At the present stage, under the environment of overcapacity and sharp decline in demand, most cement production enterprises have fallen into the passive situation of reducing production and price and making profits to varying degrees. Some enterprises have begun to try to upgrade their products or change their careers, and even have to consider reducing salaries and staff or shutting down partially. At the same time, we should also see that under the market rules of survival of the fittest, after this round of integration and shuffling, the (cement) building materials industry will get a round of overall improvement in energy saving, consumption reduction, green environmental protection, technological updates and other aspects.
Profitability is the vitality of an enterprise, and "cost reduction and efficiency enhancement" is the endogenous motive force for the survival and development of an enterprise.
(1) Graphite lubrication device
for rotary kiln tyre The tyre of rotary kiln has the functions of supporting load, transmitting motion and maintaining the concentricity of the cylinder. During the operation of the rotary kiln, there are continuous extrusion contact stress, rolling friction and sliding friction between the inner surface of the tyre and the outer surface of the cylinder (base plate), as well as between the end surface of the tyre and the stop iron; Under the condition of high temperature and heavy load, the serious wear of wheel belt and stop iron, even the falling off of stop iron and the fracture of backing plate often occur, which has become a common problem restricting the smooth operation of rotary kiln. Therefore, the continuous and reliable lubrication of the wheel belt is a necessary condition to ensure the stable operation of the rotary kiln system and to maintain the reasonable working life of each component.
At present, the industry generally chooses the way of "oil injection" to lubricate the tire belt. However, whether it is manual injection or automatic injection with high cost, there are the following main disadvantages:
(1) low efficiency and poor effect: most lubricants are injected outside the working area (more than 60%), resulting in oil waste and environmental pollution; The redundant lubricant may even overflow to the surface of the outer circle of the wheel belt, causing the change of the friction coefficient between the wheel belt and the riding wheel, destroying the balance state of the axial force of the rotary kiln system, causing the fluctuation of the temperature of the bearing Bush, and even causing malignant faults such as Bush burning;
(2) Environmental pollution: under the action of high temperature (above about 200 ~ 300 ℃), the lubricant sprayed on the wheel belt and the cylinder is fumed and gasified, and it is difficult to remain in the friction and contact areas, resulting in oil waste and environmental pollution (the following picture is the actual picture of the wheel belt lubrication of the two companies).
(3) Poor economy: the lubrication method of spraying (manual or automatic) is adopted, and 16 kg barreled lubricant is generally selected. According to statistics, a whole barrel (16 kg) of lubricant is generally needed for one spray lubrication of three tires in a production line, and the approximate reference price is 2400 ~ 3200 yuan/barrel; if the lubrication frequency is once a week, only the oil consumption is more than 100000 yuan a year-and most of the oil is wasted! Ccement. Com/news/2601/richtext/IMG/qmqrb3ot9rs1768982453935. Through on-site inspection in the Convenience and practicability: the solid graphite lubricant does not need to be frequently added and supplemented, so that the frequency of manual operation is reduced, the labor cost is saved, and the maintenance cost is reduced; and meanwhile, the solid graphite lubricant has a long service life, has no loss and waste, and does not need to be frequently replaced and maintained; Generally, it is recommended to install 4 sets of devices (uniformly distributed on the circumference) on one wheel belt, so the initial installation time of 12 sets of devices (each set of devices includes one set of UGL-100 and one set of UGL-500) on one kiln is only about 1 day; it takes less than 10 minutes to replace a set of graphite blocks. Safety: Solid graphite has excellent stability under high temperature conditions, is not easy to burn, and has no hidden dangers of fire and safety accidents; The graphite lubricating device is provided with a special limiting mechanism, so that even under the condition that the graphite block is used to the limit (for example, the graphite block is not replaced for a long time), no part is contacted or interfered with the wheel belt, and the safety of the equipment is ensured. Environmental protection: Compared with liquid lubricant, solid graphite has no volatility, will not release harmful gases or pollute the environment, meets the requirements of environmental protection, and is conducive to the improvement and protection of the working environment; Economy: The graphite consumption cost of using the graphite lubrication device is about 4000 yuan a year; compared with the initial installation cost, the cost can be recovered in half a year. application of laser welding technology can avoid the above problems and hidden dangers. The energy of laser welding comes from the "high energy density" laser beam. During the welding process, the heat is concentrated and the molten pool is small, so the heat affected zone is small, the thermal stress is small, and there are basically no defects such as deformation and micro-cracks. The process of laser welding is reliable and the operation process is simple and easy. As long as the appropriate welding wire is selected and the reasonable welding parameters are set, the on-site heat treatment before and after welding is not required, and there are no defects such as pores and slag inclusions, the surface quality after welding is better (see the table below). 
, from the point of view of production operation, the surface contact (alternating) stress continuously generated during the operation of the equipment is one of the main causes of spalling. If this condition is not treated in time, it will gradually extend, and a large area of spalling or even cracks will occur. In the past, electric welding was generally used for repair. The material of the tire is generally ZG35SiMn or ZG35CrMo, which has a certain degree of weldability, but the traditional welding process will produce a large heat affected zone on the base material, even if there are measures such as preheating before welding, knocking during welding, heat treatment after welding, there is still a hidden danger of )
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