Grinding composition, high-adhesion composite blended oil, preparation method of high-adhesion composite blended oil and non-stop repair method for abnormal wear of riding wheel shaft of rotary cement kiln

Abstract

The invention provides a grinding composition, high-adhesion composite blended oil, a preparation method of the high-adhesion composite blended oil and a non-stop repair method for abnormal wear of a rotary cement kiln riding wheel shaft, and relates to the technical field of rotary kiln riding wheel shaft repair. Under the condition that compressed air purging and cooling are ineffective, firstly, online grinding and repairing are achieved through the grinding composition, then an oil film which still keeps high viscosity and high adhesiveness at the high temperature is formed through the high-adhesion composite blending oil, and then repairing of the rotary kiln riding wheel shaft is achieved. According to the repairing method, online repairing can be conducted on the riding wheel shaft which is abnormally abraded when the rotary cement kiln is completely kept in the running state, the problem of economic losses caused by shutdown repairing in a traditional scheme is solved, and the economic benefits of enterprises are effectively improved.

Description

Technical Field

[0001] This invention relates to the field of rotary kiln support roller shaft repair technology, and in particular to a grinding composition, a high-adhesion composite blending oil and its preparation method, and a method for repairing abnormal wear of cement rotary kiln support roller shafts without shutting down the kiln. Background Technology

[0002] Rotary kilns are core thermal equipment in industries such as cement and metallurgy, and their stable operation is crucial for production continuity. As key components supporting the kiln body and transmitting loads, the lubrication condition of the roller bearings (sliding bearings) directly determines the safety and reliability of the equipment's operation. In actual production, due to kiln body movement, uneven loads, installation deviations, and long-term wear, roller bearings often experience abnormal overheating. If not handled properly, this can easily develop into severe "wire-drawing" wear, or even "bearing burnout" or "bearing overturning" accidents, leading to unplanned downtime and significant economic losses.

[0003] Currently, the industry mainly uses three methods to deal with the problem of overheating of roller bearings, but all of them have significant defects. (1) Shutting down and scraping the bearing is a common post-processing method. When the bearing temperature is abnormally high and it is determined to be wire-drawing wear, the kiln must be stopped for disassembly and scraping. In severe cases, the bearing needs to be replaced or the shaft needs to be processed offline. This method not only causes serious economic losses, but also only physically repairs the surface morphology and fails to improve the lubrication conditions under extreme working conditions, which is only a temporary solution. After the equipment is restarted, wear may still occur again under the same working conditions. (2) Using the method of strengthening lubricating oil cooling and oil replacement, the temperature is controlled by external cooling or replacing the oil. However, this method only deals with the temperature result and fails to eliminate the root cause of frictional heat generation. More seriously, the viscosity-temperature characteristics of traditional mineral-based roller oil have inherent defects. Taking ISO VG 1500 grade mineral oil as an example, the kinematic viscosity is about 1500 cSt at 40℃, but when it reaches about 80℃, its viscosity will drop sharply to 260~310 cSt. The viscosity collapse at such high temperatures will directly lead to a serious reduction in the strength and thickness of the oil film. Not only will it fail to effectively isolate the friction surfaces, but it will also exacerbate wear and heat generation, forming a vicious cycle. In addition, frequent oil changes will also result in high operating costs. (3) Water cooling method: The negative impact of water cooling method is more prominent. Water will wash away and dilute the lubricating oil on the friction pair surface, destroying its film-forming ability; at the same time, water adheres to the shaft, and the roller oil cannot penetrate and adhere well to the shaft. Water carries away the lubricating oil and cannot rebuild the oil film. Water cannot replace lubrication, which will lead to increased shaft wear.

[0004] In summary, none of the existing technologies have solved the technical problem of "how to dynamically rebuild and maintain an effective lubricating oil film during continuous operation of the equipment after the initial wear of the roller bearing has occurred".

[0005] Therefore, it is both necessary and urgent to research and develop a method that can repair worn bearings through the synergy of a special lubricating medium and a repair process while the rotary kiln is in continuous operation, thereby avoiding unplanned downtime and ensuring long-term stable operation of the equipment.

[0006] In view of this, the present invention is hereby proposed. Summary of the Invention

[0007] The primary objective of this invention is to provide a method for repairing abnormally worn support roller shafts in cement rotary kilns without shutting down the kiln. This method allows for online repair of abnormally worn support roller shafts while the cement rotary kiln is fully operational, avoiding the economic losses caused by the need for shutdown repairs in traditional solutions and effectively improving the economic benefits for enterprises.

