CN102294568B - Process for repairing breakage of rotary kiln tyre/roller - Google Patents
Process for repairing breakage of rotary kiln tyre/roller Download PDFInfo
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- CN102294568B CN102294568B CN201110109438XA CN201110109438A CN102294568B CN 102294568 B CN102294568 B CN 102294568B CN 201110109438X A CN201110109438X A CN 201110109438XA CN 201110109438 A CN201110109438 A CN 201110109438A CN 102294568 B CN102294568 B CN 102294568B
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- crackle
- acid
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- 238000000034 method Methods 0.000 title claims abstract description 18
- 230000007704 transition Effects 0.000 claims abstract description 16
- 238000005520 cutting process Methods 0.000 claims abstract description 7
- 238000005498 polishing Methods 0.000 claims abstract description 6
- 238000000227 grinding Methods 0.000 claims abstract description 5
- 238000003466 welding Methods 0.000 claims description 43
- 239000000463 material Substances 0.000 claims description 25
- 239000002253 acid Substances 0.000 claims description 23
- 208000037656 Respiratory Sounds Diseases 0.000 claims description 22
- 239000003513 alkali Substances 0.000 claims description 12
- 230000007935 neutral effect Effects 0.000 claims description 12
- 239000011230 binding agent Substances 0.000 claims description 11
- 229910000734 martensite Inorganic materials 0.000 claims description 11
- 239000011248 coating agent Substances 0.000 claims description 9
- 238000000576 coating method Methods 0.000 claims description 9
- 230000001590 oxidative effect Effects 0.000 claims description 9
- 239000002893 slag Substances 0.000 claims description 9
- 229910001566 austenite Inorganic materials 0.000 claims description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 4
- 229910052760 oxygen Inorganic materials 0.000 claims description 4
- 239000001301 oxygen Substances 0.000 claims description 4
- 229910000859 α-Fe Inorganic materials 0.000 claims description 3
- 206010011376 Crepitations Diseases 0.000 claims description 2
- 238000005516 engineering process Methods 0.000 abstract description 6
- 238000004134 energy conservation Methods 0.000 abstract description 2
- 238000000151 deposition Methods 0.000 abstract 1
- 229910052799 carbon Inorganic materials 0.000 description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 6
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 6
- 229910052698 phosphorus Inorganic materials 0.000 description 6
- 239000011574 phosphorus Substances 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- GUWKQWHKSFBVAC-UHFFFAOYSA-N [C].[Au] Chemical compound [C].[Au] GUWKQWHKSFBVAC-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 239000011449 brick Substances 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 239000012895 dilution Substances 0.000 description 2
- 238000010790 dilution Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- DQMUQFUTDWISTM-UHFFFAOYSA-N O.[O-2].[Fe+2].[Fe+2].[O-2] Chemical compound O.[O-2].[Fe+2].[Fe+2].[O-2] DQMUQFUTDWISTM-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- 230000002457 bidirectional effect Effects 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 230000002153 concerted effect Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 239000003337 fertilizer Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000003032 molecular docking Methods 0.000 description 1
- 238000000059 patterning Methods 0.000 description 1
- 229910001562 pearlite Inorganic materials 0.000 description 1
- 238000005453 pelletization Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Abstract
The invention discloses a process for repairing the breakage of a rotary kiln tyre/roller, comprising the following steps of: performing fixed connection at the two sides of a crack, cutting out a U-shaped crevasse, grinding, sequentially depositing a binding layer, a transition layer, a work layer and a processing layer at the crevasse, dismounting a fixing plate, and carrying out overall grinding and polishing. The process for repairing the breakage of the rotary kiln tyre/roller provided by the invention is low in repairing price, which is only 100,000-1500,000 Yuan, low in investment, simple in process, convenient to operate, easy to learn and grasp, novel in technology, low in cost, and practical and reliable; therefore, the process not only increases income and reduces expenditure for the country but also makes an enormous contribution to consumption reduction and energy conservation as well as resource conversation and efficiency improvement for an enterprise.
Description
Technical field
The present invention relates to a kind of rotary kiln tyre, carrying roller process for repairing breakage, it is widely used in the industries such as cement plant, power plant, pelletizing plant, chemical plant, smeltery, composite fertilizer factory, pottery.
Background technology
At present wheel band, carrying roller fracture can't meet the reparation demand from technique, technology, material, and difficulty is large, it is large to be worth, and directly impact is produced, and there is no restorative procedure at home and abroad, have to directly replace, and lose hugely, affects again production; Subject matter is: the strength grade of crackle and deposited metal, material, technique, technology is difficult to control, very easily cause the weld crack of weld seam, the crackle of weld seam and matrix border and the crackle in deposited zone are difficult to control, change a wheel and be with minimum 5,000 ten thousand yuan, contain the needs of work such as the cost of overhaul, dismounting refractory brick, docking, lifting, school kiln, block refractory brick 28 days, also need every day directly Ji loss to reach 1,000,000 yuan, as seen cost is costly, how solving this difficult problem, is the main attack problem of this technique, technology, material.
