×4.7+1.5m煤磨,全部采用中碳多元合金钢沟槽衬板,取得明显的增产节电效果,使用寿命>21,000小时。

  For Vietnam LUXS Cement Co. Ltd. Φ3.4×7.2+1.8m and Φ3.2×7.2+1.8m raw mill, Φ3.0×11m cement mill, Φ2.4×4.7+1.5m coal mill, all of them fitted with Grooved Liners. The output increased and the power consumption decreased obviously. The service lifetime of medium-carbon multi-component alloy steel is more than 21,000hrs.


  ·宣城海螺Ф4.2×13m水泥磨2台,中碳铬钼镍合金钢筛分隔仓板使用寿命>24,000小时。

  For Xuancheng Conch Cement Co. Ltd. 2 sets of Ф4.2×13m cement mills, the diaphragm is made of medium-carbon Cr-Mo-Ni alloy steel. The service lifetime is more than 24,000 hrs.


  ·台湾餘慶堂興業股份Φ3.8×12m水泥磨,铬钼合金钢沟槽衬板使用寿命>24,000小时。

  For Taiwan YCT Corporation Φ3.8×12m cement mill, fitted with Grooved Liners. The service lifetime of medium-carbon Cr-Mo alloy steel is more than 24,000 hrs.


  ·山水淄博双凤水泥Ф3.8×12m闭路水泥磨,CLF140-65型辊压机+VX2000型选粉机+双仓沟槽衬板,PO42.5水泥,比表面积370m2/kg,台产130t/h。高铬铸铁材质,使用寿命6年以上。

  For Zibo Shuanfeng Shanshui Cement Co. Ltd. Φ3.8×12m closed-circuit cement mill, fitted with CLF140-65 Roller Press, VX2000 Classifier and Grooved Liners. To grind PO42.5 cement, specific surface being 370 m2/kg and output being130t/h. The service lifetime of high-Cr cast iron is more than 6 years.


  ·巢湖铁道水泥厂Ф3.8×12m闭路水泥磨,原二仓衬板导致钢球逆分级较严重,使用沟槽组合分级衬板后,正分级效果明显。高铬铸铁材质,使用寿命6年以上。

  For Chaohu Railroad Cement Factory Φ3.8×12m closed-circuit cement mill. The counter classification of balls is severely in 2nd chamber. The positive classification obtained by grooved combined classifying liners. The service lifetime of high-Cr cast iron is more than 6 years.


  ·中联青岛即墨Ф4。2×14m闭路水泥磨,辊压机+V型选粉机+双仓沟槽衬板,高铬铸铁材质,使用寿命8年以上。

  For CUCC Qingdao Jimo Cement Co. Ltd. Φ4.2×14m closed-circuit cement mill, fitted with Roller Press, V-Classifier and Grooved Liners. The service lifetime of high-Cr cast iron is more than 8 years.


  ·苏州南新水泥厂Ф3.4×11m闭路水泥磨,双仓采用沟槽衬板,PO42.5水泥,比表面积350m2/kg,台产55t/h。高铬铸铁材质,实际使用寿命超过8年。

  For Suzhou Nanxin Cement Factory Φ3.4×11m closed-circuit cement mill, fitted with Grooved Liners. To grind PO42.5 cement, specific surface being 350 m2/kg and output being 55t/h. The service lifetime of high-Cr cast iron exceeded 8 years.


  ·数十台白水泥磨机使用高铬铸铁沟槽衬板,使用寿命均超过8~10年,达到白度要求。

  More than ten sets of white cement mills fitted with high-Cr cast iron Grooved Liners. The service lifetime exceeded 8~10 years all. This can meet the requirement of whiteness.

二、锤头类材质及性能  Materials and Properties of Hammer


材质名称

Materials

   

Application scope

   

Hardness

冲击韧 Impact toughness

超高韧性高铬铸 (Cr22Mo2NiCuWV)          Super high-toughness high-Cr cast iron

熟料破碎机锤头板锤

Clinker crusher hammer

Blow bar

HRC≥60

7~10 J/cm2

合金高锰钢 (Mn13Cr2)

Alloyed high-Mn steel

大型破碎机锤头 

Large-scale crusher hammer

HB≥220

≥120 J/cm2

超高锰钢 (Mn17Cr3)

Super high-Mn steel

HB≥240

≥120 J/cm2

双金属复合铸造

Bimetal composite casting

 head HRC≥60

柄部 handle

≥50 J/cm2

  

  组合式锤头-超高韧性高铬铸铁+钴基硬质合金     单段破碎机锤头-可表面堆焊或双金属复合
   Built-up hammer: super high-ductility high-Cr cast iron       Single-stage crusher hammer:
  + Co-based cemented carbide                    available for built-up welding or bimetal composite


  根据破碎机的型式、破碎物料条件,提供锤头结构的优化设计和材质的合理选择。
  We provide optimal structure design of hammer and proper selection of materials according to the type of crusher and materials crushed.


三、研磨体材质及性能
  Chemical composition and properties of grinding media

  

1、铸球化学成分Chemical composition of cast ball


名称

牌号

C

Si

Mn

Cr

P

S

Mo Cu

高铬铸球

ZQCr25

2.0-3.0

≤1。0

0。3-1。0

24-28

≤0.08

≤0.06

根据用户要求添加

added at customers’ request

高铬铸球

ZQCr20

2.0-3.0

≤1.0

0.3-1.0

19-21

≤0.08

≤0.06

高铬铸球

ZQCr18

2.0-3.0

≤1.0

0.3-1.0

17-19

≤0.08

≤0.06

高铬铸球

ZQCr15

2.0-3.2   

≤1。0

0.3-1.0

14-16

≤0。08

≤0.06

高铬铸球

ZQCr12

2。0-3。2

≤1.0

0。3-1。0

11-13

≤0.08

≤0.06

高铬铸球

ZQCr10

2.0-3.2

≤1。0

0。3-1。0

10-11

≤0.08

≤0.06

多元合金铸球

ZQCr4

2。0-3。2

0.3-1.2

0.3-1.0

3。0-5。0

≤0。10

≤0.08

低铬铸球

ZQCr2

2.2-3.5

0.3-1.2

0。3-1。0

0.6-1.8

≤0.10

≤0.08



  2、铸球机械性能 Mechanical properties of cast ball


  表面硬度Surface hardness  单仓磨耗(g/吨水泥)Abrasion ratio per chamber (g/t cement)
  破碎率Breaking ratio  落球冲击疲劳寿命(次数)Falling ball impact fatigue lifetime (number of times)


  3、铸段化学成分Chemical composition of cast cylpebs

高铬铸段High-Cr Cast Cylpebs         低铬铸段Low-Cr Cast Cylpebs

  4、铸段机械性能 Mechanical properties of cast cylpebs


  5、铸球规格参数 Specification parameters of cast ball


  6、微球规格参数 Specification parameters of mini ball


  7、铸段规格参数 Specification parameters of cast cylpebs


  注:可根据用户需要,生产特殊规格。
  Note:Special specifications can be made according to customers" requirements。     

 

  四、主要生产设备 Main Production Equipments

 

       树脂砂生产线                                                     迪砂挤压造型自动生产线
   

全自动热处理油淬生产线                                          铸件喷丸机

  五、主要检测设备Main Inspection Equipments

 

  日本岛津直读光谱仪                                                德国斯派克直读光谱仪
 
德国莱卡电子金相显微镜                                                机械性能检测设备


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