Method for manufacturing plate for cement industry tube mill

Abstract

A manufacture method of a lining plate structure for use with a tube mill for the cement industry. The manufacture method has the following three technical solutions: 1) metal lining plate, 2) ceramic lining plate, and 3) combined lining plate. The manufacture method includes: lining the concave-convex space, formed in the combination of metal lining plate and tube body, with corundum ceramic lining plate; then installing the combined lining plate on the steel plate of the tube body through inlaying, sticking and local welding. Under the same reference conditions of the present method, the weight of lining plate is reduced 50%, saving the steel material consumption by more than 50%; and the service life of the lining plate for use with the tube mill of cement industry is doubled, up to 15000-20000 hours.

Claims

1. A method for manufacturing and applying a lining plate structure to a concrete tube mill, comprising: providing a steel plate of a predetermined geometry; welding a surfacing layer on a side of the steel plate to form a lining plate; providing a plurality of ceramic lining plates of a predetermined geometry; attaching the plurality of the ceramic lining plates to an inner surface of a tube body in the concrete tube mill, wherein each of the ceramic lining plates is inlaid with adhesive such that all space between each of the ceramic lining plates is filled with adhesive, and wherein each of the lining plates covers a radial portion of the inner surface of the tube body in the concrete tube mill, attaching the lining plate onto a surface of the inlaid ceramic plates such that the lining plate structure covers a portion of the inner surface of the tube body in the concrete tube mill, wherein two ends of the steel plate are each positioned along two sides of one of the ceramic plates; wherein the ceramic lining plate is composed of corundum ceramic, wherein the ceramic lining plate is formed by molding with a press a mixture of 85-95% alumina powder and 5-15% zirconia powder and then roasting the molded mixture, and wherein the ceramic lining plate has a thickness of 30 mm, a specific weight of 3.7-3.9, an impact value greater than 10 J/cm2 and a hardness value (HRC) of up to 85-95.

2. A method for manufacturing a lining plate structure for application in a concrete tube mill, comprising: providing a steel plate of a predetermined geometry; welding a surfacing layer on a side of the steel plate to form a lining plate; providing a plurality of ceramic plates; inlaying the ceramic plates with adhesive on an inner surface of a tube body in the concrete tube mill, providing gaps between the ceramic plates that are filled with adhesive; and attaching the lining plate onto a surface of the inlaid ceramic plates such that the lining plate structure covers a portion of the inner surface of the tube body in the concrete tube mill, wherein two ends of the steel plate are each positioned along two sides of one of the ceramic plates.

3. The method of claim 2, wherein a portion of the steel plate is also inlaid with adhesive.

4. The method of claim 2, wherein the lining plate is attached such that the surfacing layer is exposed to an inside of the tube body of the concrete tube mill.

5. The method of claim 2, wherein the steel plate is formed by cold or hot die stamping.

6. The method of claim 2, wherein the tube body in the concrete tube mill forms a milling portion of concrete tube mill.

7. The method of claim 1, wherein a surface of the ceramic lining plate has recesses which are filled with the adhesive.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a structural representation of metal lining plate.

(2) FIG. 2 is a representation of non-metal lining plate applied to tube mill.

(3) FIG. 3 is a representation of combined lining plate applied to tube mill.

(4) Symbols in figures: 1. Surfacing Layer; 2. Lining Plate Substrate; 3. Ceramic Lining Plate; 4. Steel Plate of Tube body; 5 Cured Substance.

MODE OF CARRYING OUT THE INVENTION

(5) The present invention provides a new industrial tube mill, and the novel manufacture method of its lining plate and application thereof includes following three technical solutions:

(6) 1) Combined Lining Plate of Tube Mill Both Rigid and Flexible

(7) Please refer to FIG. 1, the present invention uses normal medium- and low-carbon steel plate =10-12 mm as material, including following steps: cold and hot die stamping medium- and low-carbon steel plate to mold a lining substrate 2 with desired geometry, then performing surfacing welding to the surface of lining substrate 2, forming a 5-15 mm metal or metal and non-metal composite surfacing layer 1. The surfacing material can be TN-65 or TM-65 made in China, UM10-65-G or MF10-GF-60-G welds made in German, or high-hardness surfacing electrodes made in Belgian. The hardness HRC of surfacing layer 1 can be up to 70-80, and the impact value still meets the requirement of 46 J/cm.sup.2. The new combined lining plate of tube mill manufactured by this method is soft inside and rigid outside, both having firmness and flexibility, thus it is an ideal combination and match, as well as an ideal lining plate for tube mill of cement industry with an enhanced grinding function.

