EP2572790B1 - Cylindre à revêtement résistant à l'usure et procédé pour sa fabrication - Google Patents

Cylindre à revêtement résistant à l'usure et procédé pour sa fabrication Download PDF

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Publication number
EP2572790B1
EP2572790B1 EP11182178.1A EP11182178A EP2572790B1 EP 2572790 B1 EP2572790 B1 EP 2572790B1 EP 11182178 A EP11182178 A EP 11182178A EP 2572790 B1 EP2572790 B1 EP 2572790B1
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EP
European Patent Office
Prior art keywords
studs
composite material
roll
matrix
spaces
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Application number
EP11182178.1A
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German (de)
English (en)
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EP2572790A1 (fr
Inventor
Gary Robert Heath
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MEC Holding GmbH
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MEC Holding GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C4/00—Crushing or disintegrating by roller mills
    • B02C4/28—Details
    • B02C4/30—Shape or construction of rollers
    • B02C4/305—Wear resistant rollers

Definitions

  • the present invention relates to an improved roll construction for a roller press, comprising a cylindrical press roll having an outer cylindrical pressing surface for use with an opposing roll, and a plurality of wear-resistant surface members, namely studs, whereby the studs are fixed to the roll and the free ends of the studs protrude radially from the surface of the roll, and whereby the spaces between the studs are filled with a matrix material being softer than the hardest material of which the studs are made.
  • the present invention relates to a method of manufacturing a roll for a roller press comprising the steps: forming a cylindrical press roll having an outer cylindrical pressing surface for use with an opposing roll, fixing a plurality of wear resistant surface members (studs) to the roll surface at spaced intervals having a hardness greater than the roll surface, so that free ends of the studs protrude radially from the surface of the roll, and filing the spaces between the studs with a matrix material, whereby the matrix material comprising a binding mass being softer than the hardest material of which the studs are made.
  • a method of manufacturing a roll for a roller press comprising the steps: forming a cylindrical press roll having an outer cylindrical pressing surface for use with an opposing roll, fixing a plurality of wear resistant surface members (studs) to the roll surface at spaced intervals having a hardness greater than the roll surface, so that free ends of the studs protrude radially from the surface of the roll, and filing the spaces between the studs with a matrix material
  • This method is characterized by two coated counter-rotating rollers which are pushed firmly together.
  • the material to be ground is fed between these rollers while their rotating motion pushes it through the small gap between them.
  • Equipment availability and the overall cost of grinding facilities utilizing roller presses are significantly influenced by the service life of wear parts, in particular the durability of the grinding rollers.
  • HEXADUR® One system is the HEXADUR® process, which provides a highly abrasion resistant material for wear protection for grinding rollers.
  • the name HEXADUR® has been derived from the shape and arrangement of hard metal hexagons which are fixed by hot isostatic pressed (HIP) on to a base metal via a matrix.
  • HIP hot isostatic pressed
  • a second system is the "Polycom process" which focused on placing studs in holes drilled into the surface of the roll.
  • the basic idea is that the stud surface is raised above the surface of the roller.
  • the ground stone/cement then fills in the space between the studs and acts as an auto protection for the studs.
  • EP 2 239 058 A1 an improved, wear-resistant roll for use in a roller press as well as a method for the production of such a roll is described.
  • the roll comprises a cylindrical press roll with plurality of wear resistant studs on the outer surface of said role.
  • the studs are welded on the roll and serve as a holding fixture for hard particles or metal inserts.