[0008] A second objective of this invention is to provide a grinding composition for repairing abnormal wear of the support roller shaft of a cement rotary kiln without shutting down the kiln.

[0009] A third objective of this invention is to provide a method for preparing a grinding composition for repairing abnormal wear of the support roller shaft of a cement rotary kiln without shutting down the kiln.

[0010] The fourth objective of this invention is to provide a high-adhesion composite blending oil for repairing abnormal wear of the support roller shaft of a cement rotary kiln without shutting down the machine.

[0011] The fifth objective of this invention is to provide a method for preparing a high-adhesion composite blending oil for repairing abnormal wear of the support roller shaft of a cement rotary kiln without shutting down the machine.

[0012] In order to achieve the above-mentioned objectives of the present invention, the following technical solution is adopted: This invention provides a method for repairing abnormal wear of the support roller shaft of a cement rotary kiln without shutting down the kiln, the method comprising: S1: When abnormal wear occurs on the roller shaft of the cement rotary kiln, compressed air is used to blow and cool the friction area while the rotary kiln is running. Abnormal wear of the support roller shaft in cement rotary kiln refers to the following: when the monitored support roller temperature rises to 60~65℃ and continues to rise by 2~5℃ per minute, it indicates abnormal wear of the support roller shaft in cement rotary kiln. S2: If the temperature is not controlled and continues to rise to the warning temperature after step S1, stop the compressed air cooling; spray cooling water to cool the friction points on the inner shaft surface of the roller, and apply the grinding composition to the high temperature points during the cooling process. Once the inner shaft surface of the support roller has cooled to the target temperature and there is no oil film on the shaft surface, grind until it is colored, then stop applying the grinding composition. S3: Spray high-adhesion composite blended oil onto the shaft while simultaneously cooling it. Once the shaft surface is covered with a film of high-adhesion composite blended oil, turn off the cooling water to complete the oil film repair. S4: Add standard roller lubricating oil to increase the speed of operation. After the working speed is restored, the rotary kiln roller shaft repair is completed.

[0013] Furthermore, during the repair process, the cement rotary kiln is in a rotating state, and the operating speed of the cement rotary kiln is ≥2.4 r / min.

[0014] Furthermore, the warning temperature in step S2 is 68~72℃; And / or, the target temperature in step S2 is 40~45℃.

[0015] Furthermore, the application cycle of the grinding composition in S2 is 1-2 minutes, and the amount applied each time is 180-220g.

[0016] Furthermore, the spraying cycle of the high-adhesion composite blending oil sprayed on the support shaft by S3 is 3-4 minutes, and the spraying amount each time is 250-280g.

[0017] The present invention provides a grinding composition for repairing abnormal wear of a cement rotary kiln support roller shaft without shutting down the kiln. The grinding composition comprises, by weight percentage: Alumina 3-5%, rosin 8-12%, lithopone 55-65%, MoS 25-7%, balance is high viscosity lubricating oil; The sum of the mass percentages of all components in the grinding composition is 100%.

[0018] Furthermore, the high-viscosity lubricating oil is a mineral base oil with a viscosity of 1500~1600 cSt at 40°C.

[0019] The present invention provides a method for preparing the above-mentioned grinding composition, the method comprising: Alumina, rosin, lithopone, and MoS2 are added to high-viscosity lubricating oil and mixed thoroughly to obtain a grinding composition.

[0020] This invention provides a high-adhesion composite blending oil for repairing abnormal wear of cement rotary kiln support roller shafts without shutting down the kiln. The high-adhesion composite blending oil comprises, by weight percentage: Petroleum asphalt 50-54%, rosin 16-19%, MoS 25-7%, graphite 1-2%, with the balance being high-viscosity lubricating oil; The sum of the mass percentages of all components in the high-adhesion composite blended oil is 100%.

[0021] Furthermore, the high-viscosity lubricating oil is a mineral base oil with a viscosity of 1500~1600 cSt at 40°C; And / or, the high-adhesion composite blended oil has a viscosity of 650~680 cSt at 100°C.

