Wear-resistant Chute
Technical Product Description
Classification by Wear-resistant Materials
According to the core wear-resistant materials used, current mainstream wear-resistant chutes can be divided into the following categories:
High-chromium Cast Iron Wear-resistant Chutes: High-chromium cast iron is one of the earliest applied metallic wear-resistant materials, featuring high hardness (HRC up to 56-65), good wear resistance, and excellent high-temperature resistance. Chute components are produced by integral casting, making them suitable for working conditions involving impact from large-particle materials. However, they have drawbacks such as poor toughness (prone to cracking under heavy impact), heavy weight, high processing difficulty, and relatively high cost.
Alloy Wear-resistant Steel Plate Welded Chutes: Fabricated by cutting and welding bimetallic composite wear-resistant steel plates, with the wear-resistant layer made of high-carbon high-chromium alloy and the base layer of ordinary low-carbon steel. This design combines the high hardness of the wear-resistant layer with the good toughness of the base layer, offering excellent weldability, easy processing and forming, and convenient installation and maintenance. It is currently the most widely used type of wear-resistant chute in the industrial field. The wear-resistant layer of bimetallic composite wear-resistant steel plates generally reaches HRC 58-62, with wear resistance 8-12 times that of ordinary low-carbon steel. It also has lower cost and stronger adaptability compared to integrally cast high-chromium cast iron chutes.
Ceramic Wear-resistant Chutes: Using alumina or zirconia ceramic tiles or monolithic ceramics as the wear-resistant layer, which are bonded or embedded on the steel base surface. Ceramics have much higher hardness than metal materials (HRA up to 88-95) and excellent wear resistance. Additionally, their smooth surface results in low friction coefficient, low material flow resistance, and reduced risk of material sticking or clogging, making them particularly suitable for conveying materials with high moisture content and viscosity. The main disadvantages are poor toughness (ceramics are prone to cracking and falling off when impacted by large materials) and high requirements for installation processes.
Rubber Wear-resistant Chutes: Made of wear-resistant rubber liners bonded to a steel base. Rubber has good elasticity, which can buffer material impact, and exhibits excellent wear resistance to small-particle materials with high sediment content, along with low noise and light weight. It is suitable for hydraulic conveying or vibrating chute conditions. However, it has poor high-temperature resistance, prone to aging and deformation under prolonged high-temperature use, and low hardness, making it unsuitable for conveying large, sharp particles.
Polyurethane Wear-resistant Chutes: Polyurethane elastomer is a new type of polymer wear-resistant material, with wear resistance 3-5 times that of ordinary rubber. It features good toughness, oil resistance, aging resistance, light weight, and easy installation, suitable for conveying medium-sized materials. It is mostly used in chutes in light industrial fields such as coal preparation plants and grain processing. The main disadvantage is average high-temperature resistance, with long-term use temperature not recommended to exceed 80℃.
Classification by Structural Form
According to different structural designs, wear-resistant chutes can also be divided into integrally cast, liner-embedded, bonded, and hardfaced types:
● Integrally cast wear-resistant chutes have high structural strength and uniform wear-resistant layers, but are costly and heavy, mostly used for small chutes.
● Liner-embedded chutes fix wear-resistant liners to the steel base via bolts, allowing individual replacement of worn liners for easy maintenance. This is the mainstream structure for large chutes.
● Bonded types are mostly used for ceramic tile wear-resistant chutes, with simple construction and suitable for wear-resistant modification of irregularly shaped chutes.
● Hardfaced types build up alloy wear-resistant layers on the chute working surface through hardfacing, offering flexible processing, on-site construction and modification capabilities, low cost, and suitability for upgrading ordinary chutes for wear resistance.
Analysis of Wear Mechanisms of Wear-resistant Chutes
The wear of wear-resistant chutes is a complex dynamic process, with varying wear mechanisms under different working conditions, mainly divided into the following four categories:
Erosive Wear Erosive wear is the most common form of wear in wear-resistant chutes. When high-speed flowing bulk materials move along the chute surface, material particles continuously impact and cut the working surface, causing continuous plastic deformation and spalling of the surface material, eventually leading to wear. The degree of erosive wear is directly related to material flow velocity, particle hardness, particle shape, and impact angle: the faster the flow velocity, the faster the wear rate (generally, wear amount is proportional to the 3rd-4th power of flow velocity); the higher the particle hardness and the sharper the edges, the stronger the cutting effect on the chute surface, resulting in more severe wear. At impact angles of 15°-30°, cutting wear dominates with the highest wear amount; when the impact angle approaches 90°, impact fatigue wear dominates, with relatively lower overall wear.
