FA Cement Application

* source: * writer: admin * time: 2021-05-24 16:00:33 * Number: 76

In the modern cement industry, wear related problems have become increasingly concerns and they are among key factors to reduce cost and improve economic benefits. But solving the problem of wear is a complex process that requires multiple factors to be considered and there is no fixed standards to query. Need to fully consider the actual use of wear parts, scientific and detailed analysis of its wear mechanism, repeated verification in order to find an economic and effective solution. Of course, many factors such as the chemical composition of the base metal and the available welding methods should be taken into full consideration for hardfacing. With the decades of experience in the wear industry, FAUSTO has mastered a large number of adequate data especially for wear parts including vertical mill, roller press, crusher, powder concentrator, draught fan, storage silo and chute in cement industry, developed different hardfacing materials and solutions of different base metals under different working conditions, which have been widely used in Europe.

Hammerhead, jaw board, quartering hammer

Take hammer crushers, for example, which are used in the cement industry to break limestone and cement clinker. It uses the high-speed rotating hammerhead to impact and crush the material entering the crusher, the material affected by the impact hits the counterattack plate at high speed, and the material falling into the crusher grate plate passes through shearing and extrusion, so as to get the suitable size of the material discharged from the grate plate. In the whole process, the hammerhead is mainly affected by the impact wear of the material in the vertical direction and the cutting abrasive wear of the material in the reverse direction.

According to the actual working condition of the hammerhead such as size of material, hardness and moisture and so on, FAUSTO have developed a series of hardfacing wires with medium carbon and medium chromium which are suitable for medium impact and strong abrasive wear, mainly used for smaller materials and hammerheads. As well as suitable for very serious impact wear and strong abrasive wear of high manganese steel series wires, mainly used for large hammerheads and larger materials.

The hardfacing wires of FAUSTO are also widely used in jaw crusher and cone crusher. We can also provide you with suitable hardfacing materials and solutions according to your actual working conditions.

Roller press

A roller press consists of two rollers moving relative at the same speed, the material is discharged from the upper feeding mouth of the roller and enters the gap between the rollers. Under the action of high pressure grinding force (the pressure between the rollers is between 50-300Mpa), the material is extruded, and the compressed material becomes a dense flat cake of material full of cracks, so that the grindability of the material is significantly improved.

The abrasive wear system of the roller press is a fixed roller and a floating roller and the interaction between the two rollers of high stress abrasive wear. Under the action of high stress, material particles make the roller surface plastic deformation, shear and compressive stresses are formed at different depths of the subsurface, when the stress exceeds the fatigue strength of the material, cracks are formed on the subsurface, however, the propagation and connection of cracks will eventually lead to fatigue shedding. According to the diameter of the squeeze roller, fatigue cracks often occur in the 5 to 20mm depth of the roller surface, this requires the hardface layer of the squeeze roller to have a certain hardness and strong plasticity to resist the fatigue shedding caused by repeated extrusion stress of the material.

The hardfacing wires of FAUSTO squeeze roller series have been successfully used in the squeeze roller of Polysius, FLS, KHD, Koppern and other brands, and the service life has been improved to varying degrees.

Vertical mill

Vertical mill is one of the most key link in cement production, it’s mainly used for grinding coal powder, cement raw materials, cement slag and preliminary broken clinker. In the new dry process cement production, the power consumption of vertical mill for grinding raw materials, fuel and cement accounts for about 65% of the whole production process, the annual power consumption of each vertical mill is more than 10 million yuan. However, due to the roller surface wear in the vertical mill, not only the grinding efficiency is reduced, but also the power consumption is greatly increased. In addition, the maintenance cost is greatly increased due to the frequent repair or replacement of the roller, which makes the service life of the vertical mill become particularly important for cost control. Often a small improvement in a vertical mill repair can reduce production costs by millions or even several millions.

The wear of the vertical mill is mainly caused by the ploughing and abrasion of the hardness phase of the material, fatigue spalling and cracking caused by the extrusion of the material, and cracking caused by the insufficient bonding strength between the matrix and carbide. These factors are often related to the size and hardness of the material, the flow of the material, the vibration of the equipment, etc., according to which the abrasive wear, stress wear, impact wear of the vertical mill can be judged, and the material and process of hardfacing of the new roller or repair of the old roller can be selected according to the base metal.

FAUSTO provides hardfacing materials for many cement plants and power plants in Europe as well as solutions for customers’ requirements. Extensive empirical data has been accumulated in the process of repair imported vertical mills such as Polysius, Loesche, Pfeiffer, FLS, Atox and so on. At present, FAUSTO has formed a complete set of product system providing hardfacing materials and solutions for vertical mills of different brands and various kinds of working conditions.

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