[0022] This invention provides a method for preparing the above-mentioned high-adhesion composite blended oil, the preparation method comprising: (A) Asphalt pretreatment: Heat the petroleum asphalt to the first temperature, filter out impurities, and set aside for use; (B) Solid lubricant dispersion: Under the second temperature condition, MoS2 and graphite are added sequentially and stirred to form a mixture; (C) Gradient mixing: The rosin is heated to the third temperature, impurities are filtered out, and it is added to the mixture in step (B). The mixture is stirred to form a homogeneous viscous matrix. (D) Viscosity adjustment: Cool the homogeneous viscous matrix to the fourth temperature, mix in high-viscosity lubricating oil, keep warm and stir to obtain high-adhesion composite blended oil.

[0023] Furthermore, in step (A), the first temperature is 138~142℃; And / or, the second temperature in step (B) is 128~132℃; And / or, in step (B), the stirring speed is 190~210 rpm and the stirring time is 15~18 min; And / or, the third temperature in step (C) is 108~112℃; And / or, in step (C), the stirring speed is 190~210 rpm and the stirring time is 30~32 min; And / or, the fourth temperature in step (D) is 100~105℃; And / or, in step (D), the stirring speed is 190~210 rpm and the stirring time is 20~22 min.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention provides a method for repairing abnormally worn support roller shafts in cement rotary kilns without shutting down the kiln. When compressed air purging and cooling are ineffective, the method first utilizes a grinding composition for online grinding and repair. Then, a high-adhesion composite blended oil is used to form an oil film that maintains high viscosity and strong adhesion even at high temperatures, thereby repairing the rotary kiln support roller shaft. This method allows for online repair of abnormally worn support roller shafts while the cement rotary kiln is fully operational, avoiding the economic losses caused by downtime repairs required by traditional methods, and effectively improving the economic benefits for enterprises.

[0025] The present invention provides a grinding composition for repairing abnormal wear of cement rotary kiln support roller shaft without stopping the machine. The grinding composition, through the synergistic effect of multiple components including alumina, MoS2, rosin, lithopone and high viscosity base oil, can complete the surface reshaping and lubrication of the rotary kiln support roller shaft without stopping the equipment operation, providing a smooth, clean shaft surface foundation with good adhesion activity for the subsequent formation of a high-strength lubricating oil film.

[0026] This invention provides a high-viscosity composite blended oil for non-stop repair of abnormal wear on the support roller shaft of a cement rotary kiln. The high-viscosity composite blended oil, through the synergistic function of petroleum asphalt, rosin, molybdenum disulfide, graphite and high-viscosity base oil, exhibits good coating and film-forming properties on the smooth shaft surface pretreated by the above-mentioned grinding composition. It can ultimately form a stable composite lubricating film, thereby achieving non-stop repair of abnormal wear on the support roller shaft of the cement rotary kiln. Attached Figure Description

[0027] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0028] Figure 1 Photographs of the Φ4.3m*62m rotary kiln before repair, provided in Experimental Example 1 of this invention; Figure 2 Photographs of the film attached to the Φ4.3m*62m rotary kiln after repair, provided in Experimental Example 1 of this invention. Detailed Implementation

[0029] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] This invention provides a method for repairing abnormal wear of the support roller shaft of a cement rotary kiln without shutting down the kiln, the method comprising: S1: When abnormal wear occurs on the roller shaft of the cement rotary kiln, compressed air is used to blow and cool the friction area while the rotary kiln is running. Abnormal wear of the support roller shaft in cement rotary kiln refers to the following: when the monitored support roller temperature rises to 60~65℃ and continues to rise by 2~5℃ per minute, it indicates abnormal wear of the support roller shaft in cement rotary kiln. S2: If the temperature is not controlled and continues to rise to the warning temperature after step S1, stop the compressed air cooling; spray cooling water to cool the friction points on the inner shaft surface of the roller, and apply the grinding composition to the high temperature points during the cooling process. Once the inner shaft surface of the support roller has cooled to the target temperature and there is no oil film on the shaft surface, grind until it is colored, then stop applying the grinding composition. S3: Spray high-adhesion composite blended oil onto the shaft while simultaneously cooling it. Once the shaft surface is covered with a film of high-adhesion composite blended oil, turn off the cooling water to complete the oil film repair. S4: Add standard roller lubricating oil to increase the speed of operation. After the working speed is restored, the rotary kiln roller shaft repair is completed.

