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General Manager: Zuchang Li
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Cement industry for wear-resistant material prosperity

     Since the 70s of last century, the development of new dry kiln cement industry a lot, the introduction of foreign advanced technology, advanced equipment, has set up Jidong, Ningguo, Huaihai, Liuzhou, totaling 4,000 tons of large-scale cement production. The introduction of advanced technology has brought new equipment from abroad, new materials: use of foreign steel mill liners and cast iron, high chromium cast grinding ball ball. During this period, the domestic research institutes, universities, manufacturers of wear resistant materials and experience in the original theory based on the analysis of foreign liner, ball use, combined with the actual situation of development and production of high-chromium cast iron series ball, lining and all kinds of alloy steel liner, so that wear-resistant materials changed dramatically.
    
For years people have high manganese steel for the best wear-resistant materials, wear failure analysis after recognition of the high manganese steel wear-resistant material is not a panacea, it is only in the case of strong impact, resulting in work hardening only wear. Cf foreign materials, a large number of people began to develop and produce all kinds of high chromium cast iron ball series, linings and other new types of alloy steel liner abrasion-resistant material, ushered in the spring of wear-resistant materials. To the formation of wear-resistant material has three systems, namely: high manganese steel series (including the high manganese steel, plus high manganese chromium molybdenum alloy, in manganese steel, etc.); AW series of high chromium cast iron (13 chromium, chromium 15, Cr 20, Cr 24, Cr 28, etc.); wear-resistant alloy steel series (including multi-carbon steel, chromium molybdenum nickel steel, chromium alloy steel, silico-manganese steel, etc.). Various types of steel can be used by adjusting the chemical composition of water quenching, oil quenching, spray quenching, air quenching and heat treatment methods to reach people in need with the hardness and toughness, wear resistance and service life of an ideal. At present, many wear-resistant materials production plant can produce according to market the series of wear-resistant material needs, while developing ADI, composite materials, wear-resistant materials, a variety of surface engineering to meet user needs.
    
20 years to meet the needs of the cement industry, combined with a number of conditions, many units have developed a new wear-resistant materials. Plant resistant materials Ningguo metal type was first developed and produced low-chromium cast ball; Hefei Cement Research & Design Institute and other units in the development of multi-carbon steel production has been widely used in China, the performance reached the international advanced level.
    
In order to standardize the variety and quality of production, standardization of our wear-resistant materials have great development. Promulgated and implemented since 1980, GB3180-82 in manganese wear iron; JC/T533-2004 building materials industry with a chromium alloy balls; GB/T5680-1998 high manganese steel castings; GB/T17445-1998 casting grinding ball; building materials system development JC/T691-1998 technical conditions of high chromium cast iron liners; countries to develop GB/T8263-1999 resistant white cast iron; building materials systems to develop JC/T880-2001 heat-resistant steel castings used in cement industry and other national and industry standards, standard of bringing the overall level of wear resistant products improve the quality.
    
In the cement industry and metallurgy, electric power development in different stages of wear resistant materials, the development of production fast and uneven. Of the last century 80's large and small cement plants, metallurgy and mining boom led to many small and medium sized wear-resistant materials factory came into being, a prosperous country in Ning region had only 104 ball factory, in China there are 1000-1200 a wear-resistant material production plant. Wear-resistant material into a sunrise industry, the development of the ascendant, but the production scale, product quality differ greatly from the need to constantly integrate, standardize and innovation.
        
Development of cement industry need to wear and production of innovative materials
    
With the new dry cement production industry, equipment, large scale development of abrasion-resistant material made of the new high demand. General small factory production ball, liner, hammer, cooler grate panels heat resistant products, the intrinsic quality of the appearance of species there are some problems, can not meet market needs. Large scale introduction of new equipment, equipment needs inherent quality, safety and reliability, appearance and excellent quality, high-quality wear-resistant material at the same time to ensure delivery. Used in cement production, vertical mill, extrusion mill, and other new devices need to provide a new wear-resistant materials. This has prompted the introduction of new production plants resistant materials technology, new equipment and perfect testing means, to meet market needs.
        