Summary of the invention
Primary and foremost purpose of the present invention is to provide a kind of rotary kiln tyre, carrying roller process for repairing breakage, and the technical solution used in the present invention is:
A kind of rotary kiln tyre, carrying roller process for repairing breakage, comprise the steps: that the two ends of fixed head are affixed with the both sides of rotary kiln tyre crackle or carrying roller crackle respectively; Cut with oxygen from the depth direction of two side direction crackles of crackle, crackle is cut into the cut of section for " U " shape, the cut bottom surface is arc; Polishing cut inwall and bottom surface to cut inwall and bottom surface expose smooth surface; Pearlitic materials is deposited together with acid welding wire, at cut inwall and bottom surface, forms binder course, brushes away coating and oxidizing slag; Martensitic material is deposited together with acid welding wire and alkaline welding wire, forms transition zone on binder course, brushes away coating and oxidizing slag; Austenite material is deposited together with acid welding wire and alkaline welding wire, forms working lining on binder course, brushes away coating and oxidizing slag; The deposited machined layer that forms on working lining of ferrite material, fill and lead up crackle, removes fixed head, carries out integral grinding and polishing.
Preferably, described pearlitic materials comprises by mass percentage: carbon below 0.5%, chromium 12%, boron 1%～2%, silicon 3%～4%, surplus is phosphorus.
Preferably, described martensitic material comprises by mass percentage: carbon 0%～0.1%, boron 1%～2%, silicon 3%～4%, iron 0%～1.5%, surplus are nickel.
Preferably, described austenite material comprises by mass percentage: carbon 0.4%～0.6%, nickel 35%, chromium 8%～12%, borosilicate mixture 6%～8%, surplus are iron.
Preferably, the deposited Thickness Ratio of described transition zone neutral and alkali welding wire and acid welding wire is 3: 1.
Preferably, the deposited Thickness Ratio of described working lining neutral and alkali welding wire and acid welding wire is 1: 3.
Preferably, the deposited thickness 6～9mm of described transition zone neutral and alkali welding wire; The deposited thickness 2～3mm of acid welding wire in described transition zone; The deposited thickness 0.1～0.15mm of described martensitic material.
Preferably, the deposited thickness 2～3mm of described working lining neutral and alkali welding wire; The deposited thickness 6～9mm of acid welding wire in described working lining; The deposited thickness 0.1～0.15mm of described martensitic material.
Preferably, adopt non-carburetting cutting mode that crackle is cut into the cut of section for " U " shape, the cut bottom surface is arc.
The method according to this invention, fixed head are used for Crack prevention and extend; Crackle is cut into section be the cut of " U " shape, avoid forming " V " shape cut and cause stress to concentrate and the generation of the vertical crack that causes; Adopt the non-carburetting cutting modes such as oxygen cutting, than carburetting cutting mode (for example: carbon arc air gouging cuts, and the excellent phosphorus content of carbon gold reaches 99.9%), be difficult for staying the carbonaceous point, do not increase phosphorus content, thereby avoid causing deposited performance extreme difference; It is deposited in the ratio of 3: 1 that alkaline welding wire in binder course adds acid welding wire, every layer of 2-3 millimeter, 0.10 millimeter to 0.20 millimeter, the pearlite alloys powder that adds preparation is deposited together, play the content of dilution sulphur and phosphorus, avoid and reduce the possibility of the cold and hot crackle generation of cladding layer, to change the structure of original material, strengthen the toughness of its joint portion, reach resizing and the purpose of transition reinforcement progressively; Transition zone is take martensitic structure as main, purpose is the good fusion that solves between each composition, the content of dilution C, Mn, this layer is deposited in alkaline welding wire and the acid welding wire ratio of 3: 1, be every layer of 2-3 millimeter, increase metallurgical junction 500 newton that make a concerted effort to make it to reach, further reach between metal and metal the effect that a kind of wear-resisting and anti-attrition is carried loose stress, increased impact flexibility of playing; Working lining, take austenite structure bidirectional wear resistant alloy as main, guarantees that reinforced metal has high anti-heavily stressed abrasive wear behavior, good anti-corrosion, heat-resisting, fatigue performance; The machined layer purpose is to reduce hardness and intensity, is convenient to machining,, for machining reserves surplus, guarantees mach precision and fineness.
