Transcript ИЗНОСОСТОЙКИЕ ТРУБОПРОВОДЫ С АЛЮМОТЕРМ
THE WEAR-RESISTANT PIPELINES
with ALUMINOTHERMIC CORUNDUM COATING Energohimkomlect ltd.
Chelyabinsk, Russia
Examples of the usage of hydraulic transport of materials in various branches of industry: Branch of industry
Production of cement (wet process) Chemical industry Coal fired TPP Coal mining, coal preparation Metallurgy Production of phosphates Potassium fertilizers Refuse incineration Sand and gravel plants Sewage treatment
Transported material
Moistened raw materials (limestone, chalk, clay) Various pulps Slag, fly ash, scrubber sludge, limestone Raw coal slurries, magnetite, tailings Blast furnace slag, furnace scrubber slurry, dross Phosphate ore, tailings Potassium salts, kieserite, salts Slag, incombustible residue Sand, gravel Storm water, grit, sludge
Examples of the usage of pneumo transport of materials in various branches of industry: Branch of industry
Aluminium industry Food industry Production of cement Chemical industry Coal fired TPP Coal mining, coal preparation Foundry Glass plants Metallurgy Minerals industry Mineral and refractory fiber production Refuse incineration, vacuum refuse collection systems Sewage treatment Technical carbon products
Transported material
Calcined alumina, bauxite, electrode carbon, crushed bath Corn, barley, soybeans, malt, cocoa beans, sunflower seeds, rice hulls Clinker dust, limestone, cement, fly ash, coal, furnace slag Caustic lime, fertilizers, lime dust, chrome ore, plastic pellets with glass fibers Coal, fly ash, slag, limestone Coal dust, mine waste Foundry sand, dust collection Glass batch, cullet, quartz, kaoline, feldspar, nepheline Sinter dust, limestone, alloy additives, coke, ores Kiln feed, ore concentrates, coal, tailings, dust Perlite, stone dust, refractory fibers, wastes, dust from sawing Domestic and industrial refuse Limestone, organic fertilizer, bio solids Technical carbon, dust, graphite
Hydraulic ash and slag removal system with dual disposal of ash and slag
Hydraulic ash and slag removal system with separated disposal of ash and slag
Pneumohydraulic ash and slag removal system
The main factors affecting the abrasive and corrosive wear of equipment and pipelines:
1. Abrasive properties of conveyed particles, hardness, sharpness and size.
2. Corrosion properties of the transported material.
3. Velocity of the moving of pneumo- and hydromixtures.
4. The materials of which equipment and pipelines are made.
5. The quality of the installation.
6. The position of the pipeline (the slope).
7. The presence of bends of the pipeline and bending radius.
Measures to reduce the abrasion of pipelines:
1. Periodic rotation of the rectilinear pipes around their axis at 90 °.
2. Transportation of hydro- or dust-air flow with velocities and concentrations of solid material, not exceeding the optimum ones.
3. Shape optimization of curved sections of pipelines (reducing of bend radius).
4. Making of the sections of aerodynamic stabilization of flows at the entrance to the shaped sections of dust flues and the output of these, taking into account the zones of maximum wear.
5. Using of wear resistant elements of equipment and pipelines.
Wear-resistant elements of pipeline
Ceramic aluminothermic coatings Stone casting Alloy steels, rubberize steels, enameled steels High-carbon steels Steel 3, steel 20
Steel pipe with basalt insert
(EUTIT s.r.o, Czech)
AlUMINOTHERMIC COATINGS
Reduction of iron oxides by aluminum (aluminothermy):
3Fe
3
O
4
-ΔH
298 0
+ 8Al → 4Al
2
O
3
+ 9Fe = 839 kJ/mole Al
2
O
3
, t
ad.comb.
= 3194 °С (1) Fe
2
O
3
-ΔH
298 0
+ 2Al → Al
2
O
3
+ 2Fe = 856 kJ/mole Al
2
O
3
, t
ad.comb.
= 3428 °С (2)
The formation of aluminothermic coating on a vertically mounting pipe by reactionary fusing method
1 – Igniter 2 – Thermite mixture 3 – Molten slag (Al 2 O 3 ) 4 – Molten reduced iron 5 – Surfaced ceramic coat (Al 2 O 3 )
The formation of aluminothermic coating on a bended pipe (elbow) by reactionary fusing method
1 – Igniter 2 – Thermite mixture 3 – Molten slag (Al 2 O 3 ) 4 – Molten reduced iron 5 – Surfaced ceramic coat (Al 2 O 3 )
Pipes Ø273х10 mm, length 2 m
Three way pipe Ø108 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
Test of thermite mixture in the pipe Ø108 mm, length 600 mm
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating on a pipe Ø273х10 mm, length 2 m
The formation of aluminothermic coating by centrifugal SHS-casting method
The structure of aluminothermic coating produced by centrifugal SHS-casting method The cross-section of steel pipe with aluminothermic coating
a – the pipe wall; b – an intermediate metal layer; c – ceramic layer.
The microstructure of the ceramic layer
The comparative properties of pipelines materials Characteristic
Thickness of coating, mm Density of coating, g/cm 3 Water uptake, % Compression strength, MPa Flexural strength, MPa Impact strength, kJ/m 2 Elastic modulus, MPa Wear resistance, g/cm 2 Mohs hardness Microhardness, GPa Heat resistance, the number of thermo cycles from 800 ° С to 20 ° С in air Heat resistance, the number of thermo cycles, quenching from 800 ° С to 20 ° С into water Acide resistance, 20% HCl, % Acide resistance, H 2 SO 4 (96%), %
Aluminothermic ceramic coating
3 – 4 2,9 0,09 300…340 70…110 1,50 102000 0,02 8…9 15…18 not less 10 not less 2 98 99
Wear-resistant stone casting (cast basalt)
20 3,0 0,13 250…500 30…50 1,25 100630 0,30 7…8 5…9 1 cracking 89 97
Gray cast iron СЧ 12-28
7,2 не опр.
500 280 3,00 120000 0,79 not determ.
not determ.
not determ.
not determ.
not determ.
not determ.
Primary characteristics of the aluminothermic coating Wear resistance Heat endurance (proven endurance up to 1200 °C) Heat resistance (at least 2 thermal shocks from 800 °С into the water with 20 °С) The thickness of the coating is adjusted from 2 to 8 mm Resistance to electric welding High acid- and corrosion resistance
Implemented products with aluminothermic coatings
JSC “Chelyabisk Zink Plant”
Pneumatic transport of calcined Waelz oxide
• Straight pipes Ø159х8 mm, length 2 m, steel 20 • Elbow Ø159х8 mm, 90°
Tobolskneftehim ltd.
Pneumatic transport of catalyst, temperature up to 650 °С
• Cyclones Ø140-331х12 , height 556 mm, steel 12Х18Н10Т
JCS “Malyshev Ore Department”
Jet mills for mica grinding
• Acceleration pipes Ø67х8 mm, length 600 mm