Abrasive Wear When multiple material particles slide relative to the chute surface, hard particles trapped between the material and the working surface act as abrasives to cut and scrape the surface, causing gradual removal of the surface material. This type of wear mostly occurs at the bottom and side bends of the chute, where materials accumulate and flow. The degree of abrasive wear is directly related to the content of hard impurities and particle size in the material. Hard materials such as iron ore and quartz sand cause far more abrasive wear on chutes than soft materials like raw coal and grain.
Impact Wear At the feed inlets and bends of chutes with large drops, materials fall from heights and directly impact the working surface. Repeated impacts cause fatigue cracks in the chute surface material, which expand continuously, leading to material spalling and the formation of pits—this is impact wear. Impact wear is most prominent in feed chutes of large mining crushing stations, where impacts from large ore blocks not only cause wear but may even lead to structural deformation and cracking of the chute.
Corrosive Wear When conveying materials containing corrosive media, such as sulfur-containing raw coal, wet ash slag, and chemical raw materials, the chute working surface is simultaneously subjected to chemical corrosion and material wear. Corrosion destroys the surface structure of the material, making it more susceptible to wear, while wear continuously removes the corroded surface, exposing new material to further corrosion. This synergistic effect significantly accelerates the wear rate of the chute. Corrosive wear mostly occurs in wet conveying conditions and chemical industries, placing higher requirements on the corrosion resistance of wear-resistant materials.
Application Scenarios
Against the backdrop of expanding bulk material conveying in China's industrial sector, market demand for wear-resistant chutes keeps rising. Driven by advances in material technology, the performance of such chutes has been steadily improved, forming a diversified product portfolio applicable to various working conditions. Technologies for composite wear-resistant materials such as bimetallic composites and ceramic composites have become increasingly mature. They not only greatly extend the service life of wear-resistant chutes but also effectively control production costs, winning wide recognition from industrial enterprises.
Currently, wear-resistant chutes are extensively used in ten-million-ton coal mines, large metallurgical mines and thermal power plants. For most enterprises, the service life of equipment has been prolonged from the original 3–6 months to 2–5 years after replacement. This has substantially cut maintenance costs and production downtime losses, delivering remarkable economic benefits.
The future development of wear-resistant chutes mainly focuses on three directions. First, composite material design. New wear-resistant structures like ceramic-metal composites and rubber-ceramic composites will be developed to combine the merits of different materials, balancing wear resistance and toughness and overcoming the performance limitations of single materials. Second, customized solutions. Wear liners with different thicknesses and materials will be tailor-made for specific operating conditions of individual enterprises, along with optimized structural design, to further improve cost performance and reduce the total life-cycle cost. Third, intelligent monitoring. Wear detection sensors will be embedded in wear liners to monitor the remaining thickness of the wear layer in real time and issue early warnings for excessive wear. This helps prevent production accidents caused by sudden penetration and material leakage, and upgrades the overall intelligent operation and maintenance level.
Company Introduction
Tangshan Runxing Machinery Co., Ltd., a professional manufacturer located in Tangshan, Hebei Province that focuses on R&D, production and on-site construction service of hardfacing wear-resistant metal products, was founded in 2010.
Our main products include chromium carbide overlay (CCO) wear plates, custom processed wear liners, wear-resistant pipes and pipe fittings, hardfacing flux-cored welding wires, automatic hardfacing welding machines, and professional roller surfacing repair service. We follow the business idea of “Integrity, Superior Quality, Innovation & Sustainable Development” and own mature advanced metal surface hardfacing technology.
We provide customized wear-resistant solutions for cement, steel, mining, port and dredging industries around the world, and have gained good market reputation in Russia and Central Asia.
All export business is fully authorized and handled by Hebei Yuwan International Trade Co., Ltd. This trading company completes all export work including customs clearance, shipment, documents and payment collection. Our factory focuses on product development and production to ensure stable product quality and on-time delivery.
Runxing Machinery sincerely hopes to establish long-term cooperation and achieve mutual benefit with you!
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FAQ
A:Of course, we can provide customers with free samples but customer should pay the courier fee.
A:Please kindly provide the grade, width, thickness, surface treatment requirement and quantities you need to purchase.
A:Prices various according to periodic price changes of raw materials.
A: 30% T/T in advance ,balance before shipment