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在极端环境下运行

烧结矿破碎机

在钢铁厂中,在高温下处理烧结矿的设备会遭受严重的磨损。尤其需要确保对高吞吐量的烧结破碎机提供磨损保护,以避免昂贵的维护费用和频繁的工厂停工。维护负责人普遍认为市场上所提供的标准解决方案不足以满足他们的需求。转子和断路器条必须定期换新。
标准解决方案所提供的耐磨性不足的原因主要有三点:

• 烧结矿的高温降低了耐磨堆焊性能;
• 烧结矿较为粗糙,将磨损部件;
• 高冲击力将对脆性耐磨堆焊造成破坏。

e3 的性能至少比标准解决方案高 3 倍

独特的 e3 技术

e3 是受法律保护的解决方案,专门为提高钢烧结矿破碎机的生产率并且延长其使用寿命而开发。在实验室以及实际工作条件下经过长达 4 年的测试后,该解决方案终于面世。它基于 Castolin Eutectic 独特的高温耐磨合金制成,即使面对冲击和磨损,也能够提供极高的耐磨性。 e3 尤为适用于保护烧结破碎机的关键零件,例如转盘、齿和破除杆。现场测试表明,e3 的性能至少比标准解决方案高 3 倍。该方案除了能够延长使用寿命外,还保留了部件的几何形状,与标准解决方案相比提高了破碎机效率。

我们的工程师能够根据您的需求,为您打造专有解决方案。

e3 的技术益处

除了延长部件使用寿命之外,e3 还能够:

• 降低烧结矿破碎机的维护频率,减少工厂停工情况的出现;
• 通过保持齿形状以实现更高的破碎机生产效率;
• 减少新部件的采购成本;
• 避免使用复杂的水冷破除杆。

MADE BY LASER CLADDING

Sieves manufactured in our workshops

We offer a comprehensive range of wear-resistant sieves with round, square or oval apertures manufactured from 3 mm thick or higher, perforated sheets. We also manufacture tailor-made solutions according to specific customer requests. Our production technology uses a state-of-the-art, high power laser cladding installation. This system ensures highest quality wearfacing coatings of tungsten carbides dispersed in a nickel-based matrix to protect standard perforated steel sheets with variable mesh sizes.

Much better than standard steel

Tailor-made for your needs

The ultra hard tungsten carbide phases which are homogeneously distributed within a self-fluxing, tough nickel-based alloy matrix, provide:

  • Extreme wear resistance performance against abrasion and erosion up to 10 times higher than standard, monolithic heat-treated steel alternatives.
  • Withstands operating service temperatures up to 400°C. For even higher service temperature requirements, a diverse range of special alloy systems may be proposed to meet specific customer needs.

Modern Castolin Eutectic LaserClad technology uses a focused laser beam to ensure low heat input welding conditions, which translates into extremely effective, wear protective coatings on industrial parts.

Other Solutions for Sinter Plants

Feeding Roller

After mixing the raw materials in the sinter plants (fine iron ores, additives such as limestone and olivine, recycled iron-bearing materials  from downstream operations, and coke breeze) we find a roller just underneath the charging system to constantly feed the sinter belt which is affected by abrasion. The lifetime of this feeding roller can be increased by our turnkey solutions.

Increase lifetime with CDP® wearplates

Sinter Cooler

In most cases after the sinter discharge, crushing and hot screening, the sintered material proceeds to a separate cooler. This is typically a rotating structure, divided into circular sectors with tipping devices, in which the sinter is placed in a layer more than 1 m thick and cooled by fresh air.

When the sinter has completed the cooling cycle, each sector is emptied via the tipping device. The cooled sinter is transferred to screens that separate the pieces to be used in the blast furnace.

Both the charge and discharge of the cooler deteriorate the surfaces whose lifetime can be increased with our CDP® wearplates.

Cooling the steel is a critical factor

Air Suction System

Along the whole sinter process, several metallurgical and chemical reactions take place which produce dust and gaseous emissions apart from the sinter itself. These gases contain particles such as heavy metals that will weaken the inner surface of air suction systems.

A complete high resistance conduction system including valves and transitions circular to square section can be manufactured with our CDP® wearplates.

高炉组件

风口冷却器

高炉作业中使用的风口冷却器部件的外径遭受了大量的工艺中损坏,这一问题在工业生产中十分常见,并且可能导致设备处理能力降低以及设备停工。当基材损坏导致风口滞留在母体外壳中并且必须被强行去除时,这就显得尤其重要。Tata Steel 与 Castolin Eutectic I Monitor Coatings Limited 共同开发了一种热喷涂沉积技术,该技术可以消除对部件的潜在损害,从而通过减少高炉副产物的堆积和粘附来延长其使用寿命。

超出预期的风口冷却器

HVOF 涂层

经过广泛的试验后,我们使用超音速火焰喷涂(HVOF)沉积的镍铬涂层以及热转化浆料组成复合涂层结构,用于保护受影响的外部表面。该涂层能够产生无孔的表面,该表面抑制了工艺副产物的粘附,同时保护了基材免受化学腐蚀的大量磨损。

Monitor Coatings 生产的 CastCoat

保护连铸机的核心部分

CastCoat 硬质复合涂层是由 Castolin Eutectic 在英国的子公司 Monitor Coatings 开发,该涂层可用于钢铁行业,尤其是作为连铸机铜模具板的涂层。该涂层自投入使用以来,至今已有 20 多年的历史。测试表明,该涂层比任何其他可用的铜模板涂层都更为坚硬。该涂层的摩擦系数很低,有助于减少摩擦警报,并且其对液态钢和铸造粉末呈惰性。涂层系统对模具液位检测器或电磁搅拌器没有影响。此外,经证明该涂层对传热速率的影响可忽略不计。

现已成长为一项成熟的技术

可延长寿命达 6 倍

结合多年以来所收集的涂层相关的现场数据,可以发现铜板寿命出现显著延长:厚板坯连铸机的寿命延长了 3-4 倍,薄板坯连铸机窄板的寿命延长了 6 倍,并且还改善了产品的形状。在操作过程中,已证明该涂层能够通过显著提高耐磨性来延长铸造使用时间。由于高应力状态下的热疲劳,最终导致了涂层的逐步降解。如今,CastCoat 已成长为一项成熟的技术,在全球范围内拥有广泛的客户基础,始终如一地为用户降低每吨成本。

新型紧凑型 HVOF 设备

也可应用于管模

通过对模具的全部四个面进行涂覆,在整个加工过程中保持了模具尺寸稳定性,从而实现持续有效的产品形状和坯壳生长。缺乏明显的磨损意味着在模具更换期间可维持更久的作业,从而实现更高的连铸机利用率。此外,涂层提供的保护可延长铜板的使用寿命,从而可以节省铜,并显著降低在线和离线维护成本。利用紧凑型 HVOF 设备的最新发展,CastCoat 复合涂层现在可以在管模上应用。

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