In the cement production line, the preheater inner cylinder is the core equipment component, and its technical performance is directly related to the production efficiency, energy consumption index and product quality stability. The traditional heat-resistant cast steel material and suspended flexible connection scheme have been verified by long-term application, but under the continuous action of high temperature, alkaline steam, sulfur steam and dust, the defects of insufficient durability and high maintenance frequency are exposed, which brings high operating cost and shutdown risk to cement production enterprises.

Technical limitations of traditional wear-resistant materials

At present, the inner cylinder of preheater is mainly made of heat-resistant cast steel. However, in the high temperature preheater section such as C4 and C5, this kind of material has the following technical shortcomings :

• High temperature corrosion phenomenon is significant.

In the high temperature environment, the accompanying alkaline steam, sulfur steam and dust particles will accelerate the oxidation and corrosion process of cast steel materials, resulting in the continuous thinning of the wall thickness of the cylinder.

• Short service life cycle

The actual operation data show that the effective service life of the inner cylinder mounting parts is usually less than 12 months, and the annual planned replacement is required.

• The comprehensive maintenance cost is high.

The purchase cost of heat-resistant steel materials is high, and the labor intensity of replacement and maintenance operations is high, which not only directly increases the cost of spare parts, but also adversely affects the production rhythm.

• Production efficiency is restricted.

The failure of the inner cylinder will lead to the decrease of the decomposition and separation efficiency of the preheater, increase the heat loss of the system, and then cause the output fluctuation and the decline of the product quality. In severe cases, it may even hinder the material circulation process and cause unplanned shutdown of the production line.

Silicon carbide ceramics : a new generation of wear-resistant solutions

In view of the above technical bottlenecks, the Sitomat R & D team optimized the structure of the preheater inner cylinder by finite element analysis method, and used high-performance silicon carbide ( SiC ) high-temperature resistant ceramic materials to manufacture installations and structural parts.

Silicon carbide ceramics have been widely used in high-temperature metallurgy, chemical industry and wear-resistant fields due to their excellent physical and chemical properties. Introducing it into the preheater system can effectively prolong the service life of the equipment and reduce the maintenance frequency.

The core technical performance of silicon carbide ceramic inner cylinder

• High temperature stability is outstanding : it can achieve long-term stable operation in high temperature environment, and the thermal stability index is much higher than that of traditional heat-resistant steel materials.
• Excellent oxidation resistance and corrosion resistance : It has strong resistance to alkaline steam, sulfur steam and dust erosion.
• Excellent mechanical properties : It has high hardness characteristics, excellent impact resistance and wear resistance, which can effectively reduce the wear caused by material erosion.
• Strong thermal shock resistance : it is not easy to produce cracks or damage under rapid heating and cooling conditions.
• The service life is significantly prolonged : the comprehensive durability is more than three times that of traditional heat-resistant steel, which can significantly reduce the replacement frequency and downtime.

Application value and economic benefit analysis

After the application of silicon carbide ceramic inner cylinder in cement production enterprises, it not only prolongs the equipment maintenance cycle, reduces the procurement cost of spare parts, but also effectively improves the decomposition efficiency and heat energy utilization efficiency of preheater, which is of great practical significance to ensure production stability, increase production and improve product quality.

Conclusion

With the technological upgrading of cement production equipment and the increasing demand for energy saving and consumption reduction, silicon carbide ceramic inner cylinder provides a more efficient and economical wear-resistant solution for preheater system. Its excellent temperature resistance, corrosion resistance and wear resistance will bring multiple benefits to the cement industry, such as prolonged equipment life, reduced operation and maintenance costs, and improved production efficiency.