  • the spaces between the studs are filled with a matrix material consisting of an alloy based on Ni or Fe.
  • the surrounding matrix material is achieved by deposition from wire, electrode, power deposition by usual methods like welding, PTA, brazing or spraying. This device is capable of operating under extremely high forces with markedly reduced wear of the grinding surface.
  • wear resistant rolls with a metallic matrix material have several disadvantages.
  • the deposition of the metallic matrix material generally includes a melting process which requires a large heat input and therefore raises the production costs.
  • the studs cannot be replaced on-site without the need for processes that involve heat.
  • EP 0 516 952 A1 describes a wear-resistant roll for a roller press according to the preamble of claim 1.
  • the roll has a plurality of spaced wear-resistant surface members joined to its surface.
  • the spaces between the surface members are filled with a matrix material, which can be for example a ceramic mass or a plastic material containing a ceramic material.
  • An object of the invention is to provide an improved, easy and cost-effective producible pressing roll for a roller press which allows the application of long studs and can furthermore easily be repaired on-site without using sophisticated process equipment.
  • the matrix material is a composite material with a non-metallic, organic binding mass whereby the non-metallic, organic binding mass is made of epoxy, and whereby the composite material comprises armouring means in form of fibers.
  • the basic idea is to fill the spaces between the studs with a softer, but still wear resistant material which is easy to apply and which ensures an excellent bonding of this material to the studs as well as to the roll.
  • the matrix is a composite material based on a non-metallic, organic binding mass. Prior to a hardening or solidifying process the binding mass is a liquid or paste-like substance.
  • Several process techniques known in the art like spraying, electrostatically supported spraying, flooding, flinging, immersion, pressing or spreading, are generally suited for applying such fluid substances to the roll and filling the space between the studs.
  • the composite material is made of the non-metallic binding mass as well as of at least one constituent.
  • a special wear resistant material is achieved, if the additional constituents have different physical or chemical properties to enhance the properties of the composite matrix.
  • the wear resistant studs are welded to the roller base.
  • the studs serve as a replacement for hard particles, preferably made of WC, or metal insert members as known in the prior art.
  • the matrix material can be applied in a single layer with a thickness up to 50 mm or in multi-layers.
  • the application of single layers with a thickness up to 50 mm allows the processing of longer studs avoiding interface problems and additional costs.
  • the studs are stabilized by the matrix material and additionally - with operation for grounding material - by the ground material itself.
  • the reason for that is that as a result of wear of the softer matrix material the studs will protrude from the matrix as to form pockets between adjacent studs, and the pockets will be filled with ground material. Therefore, shortly after beginning of the operation for grounding material, nearly the whole outer surface of the roll is covered with the grounded material having the same hardness as the material to be grounded.
  • the grounded material is best suited for stabilizing the studs and protecting the softer matrix material from further wear.
  • the matrix material with a non-metallic, organic binding mass can easily be repaired on-site. Even for the repair, a low heat process is applied which reduces the need for sophisticated process equipment as well as the maintenance costs.
  • the outer surface of the studs and the surface formed by the composite material have the same level.
  • the composite material comprises armouring means in form of fibres.
  • Armouring means increase the tensile strength, the stability, dimensional stability and the mechanical resistance of the composite material. Fibres are well suited to absorb tensile forces.
