Presentation on theme: "THE WEAR-RESISTANT PIPELINES with ALUMINOTHERMIC CORUNDUM COATING Energohimkomlect ltd. Chelyabinsk, Russia."— Presentation transcript:
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 industryTransported material Production of cement (wet process)Moistened raw materials (limestone, chalk, clay) Chemical industryVarious pulps Coal fired TPPSlag, fly ash, scrubber sludge, limestone Coal mining, coal preparationRaw coal slurries, magnetite, tailings Metallurgy Blast furnace slag, furnace scrubber slurry, dross Production of phosphatesPhosphate ore, tailings Potassium fertilizersPotassium salts, kieserite, salts Refuse incinerationSlag, incombustible residue Sand and gravel plantsSand, gravel Sewage treatmentStorm water, grit, sludge
Examples of the usage of pneumo transport of materials in various branches of industry: Branch of industryTransported material Aluminium industry Calcined alumina, bauxite, electrode carbon, crushed bath Food industry Corn, barley, soybeans, malt, cocoa beans, sunflower seeds, rice hulls Production of cement Clinker dust, limestone, cement, fly ash, coal, furnace slag Chemical industry Caustic lime, fertilizers, lime dust, chrome ore, plastic pellets with glass fibers Coal fired TPPCoal, fly ash, slag, limestone Coal mining, coal preparationCoal dust, mine waste FoundryFoundry sand, dust collection Glass plantsGlass batch, cullet, quartz, kaoline, feldspar, nepheline MetallurgySinter dust, limestone, alloy additives, coke, ores Minerals industryKiln feed, ore concentrates, coal, tailings, dust Mineral and refractory fiber production Perlite, stone dust, refractory fibers, wastes, dust from sawing Refuse incineration, vacuum refuse collection systemsDomestic and industrial refuse Sewage treatmentLimestone, organic fertilizer, bio solids Technical carbon productsTechnical 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 coatingsStone casting Alloy steels, rubberize steels, enameled steels High-carbon steelsSteel 3, steel 20 Increasing of wear-resistance
Steel pipe with basalt insert (EUTIT s.r.o, Czech)
Reduction of iron oxides by aluminum (aluminothermy): 3Fe 3 O 4 + 8Al → 4Al 2 O 3 + 9Fe (1) -ΔH = 839 kJ/mole Al 2 O 3, t ad.comb. = 3194 °С Fe 2 O 3 + 2Al → Al 2 O 3 + 2Fe (2) -ΔH = 856 kJ/mole Al 2 O 3, t ad.comb. = 3428 °С
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
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 Aluminothermic ceramic coating Wear-resistant stone casting (cast basalt) Gray cast iron СЧ Thickness of coating, mm3 – 420- Density of coating, g/cm 3 2,93,07,2 Water uptake, %0,090,13не опр. Compression strength, MPa 300…340250… Flexural strength, MPa70…11030…50280 Impact strength, kJ/m 2 1,501,253,00 Elastic modulus, MPa Wear resistance, g/cm 2 0,020,300,79 Mohs hardness8…97…8not determ. Microhardness, GPa15…185…9not determ. Heat resistance, the number of thermo cycles from 800 °С to 20 °С in air not less 101not determ. Heat resistance, the number of thermo cycles, quenching from 800 °С to 20 °С into water not less 2crackingnot determ. Acide resistance, 20% HCl, % 9889not determ. Acide resistance, H 2 SO 4 (96%), % 9997not determ.
Primary characteristics of the aluminothermic coating Wear resistanceHeat 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 mmResistance to electric weldingHigh acid- and corrosion resistance
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 Ø х12, height 556 mm, steel 12Х18Н10Т JCS “Malyshev Ore Department” Jet mills for mica grinding Acceleration pipes Ø67х8 mm, length 600 mm Implemented products with aluminothermic coatings