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PFG-NM nano-ceramic wear-resistant inner cylinder of preheaters, various inner cylinders of separators
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PFG-NM nano-ceramic wear-resistant inner cylinder of preheaters, various inner cylinders of separators

The internal environment of the preheater is complex and harsh. The cylinder is washed by a strong flow of dust and air, and corroded by the high-temperature atmosphere in acid and alkali.
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  The internal environment of the preheater is complex and harsh. The cylinder is washed by a strong flow of dust and air, and corroded by the high-temperature atmosphere in acid and alkali. Also, the Ni2OCr25 hanging plate of the inner cylinder of the preheater made of heat-resistant steel is not resistant to corrosion, and its service life is about one year. In addition, the high price of the heat-resistant steel Ni2OCr25, coupled with frequent shutdown and replacement, greatly increases the cost input of cement production and the labor intensity of workers. Considering the internal environment of the cement kiln preheater, our company initiated a project in December 2006 to develop nano-ceramic inner cylinders. After three years of brainstorming by experts, doctors, professors, and senior engineers from Henan University of Science and Technology, Zhongyuan University of Technology, Luoyang Institute of Refractory Materials and relevant cement plants as well as scientific researchers of our company and undergoing numerous laboratory experiments and field tests, we successfully developed nano-ceramic inner cylinders. The product completely addresses the shortcomings of heat-resistant steel inner cylinders of preheaters in non-resistance to corrosion and abrasion and a short service life of only one year, and extends the service life by 2 to 3 times that of heat-resistant steel inner cylinders, it is an ideal functional material to replace the Ni2OCr25 heat-resistant steel inner cylinder, and also represents a qualitative leap and technological revolution of inner cylinders of preheaters.

  Technical characteristics of nano wear-resistant ceramic inner cylinder of preheaters:

  High-temperature resistance: Since the nano-ceramic inner cylinder is made of SiC and Al2O3 as the main raw materials and is manufactured by recrystallizing at a high temperature of 2000°C, it can withstand a temperature as high as 1500°C.

  High wear resistance and sound erosion resistance: Being made of SiC and Al2O3, ceramics have a Moh's hardness equal to or larger than 9, making them highly resistant to wearing and erosion.

  Corrosion resistance: Ceramics have superior corrosion resistance properties since the high-temperature performance of SiC and Al2O3 is stable and does not react with any complex gas and acid-base components at high temperatures.

  Anti-skinning and non-adhesion: SiC and Al2O3 are stable in terms of high-temperature chemical properties. They do not react with cement raw materials or acid and alkali components, and are therefore free from adhesion or skinning.

  Good thermal shock performance: Due to nano-SiC and Al2O3 ceramics have good thermal conductivity, small thermal expansion coefficient, good thermal resistance, and resistance to sudden change of cold and hot can reach more than 50 times.

  Light weight and convenient installation: With the reasonable modular connection design, the product features easy installation and a weight of only one-third that of the heat-resistant steel Ni20Cr25 inner cylinders, making it able to reduce labor intensity, reduce downtime, and improve production efficiency.

  Physical and chemical specifications of nano wear-resistant ceramic inner cylinders of PFG-NM preheaters

 

Performance

Physical and chemical specifications of nano wear-resistant ceramic inner cylinders of PFG-NM preheaters

Volume density kg/m³

3000

Compressive strength Mpa

580

Bending strength at normal temperature Mpa 20°c

≥260Mpa

Bending strength at high temperature MPa 1100℃

≥280Mpa

Moh’s hardness

≥9

Thermal conductivity w/m · k

15

Coefficient of thermal expansion × 10-6 ℃

4.8

Working temperature ℃

≤1500

Wear resistance: (impact abrasion)

Value measured at the use temperature

Time: 15 minutes

Medium: emery

Speed: 150 m/s

Nozzle diameter: 5 mm

Distance: 230 mm

Angle: 90 °

0.028

Thermal shock stability rate (counts) at 1100°C

≥ 50 times of cold and hot snap experiments

Acid and alkali resistance (Cao.So and other complex gases)

Excellent

 

  Advantages of technical properties of the wear-resistant nano-ceramic inner cylinder of PFG-NM preheater compared with heat-resistant steel

  Our company initiated a project in December 2006 to develop nano-ceramic inner cylinders. The development was eventually successful after undergoing numerous laboratory experiments and field tests on the cement production line, representing the brainchild of more than 10 scientific researchers, experts, doctors, professors, and senior engineers from Henan University of Science and Technology, Zhongyuan University of Technology, Luoyang Institute of Refractory Materials and related cement plants. It is an ideal functional material to replace Ni2OCr25 heat-resistant steel, and also witnesses a qualitative leap and technological revolution of inner cylinder materials of preheaters.

  I. Comparison between the technical properties and parameters of the nano-ceramic inner cylinder of the preheater and the Ni20Cr25 heat-resistant steel:

  ◎ High temperature resistance: Since the nano-ceramic inner cylinder is made of SiC and Al2O3 as the main raw materials and is manufactured by recrystallizing at a high temperature of 2300°C, it can withstand a temperature as high as 1500°C after testing, which is impossible to achieve for heat-resistant steel. Tests show that heat-resistant steel will become softened, deformed, oxidated, and corroded at a high temperature of 1500°C.