  • the armouring means are organic fibres. The non-metallic, organic binding mass and the organic fibres show similar thermal expansion coefficients.
  • non-metallic binding masses made of an organic compound which can be hardened in a curing process at low temperature in a non-melting process. These binding masses usually have a liquid or paste-like consistency at room temperature.
  • Epoxy is a duroplastic organic with high stability and chemical resistance. Epoxy is formed by reaction of epoxy resin with a hardener. A matrix material based on epoxy is easy to use. The epoxy resin can be hardened after filling the spaces between the studs.
  • the composite material comprises hard particles, whereby the hard particles are dispersed in the matrix in an amount in the range of 15 wt% to 80 wt%, preferably in the range between 20 and 40 wt%, based on the entire composite material.
  • an especially wear resistant matrix material is provided. If the amount of hard particles in the composite material is lower than 20 wt%, especially if it is lower than 15 wt%, the wear resistance of the composite material is only slightly improved. If the amount of hard particles is higher than 40 wt%, especially if it is higher than 80 wt%, a paste-like material is obtained which is difficult to process.
  • the hard particles are made of Al 2 O 3 , WC and/or SiC.
  • Hard particles made of Al 2 O 3 , WC and/or SiC are commercially available in different grain sizes and characterized by high mechanical resistance and stability.
  • the armouring means are made of a synthetic plastic material, preferably the armouring means are aramid fibres, and when the armouring means are dispersed in the matrix in an amount in the range of 5 wt% to 20 wt% based on the entire composite material.
  • Armouring means made of synthetic plastic material can be easily and cost-effectively produced.
  • the armouring means are aramid fibres.
  • Aramid fibres show high tensile strength, solidity and chemical stability and can absorb tensile forces.
  • aramid fibres are heat-resistant up to 400 °C. If the amount of armouring means in the composite material is lower than 5 wt%, only a slight effect on the tensile strength of the composite material can be observed. If the amount of armouring means is higher than 20 wt% a paste-like material is obtained which is difficult to process.
  • thermostability of the composite material is an important parameter.
  • Composite parameters that can withstand temperatures of at least 250 °C can be used in roller presses without the necessity of a special cooling system.
  • the above object is achieved according to the invention in that for filling the spaces between the studs as matrix material a composite material comprising a non-metallic, organic binding mass is applied comprising a non-metallic binding mass made of epoxy, and whereby a composite material is used that comprises armouring means in form of fibres.
  • the binding mass Prior to a hardening or solidifying process, the binding mass is a liquid or paste-like substance.
  • the basic idea is to use as matrix material such fluid substances which are easy to apply to the space between the studs and which, after hardening or solidifying, ensure an excellent bonding of the material to the studs as well as to the roll.
  • Such fluid substances can easily be applied to spaces between the studs using several process techniques known in the art, like spraying, electrostatically supported spraying, flooding, flinging, immersion, pressing or spreading, are generally suited for applying such a substance to the roll and filling the space between the studs.
  • the wear resistant studs are welded to the roller base. Fixing of the studs by welding is a fast and reliable low cost process.
  • the studs are additionally stabilized by the matrix material and additionally - with operation for grounding material - by the ground material itself as explained above.
  • the filling of the spaces between the studs is performed by a low heat, non-melting process.
  • a liquid or paste-like precursor substance of the composite material is applied which after hardening forms the composite material.
  • a liquid or paste-like precursor substance can be easily filled in the spaces between the studs.
  • the precursor substance can be hardened by polymerization or polycondensation, for example, by application of low heat, radiation or by a chemical hardener which is added to the precursor substance.