[0031] This invention provides a method for repairing abnormally worn support roller shafts in cement rotary kilns without shutting down the kiln. When compressed air purging and cooling are ineffective, the method first utilizes a grinding composition for online grinding and repair. Then, a high-adhesion composite blended oil is used to form an oil film that maintains high viscosity and strong adhesion even at high temperatures, thereby repairing the rotary kiln support roller shaft. This method allows for online repair of abnormally worn support roller shafts while the cement rotary kiln is fully operational, avoiding the economic losses caused by downtime repairs required by traditional methods, and effectively improving the economic benefits for enterprises.

[0032] In a preferred embodiment of the present invention, during the repair process, the cement rotary kiln is in a rotating state, and the operating speed of the cement rotary kiln is ≥2.4 r / min.

[0033] In a preferred embodiment of the present invention, the warning temperature in step S2 is 68~72℃; In a preferred embodiment of the present invention, the target temperature in step S2 is 40~45°C.

[0034] In a preferred embodiment of the present invention, the application cycle of the grinding composition in S2 is 1-2 minutes, and the amount applied each time is 180-220g.

[0035] In a preferred embodiment of the present invention, the spraying cycle of the high-adhesion composite blending oil sprayed on the support shaft by S3 is 3-4 minutes, and the spraying amount each time is 250-280g.

[0036] The present invention provides a grinding composition for repairing abnormal wear of a cement rotary kiln support roller shaft without shutting down the kiln. The grinding composition comprises, by weight percentage: Alumina 3-5%, rosin 8-12%, lithopone 55-65%, MoS 25-7%, balance is high viscosity lubricating oil; The sum of the mass percentages of all components in the grinding composition is 100%.

[0037] The present invention provides a grinding composition for repairing abnormal wear of cement rotary kiln support roller shaft without stopping the machine. The grinding composition, through the synergistic effect of multiple components including alumina, MoS2, rosin, lithopone and high viscosity base oil, can complete the surface reshaping and lubrication of the rotary kiln support roller shaft without stopping the equipment operation, providing a smooth, clean shaft surface foundation with good adhesion activity for the subsequent formation of a high-strength lubricating oil film.

[0038] It should be noted that the functions of each component in the above grinding composition are as follows: Alumina: As a hard abrasive, it can micro-grind high wear points during shaft rotation, remove burrs and wire marks, and restore the flatness of the shaft surface.

[0039] Rosin: It has good adhesion and permeability, which can carry abrasive and lubricating components into the bearing gap. At the same time, it softens at high temperature and helps solid lubricants such as MoS2 to adhere.

[0040] Lithol: As a colorant, it facilitates observation of whether the grinding area is evenly covered, ensuring that the grinding process is controllable and visible.

[0041] MoS2: During the grinding process, it gradually fills microcracks and low points to form a solid lubricating layer, which works in conjunction with the subsequent compound blending oil to construct a composite lubricating film.

[0042] High-viscosity lubricating oil serves as a carrier, ensuring uniform dispersion of all components and providing lubrication while facilitating coating.

[0043] This application achieves excellent grinding effect through the synergistic effect of the above-mentioned raw materials, while having moderate adhesion and good permeability of the inner shaft surface of the support roller, thus providing a smooth and clean shaft surface base for the subsequent coating of the compound blending oil.

[0044] In a preferred embodiment of the present invention, the high-viscosity lubricating oil is a mineral base oil with a viscosity of 1500~1600 cSt at 40°C.

[0045] The present invention provides a method for preparing the above-mentioned grinding composition, the method comprising: Alumina, rosin, lithopone, and MoS2 are added to high-viscosity lubricating oil and mixed thoroughly to obtain a grinding composition.

[0046] This invention provides a high-adhesion composite blending oil for repairing abnormal wear of cement rotary kiln support roller shafts without shutting down the kiln. The high-adhesion composite blending oil comprises, by weight percentage: Petroleum asphalt 50-54%, rosin 16-19%, MoS 25-7%, graphite 1-2%, with the balance being high-viscosity lubricating oil; The sum of the mass percentages of all components in the high-adhesion composite blended oil is 100%.

[0047] This invention provides a high-viscosity composite blended oil for non-stop repair of abnormal wear on the support roller shaft of a cement rotary kiln. The high-viscosity composite blended oil, through the synergistic function of petroleum asphalt, rosin, molybdenum disulfide, graphite and high-viscosity base oil, exhibits good coating and film-forming properties on the smooth shaft surface pretreated by the above-mentioned grinding composition. It can ultimately form a stable composite lubricating film, thereby achieving non-stop repair of abnormal wear on the support roller shaft of the cement rotary kiln.

