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Solutions for Highly Abrasive Processes

Flow-Optimized Geometries and Materials as Solutions against Wear

Ceramic blades on a metallic hub: that is the solution, how even large impeller diameters can be realized. This has been proven their worth especially in ore processing.

In many industries, such as ore and metal processing, building materials or pigment chemistry, and salt and fertilizer manufacturing, abrasive wear leads to frequent plant downtime and the cost of repairing and replacing worn components. In applications with high product purity requirements – examples being the production of high purity silicon or toothpaste – traces of metals from the eroded steels can already lead to unacceptable contaminants and rejection of a product.

Every effective measure to extend the service life while stirring abrasive media pays off, in many cases after just a few weeks. Avoiding downtime is often much more serious than the mere cost of repair and replacement. EKATO has the know-how to determine the causes of wear in tests or through flow simulations and to derive appropriate measures: service life extensions from up to even more than 20 times are possible.

An elegant approach are flow-optimized impellers, since vortex shedding on the impeller blades especially increases the aggressive impact wear. If the flow separations can be reduced, the service life becomes longer without further measures: more than twice this is easily possible.

涂层必须非常仔细地与操作条件和所涉及的材料相匹配。 涂层的缺点:如果薄的保护层在某一点被相对较小的磨损穿透,则下方基材的磨损可以不受阻碍地进行。

现代工程陶瓷开辟了全新的视野。 陶瓷加工的进步允许制造直径为 2 m 或更大的叶轮。 甚至可以实现复杂的几何形状。 根据叶轮的尺寸和形状,它可以设计为一个实心陶瓷部件,或者陶瓷叶轮叶片连接到金属轮毂。 这种复合结构是允许的,因为磨损总是发生在最高速度的区域,即叶轮的外边缘。


视频介绍 – EKATO 陶瓷桨叶 用于强磨损和腐蚀性工艺

陶瓷材料具有许多优异的性能。 它们结合了高耐化学性和极高的硬度,这两者都保证了较长的使用寿命。 即使在高温下,它们的强度特性也保持不变。 但是,设计原则必须适应陶瓷材料。 制造公差比传统的设备和工厂工程更窄,并且必须考虑钢和陶瓷的不同热膨胀。 EKATO 专家团队不断调整计算和制造组件的专业知识,以满足新的要求。 为此,可以使用有限元分析工具以及将原型真实地进行长期测试的可能性。 在 EKATO 测试中心,可针对特定应用提供各种高达 100 m³ 和 500 kW 搅拌器功率的容器。

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