  ◎ Wear resistance: The SiC and Al2O3 nano-ceramics that apply the recrystallization technology feature a very high strength and a Moh's hardness equal to or larger than 9, while the Moh’s hardness of heat-resistant steel is about . Upon test, the wear resistance of SiC and Al2O3 nano-ceramics is about 2-3 times that of heat-resistant steel.

  ◎ Corrosion resistance: Since SiC and Al2O3 nano-ceramics are sintered at high temperature and thus have stable chemical properties at high temperature, it is an inorganic functional material with powerful resistance to acid and alkali and to various kinds of complex gas corrosion.

  ◎ Anti-skinning: SiC and Al2O3 nano-ceramics are stable in terms of their high-temperature chemical properties and do not produce any chemical reaction with acid-base substances such as calcium oxide, thus avoiding the surface skinning of cement raw materials (calcium oxide).

  ◎ Light weight: SiC and Al2O3 have a small specific gravity of 3000 kg/m3, while that of heat-resistant steel is 8000 kg/m3. The weight of a set of ceramic inner cylinders is only about 1/3 that of heat-resistant steel. According to the calculation of experts, generally, the total weight of heat-resistant steel inner cylinders of a preheating tower from the first to the fifth levels is about 80 t, while that of ceramic inner cylinders is only about 20 t, which reduces the weight of the preheating tower by about 60 t, and extends the service life of the entire preheating tower by about 10 years expectantly.

  ◎ Sound thermal shock stability: Due to the sound thermal conductivity, small thermal expansion coefficient and good thermal resistance, SiC, and Al2O3 nano-ceramics can withstand more than 50 times of cold and hot snaps.

  ◎ Reasonable structure and optimized modular hanging: easy construction, reduction of labor intensity, construction time, and maintenance costs.

  II. Comparison of abrasion between heat-resistant steel and wear-resistant ceramics at different temperatures under the same condition:

  It can be seen from the above test that the advantages, abrasion resistance, and erosion resistance of high-temperature SiC and Al2O3 wear-resistant ceramics are more than 10 times higher than that of heat-resistant steel at 1200°C.

  III. Comparison of price:

  It can be seen from the above data that the properties and abrasion resistance of SiC and Al₂O₃ nano-ceramics are generally about 5-10 times that of heat-resistant steel. That is to say, its service life is about 5-10 times that of heat-resistant steel. Taking a level-5 cylinder on a 5000 td production line as an example, assuming the life of SiC and Al₂O₃ nano-ceramics is five times that of heat-resistant steel: the market price of heat-resistant steel Ni2OCr25 is 50,000 yuan/ton, the market price of SiC and Al₂O₃ nano-ceramics is 210,000 yuan/ton: the heat-resistant steel for a level-5 cylinder is 65 tons × 50,000 yuan = 325,000 yuan, while the SiC and Al₂O₃ nano-ceramics for a level-5 cylinder are 18 tons × 210,000 yuan/ton = 378,000 yuan. However, in terms of service life, a SiC and Al₂O₃ nano-ceramic inner cylinder can be used for 5 years, while a heat-resistant steel inner cylinder can only be used for about 12 years. It means the price of a ceramic inner cylinder is only 378,000 yuan, while the price of five heat-resistant steel inner cylinders is 325,000 × 5 years = 1.625 million yuan.

  It can be seen from the above price comparison that the price of the nano-ceramic inner cylinders produced by our company is only 1/4 that of heat-resistant steel inner cylinders. In addition, the loss caused by the production suspension for replacing inner cylinders may be several or dozens of times the cost. It can be proved that the use of the nano-ceramic inner cylinders of preheaters produced by our company can reduce energy consumption and generate tens of millions of economic benefits per year.

  Clinging to the principle of honest service and quality first, our company warmly welcomes new and regular users to cooperate with us. We will offer first-class service and best-ranking quality for you.

Report on the usage of the ceramic inner cylinder of preheaters

  Our level-5 inner cylinders for preheaters used to be made of heat-resistant steel, which is not resistant to wearing or corrosion at high temperatures. With a short service life, those cylinders needed to be replaced once a year, which increased the maintenance cost of the company. In addition, since they frequently fell down in use, leading to unstable productivity, low decomposition rate, and high coal consumption, our production profitability was severely affected.

  In August 2008, our company applied nano-ceramic inner cylinder hanging plates developed by Luoyang Pengfei Wear-resistant Materials Co., Ltd. on our level-4 and level-5 cylinders. With a modular design, the nano-ceramic inner cylinders are light-weighted and easy to install, which reduces the labor intensity of workers and saves installation time. Ceramic inner cylinders produced a very obvious outcome. The preheater system ran stably without material collapse, and the decomposition rate was significantly improved, which fully met the production process requirements.

  By the end of August 2010, the ceramic inner cylinder had run continuously for more than 730 days. Upon inspection, the ceramic inner cylinder is in good condition, and the expected service life can reach more than 3 years. The use of ceramic inner cylinders improves production efficiency and reduces the number of repairs and replacements, saving and creating millions of economic benefits for our company every year.

  The ceramic inner cylinder is an ideal alternative to heat-resistant steel inner cylinders. It is worthy to popularize and apply them in the industry.

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Luoyang Pengfei Wear-resistant Materials Co., Ltd.

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TEL:

400-6037995

EMAIL:lypf0379@126.com

ADD:No. 1, Pengfei Road, Industrial Cluster Area, Ruyang County, Luoyang, China

 

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