[0048] It should be noted that the functions of each component in the above-mentioned high-adhesion compound blended oil are as follows: Petroleum asphalt: softens at 45~60℃, forming a viscoelastic film that fills micro-damage on the axial surface and enhances the film thickness and load-bearing capacity.

[0049] Rosin: Improves the adhesion and penetration of oil, helps solid lubricants enter the wear area, and forms a stable oil film after evaporation.

[0050] MoS2: The layered structure is oriented under pressure to form a high-strength solid lubricant layer.

[0051] Graphite: Its high thermal conductivity helps dissipate heat and forms a high-temperature resistant support layer.

[0052] High viscosity lubricating oil: Adjusts the viscosity for application to ensure the oil remains fluid at high temperatures, facilitating circulation.

[0053] In a preferred embodiment of the present invention, the high-adhesion composite blended oil has a viscosity of 650~680 cSt at 100°C.

[0054] In a preferred embodiment of the present invention, the high-viscosity lubricating oil is a mineral base oil with a viscosity of 1500~1600 cSt at 40°C; This invention provides a method for preparing the above-mentioned high-adhesion composite blended oil, the preparation method comprising: (A) Asphalt pretreatment: Heat the petroleum asphalt to the first temperature, filter out impurities, and set aside for use; (B) Solid lubricant dispersion: Under the second temperature condition, MoS2 and graphite are added sequentially and stirred to form a mixture; (C) Gradient mixing: The rosin is heated to the third temperature, impurities are filtered out, and it is added to the mixture in step (B). The mixture is stirred to form a homogeneous viscous matrix. (D) Viscosity adjustment: Cool the homogeneous viscous matrix to the fourth temperature, mix in high-viscosity lubricating oil, keep warm and stir to obtain high-adhesion composite blended oil.

[0055] As an optional implementation, the first temperature range in step (A) is 138~142℃, for example, it can be 138℃, 139℃, 140℃, 141℃, 142℃, or any value between 138~142℃; As an optional implementation, the second temperature range in step (B) is 128~132℃, for example, it can be 128℃, 129℃, 130℃, 131℃, 132℃, or any value between 128~132℃; As an optional implementation, the stirring speed in step (B) is 190~210 rpm, for example, it can be 190 rpm, 200 rpm, 210 rpm, or any value between 190~210 rpm, and the stirring time can be 15~18 min; As an optional implementation, the third temperature range in step (C) is 108~112℃, for example, it can be 108℃, 109℃, 110℃, 111℃, 112℃, or any value between 108~112℃; As an optional implementation, the stirring speed in step (C) is 190~210 rpm, for example, it can be 190 rpm, 200 rpm, 210 rpm, or any value between 190~210 rpm, and the stirring time can be 30~32 min; As an optional implementation, the fourth temperature in step (D) can be 100~105°C; As an optional implementation, the stirring speed in step (D) is 190~210 rpm, for example, it can be 190 rpm, 200 rpm, 210 rpm, or any value between 190~210 rpm, and the stirring time can be 20~22 min.

[0056] The technical solution of the present invention will be further described below with reference to the embodiments.

[0057] Examples 1-3 A grinding composition for repairing abnormal wear of the support roller shaft of a cement rotary kiln without shutting down the machine, the composition of the grinding composition by mass percentage is shown in Table 1.

[0058] Table 1. Composition of the grinding compositions in Examples 1-3:

[0059] The method for preparing the grinding composition includes: mixing the raw materials of each of the above embodiments to prepare the grinding compositions of each embodiment.

[0060] Examples 4-6 A high-adhesion composite blending oil for repairing abnormal wear of cement rotary kiln support roller shafts without shutting down the kiln. The composition of the high-adhesion composite blending oil by mass percentage is shown in Table 2.

[0061] Table 2. Composition of the high-adhesion composite blended oils in Examples 4-6:

[0062] The preparation method of the high-adhesion composite blended oil includes: 1. Asphalt pretreatment: Heat the petroleum asphalt to 140±2℃ and filter impurities through an 80-mesh screen.

