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Application case---Port ore conveying system blanking bin and chute wear protection solution

2024-05-10
 Latest company case about Application case---Port ore conveying system blanking bin and chute wear protection solution

Project Overview
As an important export-oriented Yangtze River port and a national first-class water port, the port has an average annual freight throughput capacity of 16 million tons. It is an important public logistics platform for transferring and transporting bulk and groceries in surrounding areas.

 

Currently, the port mainly loads and unloads ore and ore powder. Due to the highly abrasive nature of the materials and the large transport volume, equipment such as hoppers and chutes are severely worn. Most of the original wear-resistant steel plates wear out after a few months of operation, causing the equipment shell to leak and requiring frequent repairs. This increases the burden of maintenance and seriously affects the normal operation of the equipment and on-site production safety.

 

latest company case about Application case---Port ore conveying system blanking bin and chute wear protection solution  0latest company case about Application case---Port ore conveying system blanking bin and chute wear protection solution  1

Analysis of project-specific situation
The chute is severely worn and has been repaired many times. There is no possibility of repairing it again. The following problems exist:
1. Most chutes have small spaces and are very difficult to repair. They can only make external repairs, which cannot completely solve the problem;
2. Due to equipment wear and leakage, the dust and material accumulation on site are very serious, which is not conducive to the achievement of pollution control standards;
3. The design of some equipment is unreasonable, and the material accumulation and blockage are serious. The material needs to be cleaned every few hours, which seriously affects the normal operation of the equipment and makes the operators miserable.
4. Based on the above situation, it is urgent to optimize the design of the useless chutes and pipes and replace them with more wear-resistant wear-resistant materials to completely reverse the current situation on-site.

 

As a comprehensive service provider of professional equipment anti-wear solutions, our company has accumulated rich experience in anti-wear of bulk terminal equipment. We are honored to participate in the optimization and anti-wear transformation of a port’s blanking bin and blanking chute. We will carefully design and be Responsible for the heavy responsibility and contribute to the safe and civilized production of a certain port.

 

Solution
According to the characteristics of a certain port material conveying system with large annual throughput, heavy material proportion, and strong abrasiveness, and drawing on our company’s experience in other similar working conditions, it is recommended to install ceramic+rubber+ with ZTA as the main wear-resistant material at the impact area. Steel plate composite products, the non-impact surface uses ZTA ceramic + steel plate composite lining plate

 

The impact surface adopts ZTA ceramic + rubber + steel plate ceramic rubber composite lining plate
1. Ceramic-rubber composite lining plates are produced using the ZTA-toughened ceramic, rubber, and steel plate integrated vulcanization process.
2. The outer dimensions of the lining plate are made strictly per the requirements of the design drawings. Each bolt hole on the plate is accurately positioned. The center distance deviation of the casting holes is controlled within the national standard. The size of the bolt holes is strictly controlled to meet the requirements confirmed by both parties. The position of the screw holes shall be carried out according to the drawings confirmed by both parties to ensure that the connection between the liner and the blanking pipe is smooth and well-sealed.
3. The specifications of fasteners used for ceramic rubber composite linings are as follows:
Bolt M16     Grade 8.8       Nut M16      Grade 8

Flat washer 16 200HV Add an anti-loosening pad
4. The back of the lining plate adopts bevel reinforcement and welding method. It is required that the lining plate and bolts are welded and shipped as a whole.
5. The outer surface of the ceramic-rubber composite lining board is anti-rust treated before leaving the factory, painted with two layers of blue-red anti-rust paint, and fixed and packaged with a wooden pallet.

 

 

The non-frontal impact part adopts a ceramic lining plate
1. The cermet lining plate is made using the ZTA ceramic and steel plate combination process.
2) The overall dimensions of the board are made in strict accordance with the requirements of the design drawings; the positioning of each bolt hole on the board is accurate, the center distance deviation of the casting holes is controlled within the national standard, and the size of the bolt holes is strictly controlled to meet the requirements confirmed by both parties. The position of the screw holes shall be carried out according to the drawings confirmed by both parties so that the connection between the liner and the blanking pipe is smooth and well-sealed.
3) The specifications of fasteners used for wear-resistant ceramic lining plates are as follows:
Bolt M16   Grade 8.8  Nut M16  Grade 8
Flat washer 16 200HV with anti-loosening washer added

4) The back of the lining plate adopts the bevel reinforcement and welding method, and the lining plate and bolts are required to be shipped as one piece after welding.
5) The outer surface of the wear-resistant ceramic lining board is anti-rust treated before leaving the factory, painted with two layers of blue-red anti-rust paint, and fixed and packaged with a wooden pallet.

 

Expected transformation effects

1. Increase production capacity by more than 5%: Reduce downtime and maintenance time caused by equipment wear and tear, and conservatively estimate that production capacity can be increased by more than 5%.

2. Reduce the blocking phenomenon: Through advanced DEM optimization design and streamlined blanking design, the impact angle between the material flow and the pipe wall is reduced, and the probability of blockage of wet and sticky materials is reduced. ZTA ceramics produced with the company's process technology, It can reduce the phenomenon of material clogging;

3. Extend the service life to more than 2 years: Through structural design optimization, the direct impact wear of the material on the lining plate is minimized. At the same time, the use of ZTA high wear-resistant ceramics can extend the service life of the chute to more than 2 years;

4. solve the dust problem: reduce dust on the ground and reduce the cleaning work on the floor of the material conveying workshop;

5. Reduce operating noise: Control the trajectory and speed of the material flow, reducing the noise generated by the drop tube in the transfer station.