(8) With a reduced thickness, the weight of 1010 cm=100 cm.sup.2 area of tube body surface is decreased from 5.07 kg to 2.1 kg, by 2.4 times. Therefore, the lining plate manufactured in the present invention can be installed on the steel plate 4 of tube body by way of inlaying, sticking and local welding. The cured substance 5 can be high-strength cement mortar, epoxy resin or inorganic adhesives, etc.; the high-strength cement mortar (ratio of 525# cement and fine sand is 1:1.5-2, and the three-day rupture strength can be over 5.5 kg/cm.sup.2), epoxy resin E03 and E06 with a uneven pull-off strength of 30 kg/cm.sup.2, and various inorganic adhesives are used in inlaying, sticking and local welding, very simple and convenient for construction. Meanwhile, it saves the need of drilling holes for tube body in bolt connection.

(9) 2) Non-Metal Ceramic Lining Plate of Tube Mill

(10) The manufacture of the ceramic lining plate 3 includes two ways:

(11) The first way is to make full use of the production technology and equipment of existing ceramic factories (such as MIXING Ceramics), we only need to provide the sizes of various bars, sheets, blocks and plates required, and the drawings of surface geometry, then the ceramic factory reopen the mold according to the drawings, to produce the ceramic lining plate 3 we desire.

(12) The second way is to prepare the materials based on the compositions of corundum ceramics, belonging to existing technology, and it is then molded with a 1500-2000 T press by use of a metal mold. After that, it is sent directly to a high temperature furnace to be roasted at 1600-1800 C., and is cooled after 1 hour of roasting, thus the ceramic lining plate 3 for use with tube mill of cement industry is produced, where the size thereof can be determined depending on the specifications of tube mills, the thickness can be controlled within 30 mm, the dimension can also be 10010030 mm, 20020030 mm, 30030030 mm, and the geometric surface is made depending on the corrugated dimension we determine.

(13) The impact value of corundum ceramics is not less than 10 J/cm.sup.2, and corundum ceramics has a unique hardness any kind of wear-resistant steel material cannot reach, the hardness value HRC being up to 85-95, even the hardness of sharp steel is only within 75-80.

(14) The chemical compositions of corundum ceramic lining plate we use are as follows (weight ratio): Alpha-alumina powder: 85%-95% Zirconia powder: 5%-15%

(15) With following properties: Compression strength: 700-900 kg/cm.sup.2 Specific Weight: 3.7-3.9 Hardness HRC: 85-95 Impact value : >10 J/cm.sup.2

(16) The specific weight of corundum ceramics lining plate 3 is small, only of 7.9, namely that of cast ling plate, thus the weight of 1010 cm=100 cm.sup.2 area of tube body surface is decreased from 5.07 kg to 1.17 kg, by 4.3 times. It is truly be thin-wall, light-weight and high-performance. Please refer to FIG. 2, the installation on the steel plate 4 of the tube body can be done with abovementioned cured substances 5 by way of inlaying, sticking and local welding. It is very convenient for construction, and the tube body can be free of or have few drilling holes.

(17) 3) New Method of Extending the Service Life of Novel Surfacing Lining Plate

(18) Please refer to FIG. 3, when the novel surfacing lining plate manufactured in the present invention is installed on the steel plate 4 of the tube body with the cured substances 5 by way of inlaying, sticking and local welding, the corundum ceramic lining plates 3 having different shapes of bars, sheets and blocks can be particularly lined in the concave-convex space formed in the combination of the surfacing lining plate and the steel plate 4 of the tube body, and the preferred is corundum ceramic lining plates 3, which is a wear-resistant non-metal material with a hardness up to 85-95. The tube mill can operate normally for quite some time even when the surfacing lining plate is completely worn, thus the service life of novel surfacing lining plate can be further enhanced and extended, and this improvement cannot be achieved by any form of existing lining plates.

(19) Related descriptions of the present invention:

(20) 1) Differences Between Existing Lining Plate and Present Invention:

(21) So far, the lining plates for use with the tube mill of cement industry home and abroad are manufactured with steelmaking equipments, through the steps of ingredient preparation and smelting as well as making sand mold or metal mold for the lining plates, then the steps of casting, removing from mold and heat treatment, having essential differences with the stamping molding and surfacing processes of the present invention, and further differences and discrepancies with that of the wear-resistant non-metal ceramic lining plate of the present invention.