[0063] 2. Solid lubricant dispersion: MoS2 and graphite are added sequentially at 130±2℃ and stirred for 15 minutes (200±10 rpm) to form a mixture; 3. Gradient mixing: Heat rosin to 110±2℃, filter impurities through an 80-mesh screen, add it, and stir for 30 minutes (200±10 rpm) to form a homogeneous viscous matrix.

[0064] 4. Viscosity adjustment: After cooling to 100℃, mix in 1500 base oil, keep warm and stir for 20 minutes. The final product viscosity at 100℃ is controlled at 650±10mm² / s.

[0065] Comparative Examples 1-3 A grinding composition for repairing abnormal wear of the support roller shaft of a cement rotary kiln without shutting down the machine, the composition of the grinding composition by mass percentage is shown in Table 3.

[0066] Table 3. Composition of the grinding compositions in Comparative Examples 1-3:

[0067] The preparation method is the same as in Examples 1-3.

[0068] Comparative Examples 4-6 A high-adhesion composite blending oil for repairing abnormal wear of cement rotary kiln support roller shafts without shutting down the kiln. The composition of the high-adhesion composite blending oil by mass percentage is shown in Table 4.

[0069] Table 4. Composition of high-adhesion composite blended oils in Comparative Examples 4-6:

[0070] The preparation method of the high-adhesion composite blended oil is the same as in Examples 4-6.

[0071] Example 7 A method for repairing abnormal wear of a cement rotary kiln support roller shaft without shutting down the kiln, the repair method comprising: 1. When the temperature alarm of the monitored roller rises to 60°C and continues to rise by 2°C per minute, compressed air is used to blow and cool the friction area while the rotary kiln is running. If the temperature of the roller does not decrease, and there are localized areas without oil film on the shaft surface, and the temperature continues to rise to 70°C, turn off the compressed air cooling. 2. Cool the inner shaft surface of the support roller by spraying cooling water onto the friction points. Then drain the oil and water. During the cooling process, apply the grinding composition of Example 1 to the high-temperature points at intervals of 200 grams every minute. Control the kiln speed at 2.6 r / min and continue to apply for 60 minutes. When the temperature drops to 40°C by spraying water, grind the areas on the shaft surface without oil film until they are colored, and then stop applying the grinding composition. 3. Apply the high-adhesion composite blended oil prepared in Example 4 to the bearing shaft, applying 250 grams every 3 minutes. Continue the operation until the temperature drops to (cooling water temperature + 18°C). When the bearing surface is covered with a composite oil film, turn off the cooling water and drain the cooling water inside the bearing roller to complete the oil film repair. Add lubricating oil to the support rollers according to the usual standard. After running for 2 hours, if the temperature does not rise and fluctuates within 1°C, the kiln speed can be increased by 0.2-0.5 r / min every 2 hours until it returns to normal speed.

[0072] Example 8 This embodiment is the same as Example 7 except that "Example 1 grinding composition" is replaced with "Example 2 grinding composition" in step 2.

[0073] Example 9 This embodiment is the same as Example 7 except that "Example 1 grinding composition" is replaced with "Example 3 grinding composition" in step 2.

[0074] Comparative Example 7 This comparative example is the same as Example 7, except that "Example 1 grinding composition" in step 2 is replaced with "Comparative Example 1 grinding composition".

[0075] Comparative Example 8 This comparative example is the same as Example 7, except that "Example 1 grinding composition" in step 2 is replaced with "Comparative Example 2 grinding composition".

[0076] Comparative Example 9 This comparative example is the same as Example 7, except that "Example 1 grinding composition" in step 2 is replaced with "Comparative Example 3 grinding composition".

[0077] Example 10 This embodiment is the same as in Example 7, except that "Example 4 high-adhesion composite blending oil" in step 3 is replaced with "Example 5 high-adhesion composite blending oil".

[0078] Example 11 This embodiment is the same as in Example 7, except that "Example 4 high-adhesion composite blending oil" in step 3 is replaced with "Example 6 high-adhesion composite blending oil".

[0079] Comparative Example 10 This embodiment is the same as Example 7, except that "Example 4 high-adhesion composite blending oil" in step 3 is replaced with "Comparative Example 4 high-adhesion composite blending oil".

[0080] Comparative Example 11 This embodiment is the same as Example 7, except that "Example 4 high-adhesion composite blending oil" in step 3 is replaced with "Comparative Example 5 high-adhesion composite blending oil".