  • a composite material comprising a non-metallic binding mass made of epoxy.
  • non-metallic binding masses made of epoxy which can be hardened at low temperature in a non-melting process. These binding masses usually have a liquid or paste-like consistency at room temperature. Filling the space between the studs and hardening the material is fast and less energy consuming process.
  • Armouring means increase the tensile strength, the stability, dimensional stability and the mechanical resistance of the composite material. Fibres are well suited to absorb tensile forces.
  • the composite material used comprises hard particles which are dispersed in the composite material in an amount in the range of 15 wt% to 80 wt%, preferably in the range between 20 and 40 wt%, based on the entire composite material.
  • an especially wear resistant matrix material is provided. If the amount of hard particles in the composite material is lower than 20 wt%, especially if it is lower than 15 wt%, the wear resistance of the composite material is only slightly improved. If the amount of hard particles is higher than 40 wt%, especially if it is higher than 80 wt% a paste-like material is obtained which is difficult to process.
  • Hard particles made of Al 2 O 3 , WC and/or SiC are commercially available in different grain sizes and characterized by high mechanical resistance and stability.
  • the amount of armouring means in the composite material is lower than 5 wt%, only a slight effect on the tensile strength of the composite material can be observed. If the amount of armouring means is higher than 20 wt% a paste-like material is obtained which is difficult to process.
  • Fig. 1 illustrates a two roller press for comminution of granular material by interparticle crushing.
  • the press is formed between cylindrical rolls 1 and 2 which form a press nip 3 therebetween.
  • the rolls are suitably supported on high force bearings 4 with means for adjusting the nip width and pressure to obtain the nip forces required for interparticle crushing.
  • Granular material is supplied from above the nip by a suitable product delivery shaft.
  • End plates 5 positioned at the end of the nip 3 for aiding in retaining material and preventing it from exiting axially out the ends of the nip 3.
  • a suitable receiving means is provided beneath the nip for receiving the comminuted material.
  • a plurality of wear-resistant studs 6 are shown, which are welded to the cylindrical surface of the rolls 1, 2.
  • the place between the studs is filled with hardened polymer composite material 12 (MECATEC® A5 HT; Castolin GmbH, Germany).
  • the studs 6 are made of a wear resistant core made of a Fe-based alloy, surrounded by a metal stud casing made of a tough steel and a base made of low cost steel. Such studs are known from DE 20 2004 007 809 U1 which is incorporated into this patent application by reference.
  • Fig. 2 to 4 show a preferred process for manufacturing the rolls 1, 2.
  • the studs 6 are welded to the surface of the roll 1 by bold welding.
  • the space between the studs 6 is filled with a paste-like precursor material 11 (MECATEC® A5 HT, Castolin GmbH, Germany) by using a spatula.
  • This material consists of a bulkpolymer and hardening reagent.
  • the bulkpolymer comprises a binding mass, armouring means and hard particles.
  • the binding mass is made of epichlorohydrin, bisphenol A and bisphenol F.
  • armouring means made of aramid fibres are dispersed.
  • the hard particles are a mix of Al 2 O 3 ceramic particles and SiC particles.
  • the hardening reagent is triethylenetetramine.
  • the precursor material 11 is MECATEC® 101 F or MECATEC® 101 P.
  • the studs 6 are completely embedded in the composite material having the same height as the stud top ( Fig. 3 ).
  • the surface of the roller is then smooth.
  • the precursor material rapidly solidifies and polymerises completely at ambient temperatures forming a thermosetting polymer with a three-dimensionally cross linked network structure and forms the composite matrix material 12 as shown in Fig. 4 .
  • the obtained composite material 12 is wear resistant, but still softer than the casing 9 of the studs 6 and can withstand temperatures up to 250 °C

