Anti-wear Optimization Design And Experiment Study For The Separator Of Vertical Mill

Large vertical mill is an important cement industry equipment, and the separator is one of its important working parts. The wear failure of the separator aggravates the normal operation of the vertical mill and results in lower-quality product and lower economic benefits. The research of the separator wear failure and the application of anti-wear design could be help to reduce separator wear and extend separator life. It is of important significance for ensuring stable powder quality and decresing energy consumption.For the polysius (RM) of vertical mill separator, the failure positions were in the separator vanes made with surfacing wear-resistant compound plate. With SEM and other analytical tools, it was found that the low-carbon steel layer was completely worn out because of the strong erosion to blades by powder particles. The duct function of blades failured because of the wear-resistant layer of blades breaking off.The 2 abrasion resistant designs were taken for the duct vanes.The first one is that the blade area was processed with double-sided welding wear resistant layer. The double-sided welding zone can be gradually widened until to the whole blade area according to the worn condition. The second one is the addition of the B element in the Fe-Cr-C hardfacing alloy for optimizing and enhancing its wear resistance. The test showed that B addition increased the hardness of the material and the number of carbide, so that the surface morphology and distribution of welding crack were improved significantly and the better processing performance was got.Because of the process complexation of both-sided welding process, we recommend the process of two back to back single-sided composite steel plug welding process.In order to test the erosion properity of Fe-Cr-C-B alloys, an erosion wear tester was designed and manufatured. The abrasive wear test with wet sand rubber wheel tester and the dynamic load impact wear test were taken to study materials wear characteristics under different wear way. The wear resistance increased with the Cr, C content increasing and B content affects the wear resistance of Fe-Cr-C alloy significantly. It was found that the wear resistance of Fe-Cr-C-B alloy is the double of that of Fe-Cr-C-alloy. Under the conditiong of impact abrasive wear tests, the wear resistance of Fe-Cr-C-B alloy was 2 times higer than that of Fe-Cr-C alloy.When the impact times were over 2000, the sample broke into fragmentation.It was found that erosion rate of the Fe-Cr-C-B alloy increases with the abrasive rate and size. The ratio of alloy hardness and abrasive hardness affected significantly on the wear resistance.A particle projected test with a small number of avbrasive were taken for cladding layer.It was found that the erosion occurred mainly in the way of plow even for the sample with a large number of carbide and higher macro-hardness than HRC63. This showed that the maximum erosion occurred in the 30-45 0 angle.