[0081] Comparative Example 12 This embodiment is the same as in Example 7, except that "Example 4 high-adhesion composite blending oil" in step 3 is replaced with "Comparative Example 6 high-adhesion composite blending oil".

[0082] Experimental Example 1 This experimental example demonstrates how the abnormal wear of the cement rotary kiln support roller shaft in our Φ4.3m*62m rotary kiln was repaired using the non-stop repair method described in Example 7. Specific procedures are detailed in Table 5.

[0083] Table 5. Specific operating procedures and key control parameters:

[0084] Figure 1 The photograph of the film attached to the Φ4.3m*62m rotary kiln before repair is provided for this experimental example; Figure 2 Photographs of the film attached to the Φ4.3m*62m rotary kiln after repair, provided for this experimental example; In this experimental example, the operational effects of the "Grinding Composition of Example 1" and "High Adhesion Composite Blending Oil of Example 4" used in Example 7 were recorded during the non-stop repair process. See Tables 6 and 7 for details.

[0085] Table 6. Test results after treatment with the grinding composition of Example 1:

[0086] Table 7. Test results of high-adhesion composite blended oil after film formation in Example 4, after 2 hours of operation:

[0087] Experimental Example 2 This experimental example verifies the composition of the "grinding composition" and the "high-adhesion composite blending oil" when the applicant experiences abnormal wear of the support roller shaft in a Φ4.3m*62m rotary kiln. Specifically: (a) Examples 8 and 9 and Comparative Examples 7 to 9 are experiments to verify the composition of the "grinding composition". The specific results are shown in Table 8.

[0088] Table 8. Test results after treatment with the grinding compositions of Examples 2 and 3:

[0089] In contrast, Comparative Example 1, which did not contain alumina, showed the following results: it could not effectively remove high points on the shaft surface; after grinding for 60 minutes, the shaft temperature was still above 50°C; the coloring was uneven; and the film formation failed.

[0090] The MoS2 content of Comparative Example 2 was too high (10%), resulting in: the abrasive being too viscous and difficult to coat evenly, the shaft temperature dropping slowly, and the subsequent coating layer easily falling off.

[0091] The resin content of Comparative Example 3 was too low (5%), resulting in poor permeability, the abrasive could not effectively enter the gaps between the tiles, poor grinding effect, and continuous rise in shaft temperature.

[0092] As shown in the above comparative examples 1 to 3, the components of the grinding composition of this application need to work synergistically within a specific range. Exceeding or missing a certain key component will lead to repair failure.

[0093] (ii) Examples 10 and 11 and Comparative Examples 10 to 12 are experiments to verify the composition of the "high-adhesion composite blended oil". The specific results are shown in Table 9.

[0094] Table 9. Test results of high-adhesion composite blended oils in Examples 10 and 11 after film formation for 2 hours:

[0095] In contrast, Comparative Example 10 had an excessively low petroleum asphalt content (45%), resulting in an excessively thin oil film that could not effectively fill the wear, causing the shaft temperature to quickly rise to over 60°C.

[0096] Comparative Example 11, lacking graphite, exhibited poor heat dissipation, leading to localized overheating of the oil film and subsequent MoS2 failure. After the film formation, the temperature fluctuated significantly, with the temperature ranging from 48-55℃ fluctuating depending on the rotary kiln's production rate and speed.

[0097] Comparative Example 12 had an excessively high resin content (25%), resulting in an overly viscous oil that was difficult to flow, uneven coating, uneven shaft temperature after coating, and localized overheating.

[0098] Since the rotary kiln support rollers are lubricated by circulating oil onto the shaft using an oil ladle, the applicant conducted multiple experiments adjusting the rosin ratio based on this principle. At 25%, poor fluidity led to poor oil distribution, resulting in uneven coating and ultimately localized overheating. The temperature of the coated areas did not exceed 48°C, while the temperature of the uncoated areas exceeded 48°C. Therefore, the rosin content in the high-adhesion composite blended oil of this application should be controlled between 16% and 19%.