During this period some domestic production plants resistant materials were from Japan, Germany, Yugoslavia, Belgium and other countries introduced a number of semi-automatic production line of mechanization. Cement Machinery Plant as the introduction of the former Yugoslavia Beijing Di sand-cast ball production line; MOS ball production line imported Japan; Ning country wear-resistant materials plant, cement machinery factory original Shaanxi Yanhe Japan Xindong company introduced the production of lining VRH casting production lines, etc., etc. . Meanwhile, many domestic production plants, in order to increase productivity, improve product quality or development in the introduction of advanced technology, advanced production equipment, advanced testing equipment purchase the product yield and quality to a new level. Plant resistant materials such as Ning China has independently developed the six production lines of metal type cast ball, a perfect physical and chemical detection methods have 1.2 billion tons of annual production capacity of high-quality cast ball; Henan Zhumadian Casting Set Jumbo smelting company more frequent in Taichung, using oil quenching and water quenching produce all kinds of alloy steel, high manganese steel liner hammer 5 thousand tons per year and 10,000 tons ductile iron castings; has invested 2 billion acquisition of 5-ton electric arc furnace, the establishment of large-scale production line V-hammer and liners and other wear-resistant casting; with direct reading spectrometer, universal testing machine, metallographic microscope, testing to ensure superior product quality; Hebei China-US Hout casting company has established two metallic balls mechanized production line, an EPC EPC production line, a direct reading spectrometer, dynamic loading and wear tester, metallurgical microscope and other test methods, since the beginning of production that is high quality wear resistant liner cast into the ball market. Many units, such as wear-resistant materials, wear-resistant materials Xuzhou Hongda Company, through the company, Zhengzhou height of the company, Ma On Shan, Haifeng wear company and so great efforts to develop new products, the purchase of advanced equipment and testing methods to increase the number of products to improve product quality to meet market needs. Cement industry and metallurgy, power and other industries need to wear and production of innovative materials, wear-resistant units continuous improvement, development and innovation.
        
Wear resistant material production opportunities and challenges facing
    
1. Wear resistant material production problems facing the development of circular economy
    
1). Wear resistant materials low labor productivity, energy consumption, serious pollution; excessive consumption of resources; any information that: 1 ton of qualified casting emissions produced 500 kg of dust, emission of 300 kilograms of smelting and casting waste, 1,000 cubic meters of gas, exhaust 1-1.5 tons of waste sand;
    
2) low-end products, extensive, the products of low added value, added value is only 10-15%;
    
3) Industrial decentralization messy, lack of innovation, invention patents less technology to create poor, low productivity;
    
4) energy and raw materials wasted, poor environmental awareness, the concept of circular economy is weak.
    
5) large-scale equipment in cement industry also need to import some of wear-resistant castings, made low, the quality is poor, rely on market price advantage.
    
In order to improve the yield and quality of wear resistant castings to meet the market needs, we must gradually solve the problems facing the development of circular economy and the poor quality problems.
    
2. Production of wear resistant materials development opportunities
    
1) wear-resistant material has a vast domestic market. In addition to the cement industry, the metallurgy, electric power, coal, petrochemical and other industries need to consume each year 220-250 million tons of wear resistant castings, of which 130-140 million tons of balls, liners, hammer, etc. 110-120 tons;
    
2) The export situation of strong wear-resistant castings. With the progress of economic globalization, the developed countries the manufacturing industry was gradually shift to China, China has become non-innovative products manufacturing power, the first when casting wear them; currently exports about 100,000 tons wear-resistant castings, will increase each year;
    
3) With economic development, industrial production in wear resistant materials needed, the market has a lot of new growth points, such as cement vertical mill; thermal power plant in the MPS and the RP-speed grinding, the mill, roller need a lot of wear-resistant materials with high chromium cast iron class; the newly developed all kinds of crusher hammer, grate plate, that require long life and a new wear-resistant material.
    
In short, with the development of national economy, the prosperity of the cement industry, the production of wear-resistant materials, the development also has broad market space.
    
3. Wear-resistant materials and production trends
    
Green manufacturing, recycling economy is the production of wear-resistant material development. Cement, metallurgy, electric power industries driving the rapid growth of wear-resistant materials development, combined with the high-tech, armed with new technologies and equipment wear-resistant materials, small to medium-sized development, the establishment of associations from the organizational integration, in technology, equipment Innovation is the wear-resistant material development.
    
1) development, developing high-performance wear-resistant material; prices for raw materials, the face of market demand for research and development of new materials;
    
2) According to the different alloys, different casting characteristics, different production environments, the development of different sand and core sand, sand clay, such as high density, ester cured water glass sand, resin sand;
    
3) advanced melting alloy melting equipment, induction furnaces, electric arc furnace, vacuum furnace, etc., to improve the metallurgical quality, reduce energy consumption;
    
4) the use of advanced casting equipment; by EPC method, V method, VRH production of mill liners and crusher castings;
    
5) the use of advanced heat treatment equipment; such as coal, oil, electricity, heat treatment furnace, under different conditions using water, oil, spray, quenching media for heat treatment, for the alloy to improve wear-resistant material price increases performance, must be work hard in the heat treatment;
    
6) The use of advanced cleaning equipment, to ensure a perfect appearance quality;
    
7) establish a perfect quality assurance system; strict accordance with the business, industry, national and international standards of production; with perfect physical and chemical testing methods; such as spectrum analyzer, plasma cutting machine, impact testing machine, universal testing machine, abrasion tester, ultrasonic testing, X-ray detection, advanced equipment such as optical microscopy.
    
The use of advanced production equipment, develop new wear-resistant material is the future direction of development. 
    Wear-resistant material production is full of opportunities and challenges. Only with the advanced production technology, in accordance with the scientific concept of development of circular economy in the use of advanced technology, advanced equipment, advanced detection methods, advanced management, continuous improvement and innovation, to lead the future of wear-resistant materials and services in the cement industry and metallurgy , and electric power industries, creating new prosperity and glory.

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