(22) 2) Important Technical Features of the Present Invention

(23) Existing cast lining plates are restricted by smelting and heat treatment, and more importantly suffer a mutual constraint from the hardness HRC and the impact value of materials. Therefore, it is quite difficult to increase the hardness HRC of cast lining plate from 60. The only solution is to increase the casting thickness to cover the shortage, thus ensuring the service life.

(24) The present invention broke the restraints of steel material properties, realizing the feature of soft inside and rigid outside, and the surfacing hardness is up to 70-80; in order to be wear-resistant and extend service life, the first is to increase the hardness of materials. The corundum ceramic has a better performance; therefore, the thickness half reduction and the service life doubling of the lining plate of the present invention is a minimum requirement.

(25) 3) Installation Difference of Existing Casting Lining Plate and Present Invention:

(26) Existing casting lining plate is heavy, in particular when tube mill is upsizing, it is heavier. In order to prevent the occurrence of major accidents, the installation in the tube body can be realized only by drilling holes on the tube body and bolting, and the drilling holes on the tube body are over 1600, seriously weakening the stiffness and strength of the tube body.

(27) However, for the surfacing lining plate and ceramic lining plate of the present invention, the weights per unit area of the tube bodies are respectively reduced by 2.4 times and 4.3 times, thus the way of inlaying, sticking and local welding is absolutely available, truly realizing no or few drilling holes.

(28) 4) The service life extension measures, taken on existing casting lining plate home and abroad, are ineffective. When the remaining thickness of lining plate closes to of the original thickness during the grinding of tube mill, the only choice is to remove and replace it completely, without any other alternative. This is not comparable to the present invention.

(29) 5) Following table gives a comparison of different lining plates with the same specifications of 3.813 m, to show the economical efficiencies of them:

(30) TABLE-US-00001 Unit Installation Total price (10 weight of (10 thousand complete mill thousand Service life Name Yuan/ton) (ton) Yuan) (hour) Casting 1.5 105 157.5 7000~10000 plate lining Novel 3.5 50 175 15000~20000 surfacing lining plate Corundum 3.0 50 150 Expected >50000 ceramics lining plate

(31) The overall installed weights are different due to different thicknesses and specific weights, the investment differences are not significant, but the service life differences are huge.

(32) Effects the present invention can achieve are as follows:

(33) 1. The manufacture of the lining plate of tube mill is changed from hot working to cold working, that is, from casting to stamping molding and then surfacing, thereby simplifying the manufacture method, and improving the production conditions of hot working, namely, hard, dirty, tiring and intensive labors needful conditions. It can realize automated operation.

(34) 2. The surfacing layer has an excellent mechanical and physical performance, thus the high-hardness surface and high-toughness substrate can reach an optimal match when working under a Small Energy & Repeated Impact condition, and the service life can be doubled on the basis of existing 7000-10000 hours, up to 15000-20000 hours.

(35) 3. The materials of the lining plate of the present invention are excellent, thus the thickness can be reduced 50%; for example, the thickness of 3.813 m mill can be reduced from 65 mm to 30-35 mm, and the weight can be decreased for more than 50 tons, thereby saving steel material for more than 50% and the power consumption for about 300 Kw. The effects of ceramic lining plate are further better than these data.

(36) 4. The weight of lining plate is decreased and power consumption is saved, then the load of grinding medium can be increased for 24 tons, improving the production of mill for 10%-15%.

(37) 5. With the lightened lining plate, the fixing way of bolt connection can be eliminated absolutely; instead, a new way of cement inlaying, sticking and local welding is used, which can realize no or few drilling holes, thereby eliminating the loss of rigidity and strength of the tube body, improving the operating reliability of equipment, and avoiding 20%-30% loss of rigidity and strength of the tube body.

(38) 6. The installation of lining plate only requires the steps of inlaying, sticking and local welding, greatly reducing the original workload, as well as the labor intensity.

(39) 7. Popularization and application of the corundum ceramic lining plate to cement industry is a revolutionary means, with important breakthroughs on various economic indicators. The time of Ten years free of replacement has come to the lining plate of tube mill. The savings of steel are very impressive. With the technology of Replace Steel with Ceramics, both the environmental significance and the economic significance are immeasurable, in particular nowadays when global prices of iron ores are continuing to soar.