蜂窩ZTA陶瓷復合高鉻鑄鐵碾底

DJM 陶瓷復合立磨備件（輥套與磨盤）技術介紹

DJM ceramic composite vertical mill spare parts (roller and pan) technology introduction

由于立磨的低能耗，新建的大型水泥生產線基本均采用立磨作為生料磨/煤磨，甚至水泥磨，最大的立磨產量可達600-700噸/小時，而對立磨中備件即輥套與磨盤要求具有防斷裂的可靠性及抗磨損的耐磨性。通常輥套與磨盤所采用的合金有4類，即：Mn鋼、NihardIV合金、高Cr合金、Hardfacing（表面堆焊）。雖然從Mn鋼至表面堆焊，其材料硬度越來越大，耐磨性提高，但同時其脆性也大大增加，斷裂的危險性也越來越大。因而如何選擇具有高耐磨性但又咳防止斷裂的材料成為決定立磨備件材料的重要決定因素。

一般LM和CKP立磨的輥子為一個整體，故若采用高Cr合金，其斷裂的危險較大，故一般原設備制造商均采用塑性較好的Mn鋼輥，但其耐磨壽命自然較低。針對這一情況，DJM 選用鐵基陶瓷復合材料， 即輥子的基體采用塑性鑄鐵，其有4%的彈性伸長，因而具有抗斷裂的完全安全性，同時在基體上嵌鑄具有高耐磨性的陶瓷加強筋，因而大大提高輥子的耐磨性。由于其完全抗斷裂的性能，這種輥子的磨損后重量甚至可以為初始重量的30% - 40%，而Mn鋼或NihardIV合金一般為50 – 60%，而這種加強筋的設計使得即使在加強筋上出現裂紋，也不會擴展至基體，因而完全不影響耐磨使用壽命。另外，這種設計也使得磨損更為均勻，在整個壽命期內產量更為穩定，避免了Mn鋼輥子通常出現的大波紋磨損及大直徑端的尖角形成。陶瓷復合材料輥子的壽命與一般Mn鋼輥相比，壽命可達1.5 – 2倍以上。

針對MPS、ATOX和RM立磨的陶瓷復合材料技術及高Cr材料，一般MPS立磨、ATOX和RM立磨的輥套由數塊組成。這類輥套的斷裂危險性不大，最主要的因素為其耐磨性即耐磨壽命，一般原設備制造商均采用NihardIV合金或高Cr合金。為進一步提高其耐磨壽命，DJM 選用高Cr陶瓷復合材料，即在高Cr材料表面注入陶瓷顆粒形成陶瓷金屬復合材料層，這層復合層的耐磨性能可達高Cr材料的3 – 4倍，同時這一復合層的厚度可制成達到原備件厚度的1/3，并可根據原磨損曲線有針對性的制作，即使某些顆粒出現裂紋，也只局限于顆粒本身而不擴展至基體。陶瓷復合材料輥套的壽命約為NihardIV合金及高Cr合金輥套的2倍以上。

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.

附圖-3-鐵基陶瓷復合材料磨盤示意圖         附圖-3-3-鐵基陶瓷復合材料輥套示意圖

Picture -3 sketch map of Mill pan               Picture -3-3 sketch map of roller

Position-1 basis material  Position-2 Ceramic composites

附圖-3-1鐵基陶瓷復合輥套外觀圖        

Picture 3-1  external view of Roller in GGG + High Cr + ZAT (ceramic composite)  

附圖-3-2鐵基陶瓷復合輥套外觀圖

Picture 3-2  after 1 year  (Roller in GGG + High Cr + ZAT)

附圖-3-4 高鉻基陶瓷復合襯板外觀圖

Picture 3-4  Liner of High Cr +ZTA ceramic