Industry News

In cement production, the basic process can be summed up in one sentence: two grinding and one burning! Namely: raw meal mill, calcination, clinker mill.

The main production equipment in the cement industry is: crusher, vertical mill, calcining kiln, caster cooler, roller press, ball mill, fan, etc., the main oil used in each equipment is: 46# anti-wear hydraulic oil, 46#, 68# steam turbine oil, 220#, 320#, 460# gear oil.

(1) Problems and current situation

      Considering the transportation of raw materials and environmental pollution, most cement plants are built near mines, with harsh environment and large sandstorms. There is a lot of dust in cement raw materials and cement products on the site of equipment use, and these particle impurities are easy to mix into the lubricating oil of the equipment, resulting in serious pollution of the lubricating oil. The main pollutants in the oil are a large amount of dust and mineral powder into the oil sludge formed, the on-site production environment is bad, the impurities are seriously exceeded, the lubrication effect of the reducer is not good, and the rotating parts of the equipment are seriously worn, resulting in an increase in the labor cost of maintenance personnel and an overrun in the cost of spare parts.

      According to the requirements of the national standard, the particle size standard of finished cement is: slag Portland cement, pozzolana Portland cement, fly ash Portland cement and composite Portland cement The particle size is expressed in sieve residue, and the screen residue of 80μm square hole sieve is not more than 10% or 45μm square hole sieve screen residue is not more than 30%. It can be seen that the diameter of the particulate impurities mixed into the lubricating oil is smaller.

       At present, the filtration accuracy of the in-line filter element of equipment lubricating oil in most cement industries is above 40μm, and the filtration accuracy is not high, and many tiny particles and impurities cannot be removed through the in-line filter, resulting in heavy pollution of equipment lubricating oil. Oil pollution will lead to: 1. The lubrication of the equipment is not guaranteed, and the particle impurities aggravate the wear and tear of the lubricating surface of the equipment, resulting in equipment failure and shutdown, and increasing the cost of equipment repair and maintenance. 2. The operation of the hydraulic system is not guaranteed, which is easy to cause the jamming of the hydraulic valve body and aggravate the wear of the hydraulic components. 3. Particulate impurities aggravate the oxidation and deterioration rate of the oil, resulting in the decline of the oil performance and shortening the service life of the oil.

(2)  the solution

      According to the above analysis, in order to improve the cleanliness of the equipment lubricating oil, it is necessary to improve the filtration accuracy of the existing filtration system. There are two solutions:

1. Improve the filtration accuracy of the existing online filter

     Improving the filtration accuracy of the existing on-line filter can remove smaller particle impurities in the lubricating oil and improve the cleanliness of the lubricating oil of the equipment, but there are also the following problems: 1. Due to the heavy pollution of the lubricating oil, it will lead to frequent blockage of the filter element, and the use cost of the filter element is high, and the replacement of the filter element may require equipment shutdown, which affects the normal production of the enterprise. 2. With the improvement of the filtration accuracy of the filter element, and the viscosity of the lubricating oil of some key equipment in the cement industry is high, the speed of the lubricating oil passing through the filter element will decrease, and the supply of lubricating oil will decrease, which will affect the lubrication of the equipment. So this scheme is not very scientific.

2. Increase online bypass purification equipment

    On the basis of the existing on-line purification, the on-line bypass purification equipment is added to improve the existing purification capacity. Since the lubricating oil pollutants of the cement industry equipment are mainly particulate impurities, a new centrifugal oil purifier can be used to purify the lubricating oil. 

The centrifugal oil purifier has the following 7 outstanding features:

(1) High performance: high precision, high efficiency, organic combination of efficiency and precision, and the oil will be processed to the required high purification accuracy in a short time. The highest accuracy of oil purification can reach NAS level 1; The purification efficiency is more than 7 times that of filter products;

(2) Low consumption: the working power of the oil purifier is only 2.2~4.4KW. Centrifugal principle, no consumption of filter media, low consumption.

(3) No damage to oil: it will not change the original performance of the oil.

(4) Multi-function: it can quickly remove impurities and remove water and gas; Comprehensive.

(5) Long life: the design is firm, durable and reliable, the friction pair realizes self-lubrication, the wear amount is small, and the main structural parts have a long service life.

(6) Easy to use, large dirt holding capacity: simple operation, easy to move, convenient for users to connect the equipment to the system to achieve online purification. It can hold 6KG of dirt, and the maintenance cycle is long under normal use.

(7) Environmental protection, safety and pollution-free: equipped with a variety of automatic protection functions, no pollutants and pollutant gas emissions, to protect the health of the operator; It can reduce the emission of waste oil, waste working fluid and waste filter element, which is beneficial to the protection of the environment.

3. Specific application

     centrifugal oil purifier is mainly used for the purification of gear oil, hydraulic oil and steam turbine oil in production equipment, and the use effect is very obvious. The cleanliness of the oil purified by the centrifugal oil purifier is greatly improved, the consumption of the in-line filter element of the equipment is greatly reduced, and the service life of the lubricating oil is prolonged.

      The main pollutants in the oil are a large amount of dust and mineral powder of the cement mill reducer and the sludge formed by the mineral powder entering the oil, the on-site production environment is poor, the impurities are seriously exceeded, the lubrication effect of the reducer is not good, and the rotating parts of the equipment are seriously worn, resulting in an increase in the labor cost of maintenance personnel and an overrun of spare parts. After using the centrifugal oil purifier, the cleanliness of the oil can be greatly improved, the lubrication effect of the reducer is good, and the equipment failure rate is reduced. The cleanliness of the oil is guaranteed to be maintained at level 7-9, the replacement cycle of the filter element can be extended by 2-3 times, the equipment failure rate is reduced by 70-80%, and the repair and maintenance costs of the equipment are greatly reduced.