Rotary kiln tyre provided by the invention, carrying roller process for repairing breakage, repairing price is only 10～150,000 yuan, small investment, simple process, easy to operate, easy to learn, easy grasp, technology are novel, cost is low, solid, both, for country increases income and decreases expenditure, made huge contribution for enterprise's energy-conservation of consumption reduction, joint source synergy again.
The specific embodiment
Describe the present invention in detail below in conjunction with specific embodiment, in this illustrative examples of the present invention and explanation, be used for explaining the present invention, but not as a limitation of the invention.
Embodiment
Take the wheel bandwidth as 700mm, thickness is 600mm, and the crack depth of fracture is that 460mm is example:
1), with the block plate that specification is 200*300*20mm or 200*300*30mm, be weldingly fixed on the crack width both sides;
2), line centered by crackle, divide 230 millimeters depth directions to crackle equally cuts with oxygen to both sides, depth of cut surpasses crack depth 20mm, and crackle is cut into the cut of section for " U " shape, and the cut bottom surface is arc, do not allow to cut with carbon arc air gouging, the excellent phosphorus content of carbon gold reaches 99.9%, very easily stays the carbonaceous point, increases phosphorus content, cause deposited performance extreme difference, so can not use the carbon arc air gouging patterning method;
3), cut after, till being ground to cut inwall and bottom surface and exposing the smooth surface of metal with abrasive machine; Purpose is to eliminate the rear remaining residual dystectic di-iron trioxide of cutting, is convenient to deposited and combination;
4), pearlitic materials is deposited together with acid welding wire, at cut inwall and bottom surface, forms binder course, brushes away coating and oxidizing slag;
Binder course component (mass percent):
5), martensitic material is deposited together with acid welding wire and alkaline welding wire, forms transition zone on binder course, brushes away coating and oxidizing slag;
Transition zone component (mass percent):
The deposited thickness 6～9mm of described transition zone neutral and alkali welding wire: the deposited thickness 2～3mm of acid welding wire in described transition zone; The deposited Thickness Ratio that makes transition zone neutral and alkali welding wire and acid welding wire is 3: 1, the deposited thickness 0.1～0.15mm of described martensitic material;
6), austenite material is deposited together with acid welding wire and alkaline welding wire, forms working lining on binder course, brushes away coating and oxidizing slag;
Working lining component (mass percent):
The deposited thickness 2～3mm of described working lining neutral and alkali welding wire; The deposited thickness 6～9mm of acid welding wire in described working lining; The deposited Thickness Ratio that makes described working lining neutral and alkali welding wire and acid welding wire is 1: 3, the deposited thickness 0.1～0.15mm of described martensitic material;
7), the deposited machined layer that forms on working lining of ferrite material, crackle is filled and led up, remove fixed head, carry out integral grinding and polishing.
Detection after reparation:
Be standard by unspoiled position, do an arcograph, press arcograph and basic circle contact site, with clearance gauge, detect, be no more than 0.10mm～0.20mm and get final product, and as the outward appearance examination criteria of checking and accepting;
Whether have weld defect is arranged with the supersonic detector flaw detection;
Detect with hardometer, whether hardness is consistent with the hardness of matrix originally, and error is generally the requirement that can meet hardness fully between HB5～10.
The above technical scheme that the embodiment of the present invention is provided is described in detail, applied specific case herein principle and the embodiment of the embodiment of the present invention are set forth, the explanation of above embodiment is only applicable to help to understand the principle of the embodiment of the present invention; Simultaneously,, for one of ordinary skill in the art,, according to the embodiment of the present invention, all will change on the specific embodiment and range of application, in sum, this description should not be construed as limitation of the present invention.