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  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Rolls And Other Rotary Bodies (AREA)

Claims (10)

  1. Rouleau pour presse à rouleaux, comprenant un rouleau presseur cylindrique (1) présentant une surface de pression cylindrique extérieure à utiliser avec un rouleau en opposition (2), et une pluralité d'éléments de surface résistant à l'usure, à savoir des goujons (6), attendu que les goujons (6) sont fixés sur le rouleau (1, 2), et attendu que les extrémités libres des goujons (6) font saillie radialement à partir de la surface du rouleau (1, 2), et attendu que les espaces entre les goujons (6) sont remplis avec un matériau de matrice plus mou que le matériau le plus dur à partir duquel les goujons (6) sont fabriqués, dans lequel le matériau de matrice est un matériau composite (12) comprenant une masse liante organique non métallique, caractérisé en ce que la masse liante organique non métallique est fabriquée en époxy, et le matériau composite (12) comprend des moyens de blindage sous la forme de fibres.
  2. Rouleau selon la revendication 1, caractérisé en ce que la surface extérieure des goujons (6) et la surface formée par le matériau composite (12) sont de même niveau.
  3. Rouleau selon la revendication 1 ou 2, caractérisé en ce que le matériau composite (12) comprend des particules dures, attendu que les particules dures sont dispersées dans la matrice en une quantité comprise dans la plage de 15 % en poids à 80 % en poids, de préférence dans la plage comprise entre 20 % en poids et 40 % en poids, sur la base de la totalité du matériau composite (12).
  4. Rouleau selon la revendication 3, caractérisé en ce que les particules dures sont fabriquées en Al2O3, WC, et/ou SiC.
  5. Rouleau selon la revendication 4, caractérisé en ce que les moyens de blindage sont fabriqués dans un matériau de plastique synthétique ; de préférence les moyens de blindage sont des fibres aramide, et en ce que les moyens de blindage sont dispersés dans la matrice en une quantité comprise dans la plage de 5 % en poids à 20 % en poids, sur la base de la totalité du matériau composite (12).
  6. Procédé destiné à fabriquer un rouleau pour presse à rouleaux, comprenant les étapes consistant à : former un rouleau presseur cylindrique (1) présentant une surface de pression cylindrique extérieure à utiliser avec un rouleau en opposition (2), fixer une pluralité d'éléments de surface résistant à l'usure (goujons) (6) sur la surface de rouleau suivant des intervalles d'espacement et présentant une dureté supérieure à celle de la surface de rouleau, de sorte que les extrémités libres des goujons (6) font saillie radialement à partir de la surface du rouleau (1, 2), et remplir les espaces entre les goujons (6) avec un matériau de matrice, attendu que le matériau de matrice comprend une masse liante plus molle que le matériau le plus dur à partir duquel les goujons (6) sont fabriqués, caractérisé en ce que pour le remplissage des espaces entre les goujons (6), on applique comme matériau de matrice un matériau composite (12) comprenant une masse liante non métallique fabriquée en époxy, et attendu que le matériau composite (12) comprend des moyens de blindage sous la forme de fibres.
  7. Procédé selon la revendication 6, caractérisé en ce que le remplissage des espaces entre les goujons (6) est réalisé par un processus sans fusion à faible chaleur.
  8. Procédé selon la revendication 6 ou 7, caractérisé en ce que pour le remplissage des espaces entre les goujons (6), on applique une substance de précurseur liquide ou de type pâteuse du matériau composite (12), laquelle forme, après durcissement, le matériau composite (12).
  9. Procédé selon l'une quelconque des revendications 6 à 8, caractérisé en ce que l'on utilise un matériau composite (12) comprenant des particules dures, de préférence fabriquées en Al2O3, WC, et/ou SiC, lesquelles sont dispersées dans le matériau composite (12) en une quantité comprise dans la plage de 15 % en poids à 80 % en poids, de préférence dans la plage comprise entre 20 % en poids et 40 % en poids, sur la base de la totalité du matériau composite (12).
  10. Procédé selon la revendication 6, caractérisé en ce que les moyens de blindage sont dispersés dans matériau composite (12) en une quantité comprise dans la plage de 5 % en poids à 20 % en poids, sur la base de la totalité du matériau composite (12).
EP11182178.1A 2011-09-21 2011-09-21 Cylindre à revêtement résistant à l'usure et procédé pour sa fabrication Active EP2572790B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP11182178.1A EP2572790B1 (fr) 2011-09-21 2011-09-21 Cylindre à revêtement résistant à l'usure et procédé pour sa fabrication

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP11182178.1A EP2572790B1 (fr) 2011-09-21 2011-09-21 Cylindre à revêtement résistant à l'usure et procédé pour sa fabrication

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EP2572790A1 EP2572790A1 (fr) 2013-03-27
EP2572790B1 true EP2572790B1 (fr) 2018-11-07

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Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102014006427A1 (de) * 2014-05-02 2015-11-05 Khd Humboldt Wedag Gmbh Walze mit Verschleißschutzschicht für eine Rollenpresse
CN111760636A (zh) * 2020-07-03 2020-10-13 浙江申轮水泥机械制造有限公司 一种辊压机辊套及其制造工艺

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Publication number Priority date Publication date Assignee Title
DE4132474A1 (de) * 1991-05-28 1992-12-03 Kloeckner Humboldt Deutz Ag Verschleissfeste mahlwalze fuer die verwendung in walzenmaschinen, insbesondere in hochdruckwalzenpressen
DE202004007809U1 (de) 2004-05-14 2004-09-16 Castolin Ges.M.B.H. Verschleißfestes Element
PL2239058T3 (pl) 2009-04-01 2017-10-31 Mec Holding Gmbh Walec odporny na zużycie i sposób jego wytwarzania

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