Since the 1920s, humans have used raw cement, experienced 100 years of bottle kiln, vertical kiln and mechanical shaft kiln. In the 1920s, we entered the kiln period. Since then, bearings that support and maintain rotation have also become one of the key components in the cement industry. It was more than 30 years since the establishment of Timken in 1899.
The precalciner kiln (PC), also known as the new dry process kiln, appeared around 1980, which has doubled the capacity of the dry suspension preheater kiln (SP) that has replaced the wet kiln. The maximum capacity of each production line can be reached today. 13,000 tons / day. At the same time, Timken, which has 110 years of bearing manufacturing and more than 90 years of high-quality alloy steel manufacturing history, has applied bearings to various equipments in the cement industry, leading the technology in the bearing industry with high quality and high reliability products. progress.
Today, Timken is transforming its business strategy into an industrial market as a powerful engineering company dedicated to industrial technology, products and services that provides outstanding friction management and power transmission solutions for a wide range of industries. As the core, as one of the important businesses in the industrial market, we are also committed to providing higher quality products for the cement industry.
As early as 2007, the National Development and Reform Commission issued eight measures to strengthen energy conservation and emission reduction, including increasing structural adjustment, advancing technological progress, strengthening energy conservation and consumption reduction, promoting the development of circular economy, and strengthening pollution prevention and control. It clearly pointed out that the cement industry should eliminate backward production capacity and apply new production technologies to control energy consumption and strengthen energy conservation and emission reduction and pollution control. This is a sustainable development path for the cement industry. On this road, Timken's solution has been and will help the cement industry's new force.
Before introducing the high-tech bearing product technology solutions used in the cement industry, let us look at two examples of the cement industry to illustrate the contribution of new technology applications to energy conservation.
Compared with the new dry-process cement kiln, the machine shaft kiln converts 60 million tons of annual cement clinker demand, saves more than 1 million tons of standard coal per year, saves more than 7 million tons of limestone, and can save about 20,000 mu of land. (Excerpted from the special plan for cement industry development in Zhejiang Province during the 11th Five-Year Plan)
The cement clinker dry production line with a capacity of 5,000 tons/day is equipped with a low-temperature waste heat power generation system. The annual operation is 7000h, the clinker power generation is 33.7KWh, the annual power generation is 5411x104KWh, and the annual power supply is 4924x104KWh. According to the large-scale thermal power plant, the power generation efficiency is 0.383Kg. The standard coal/KWh calculation saves 18,859 tons of standard coal and reduces the annual carbon dioxide emissions by 47,148 tons. (Excerpted from Song Jiyuan's "Experience in the Project of Cement Waste Heat Power Generation General Contracts")
Product technical features of high reliability bearing solutions
Imagine if a highly reliable bearing solution can bring great value?
Let us explain the technical characteristics of Timken's products as an example:
- Pure bearing steel material - optimized contact profile design - high standard surface roughness
1. Pure bearing steel material
Since 1917, Timken has established its own steel mill to better control the source of bearing quality, and mainly supplies steel to its own bearing manufacturing plant. With the rise and rapid development of computer technology, from the beginning of the 1980s, as you can see in Figure 1, Timken ® bearing steel purity continue to a new level. Due to the improved purity of the bearing steel, the probability of bearing failure due to internal impurities is greatly reduced. Tests have confirmed that the effective life of the bearing can be doubled compared to Other similar bearings under the same operating conditions. Obviously, the life of bearings and equipment can be improved, and reliable operation for a longer period of time undoubtedly provides direct benefits for cement manufacturers.
Figure 1 Continuous improvement of bearing materials
2. Optimized contact profile design
We know that eccentric high loads are inevitable during the operation of cement equipment. Not only that, as the requirements for equipment energy consumption standards continue to increase, the size of equipment and bearings is limited to a smaller range. To this end, Timken has adopted an optimized contact profile geometry. As shown in Fig. 2, due to the multi-radius contact profile design, the stress in the bearing contact zone is effectively equalized, avoiding local stress concentration and leading to premature failure. As shown in Figure 3, the corresponding experiment can prove that Timken's optimized contact profile geometry can improve bearing life by up to 4 times under severe conditions. Then, on the other hand, we can reduce the design size of parts, reduce the weight of equipment, and reduce the running energy. In addition, it saves original equipment manufacturers manufacturing costs and increases profit margins.
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