Claims (1)
1. a rotary kiln tyre, carrying roller process for repairing breakage, is characterized in that comprising the steps:
The two ends of fixed head are affixed with the both sides of rotary kiln tyre crackle or carrying roller crackle respectively;
Cut with oxygen from the depth direction of two side direction crackles of crackle, adopt non-carburetting cutting mode that crackle is cut into the cut of section for " U " shape, the cut bottom surface is arc;
Polishing cut inwall and bottom surface to cut inwall and bottom surface expose smooth surface;
Pearlitic materials is deposited together with acid welding wire, at cut inwall and bottom surface, forms binder course, brushes away coating and oxidizing slag; Martensitic material is deposited together with acid welding wire and alkaline welding wire, forms transition zone on binder course, brushes away coating and oxidizing slag, the deposited thickness 6～9mm of described transition zone neutral and alkali welding wire; The deposited thickness 2～3mm of acid welding wire in described transition zone; The deposited Thickness Ratio that makes transition zone neutral and alkali welding wire and acid welding wire is 3: 1, the deposited thickness 0.1～0.15mm of described martensitic material;
Austenite material is deposited together with acid welding wire and alkaline welding wire, forms working lining on binder course, brushes away coating and oxidizing slag, the deposited thickness 2～3mm of described working lining neutral and alkali welding wire; The deposited thickness 6～9mm of acid welding wire in described working lining; The deposited Thickness Ratio that makes described working lining neutral and alkali welding wire and acid welding wire is 1: 3, the deposited thickness 0.1～0.15mm of described martensitic material;
The deposited machined layer that forms on working lining of ferrite material, fill and lead up crackle, removes fixed head, carries out integral grinding and polishing.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201110109438XA CN102294568B (en) | 2011-04-27 | 2011-04-27 | Process for repairing breakage of rotary kiln tyre/roller |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201110109438XA CN102294568B (en) | 2011-04-27 | 2011-04-27 | Process for repairing breakage of rotary kiln tyre/roller |
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| Publication Number | Publication Date |
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| CN102294568A CN102294568A (en) | 2011-12-28 |
| CN102294568B true CN102294568B (en) | 2013-11-20 |
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Families Citing this family (8)
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| CN103223568B (en) * | 2012-01-30 | 2016-06-01 | 宝山钢铁股份有限公司 | Heavy plate mill roller boss back side method of worn |
| CN102873498B (en) * | 2012-10-16 | 2014-10-15 | 武汉开明高新科技有限公司 | Crack restoring process of ball mill slide sliding shoe and connection thereof with barrel |
| CN102922215A (en) * | 2012-11-23 | 2013-02-13 | 水文文 | Repairing process and repairing tool for excircle crack conquassation of tires and carrier rollers of rotary kiln |
| CN103192226B (en) * | 2013-04-22 | 2015-04-15 | 潍柴动力(潍坊)再制造有限公司 | Method for remedying water-eroded defects on finished surface of engine cylinder block |
| CN110158079A (en) * | 2019-06-03 | 2019-08-23 | 湖北开明高新科技有限公司 | The single-tooth roller of crusher breaks tooth and spindle abrasion renovation technique |
| CN110125610A (en) * | 2019-06-10 | 2019-08-16 | 湖北开明高新科技有限公司 | A kind of steel ladle trunnion of converter bearing position abrasion reconstructing and repairing process |
| CN110091119A (en) * | 2019-06-10 | 2019-08-06 | 湖北开明高新科技有限公司 | A kind of 600 tons of stand motor rotor shaft fracture recovery techniques |
| CN112872706B (en) * | 2021-01-13 | 2023-03-31 | 武汉彤烨科技有限公司 | Rotary kiln riding wheel and wheel belt damage repairing method |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0008030A1 (en) * | 1978-08-11 | 1980-02-20 | Veitscher Magnesitwerke-Actien-Gesellschaft | Process for repairing the refractory lining of industrial furnaces and vessels used at high temperatures |
| US5792393A (en) * | 1997-03-25 | 1998-08-11 | Atlantic Richfield Company | Method of repairing hot refractory linings in high-temperature vessels |
| JP2003114090A (en) * | 2001-10-05 | 2003-04-18 | Shinagawa Refract Co Ltd | Cement rotary kiln and repair method therefor |
| JP2007107812A (en) * | 2005-10-13 | 2007-04-26 | Hitachi Ltd | Kiln repairing method |
| CN101691965A (en) * | 2009-10-16 | 2010-04-07 | 中国铝业股份有限公司 | Method for maintaining rotary kiln structural parts |
| CN201488533U (en) * | 2009-08-24 | 2010-05-26 | 范立国 | Rotary kiln carrier roller |
| CN201493645U (en) * | 2009-05-14 | 2010-06-02 | 交城义望铁合金有限责任公司 | Online repair device of rotary kiln roller |
-
2011
- 2011-04-27 CN CN201110109438XA patent/CN102294568B/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0008030A1 (en) * | 1978-08-11 | 1980-02-20 | Veitscher Magnesitwerke-Actien-Gesellschaft | Process for repairing the refractory lining of industrial furnaces and vessels used at high temperatures |
| US5792393A (en) * | 1997-03-25 | 1998-08-11 | Atlantic Richfield Company | Method of repairing hot refractory linings in high-temperature vessels |
| JP2003114090A (en) * | 2001-10-05 | 2003-04-18 | Shinagawa Refract Co Ltd | Cement rotary kiln and repair method therefor |
| JP2007107812A (en) * | 2005-10-13 | 2007-04-26 | Hitachi Ltd | Kiln repairing method |
| CN201493645U (en) * | 2009-05-14 | 2010-06-02 | 交城义望铁合金有限责任公司 | Online repair device of rotary kiln roller |
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| CN101691965A (en) * | 2009-10-16 | 2010-04-07 | 中国铝业股份有限公司 | Method for maintaining rotary kiln structural parts |
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| CN102294568A (en) | 2011-12-28 |
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