[0099] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for repairing abnormal wear of a cement rotary kiln roller shaft without stopping the operation, characterized in that, The method includes: S1: When abnormal wear occurs on the roller shaft of the cement rotary kiln, compressed air is used to blow and cool the friction area while the rotary kiln is running. Abnormal wear of the support roller shaft in cement rotary kiln refers to the following: when the monitored support roller temperature rises to 60~65℃ and continues to rise by 2~5℃ per minute, it indicates abnormal wear of the support roller shaft in cement rotary kiln. S2: If the temperature is not controlled and continues to rise to the warning temperature after step S1, stop the compressed air cooling; spray cooling water to cool the friction points on the inner shaft surface of the roller, and apply the grinding composition to the high temperature points during the cooling process. Once the inner shaft surface of the support roller has cooled to the target temperature and there is no oil film on the shaft surface, grind until it is colored, then stop applying the grinding composition. S3: Spray high-adhesion composite blended oil onto the shaft while simultaneously cooling it. Once the shaft surface is covered with a film of high-adhesion composite blended oil, turn off the cooling water to complete the oil film repair. S4: Add standard roller lubricating oil to increase the speed of operation. After the working speed is restored, the rotary kiln roller shaft repair is completed.

2. The hotfix method of claim 1, wherein, During the repair process, the cement rotary kiln was in a rotating state.

3. The hotfix method of claim 1, wherein, The warning temperature in step S2 is 68~72℃.

4. The non-stop repair method according to claim 1, characterized in that, The target temperature in step S2 is 40~45℃.

5. The non-stop repair method according to claim 1, characterized in that, The application cycle of the grinding composition in S2 is 1-2 minutes, and the amount applied each time is 180-220g.

6. The non-stop repair method according to claim 1, characterized in that, The spraying cycle of the high-adhesion composite blending oil sprayed on the support shaft by S3 is 3-4 minutes, and the spraying amount each time is 250-280g.

7. A grinding composition for repairing abnormal wear of a cement rotary kiln support roller shaft without shutting down the kiln, characterized in that, The grinding composition comprises, by weight percentage: Alumina 3-5%, rosin 8-12%, lithopone 55-65%, MoS2 5-7%, balance is high viscosity lubricating oil; The sum of the mass percentages of all components in the grinding composition is 100%.

8. The grinding composition according to claim 7, characterized in that, The high-viscosity lubricating oil is a mineral base oil with a viscosity of 1500~1600 cSt at 40℃.

9. A method for preparing the grinding composition according to claim 7 or 8, characterized in that, The preparation method includes: Alumina, rosin, lithopone, and MoS2 are added to high-viscosity lubricating oil and mixed thoroughly to obtain a grinding composition.

10. A high-adhesion composite blending oil for non-stop repair of abnormal wear on the support roller shaft of a cement rotary kiln, characterized in that, The high-adhesion compound blending oil comprises, by weight percentage: Petroleum asphalt 50-54%, rosin 16-19%, MoS2 5-7%, graphite 1-2%, with the balance being high-viscosity lubricating oil; The sum of the mass percentages of all components in the high-adhesion composite blended oil is 100%.

11. The high-adhesion composite blended oil according to claim 10, characterized in that, The high-viscosity lubricating oil is a mineral base oil with a viscosity of 1500~1600 cSt at 40℃; And / or, the high-adhesion composite blended oil has a viscosity of 650~680 cSt at 100°C.

12. A method for preparing a high-adhesion composite blended oil according to claim 10 or 11, characterized in that, The preparation method includes: (A) Asphalt pretreatment: Heat the petroleum asphalt to the first temperature, filter out impurities, and set aside for use; (B) Solid lubricant dispersion: Under the second temperature condition, MoS2 and graphite are added sequentially and stirred to form a mixture; (C) Gradient mixing: The rosin is heated to the third temperature, impurities are filtered out, and it is added to the mixture in step (B). The mixture is stirred to form a homogeneous viscous matrix. (D) Viscosity adjustment: Cool the homogeneous viscous matrix to the fourth temperature, mix in high-viscosity lubricating oil, keep warm and stir to obtain high-adhesion composite blended oil.

13. The method for preparing the high-adhesion composite blended oil according to claim 12, characterized in that, The first temperature in step (A) is 138~142℃; And / or, the second temperature in step (B) is 128~132℃; And / or, in step (B), the stirring speed is 190~210 rpm and the stirring time is 15~18 min; And / or, the third temperature in step (C) is 108~112℃; And / or, in step (C), the stirring speed is 190~210 rpm and the stirring time is 30~32 min; And / or, the fourth temperature in step (D) is 100~105℃; And / or, in step (D), the stirring speed is 190~210 rpm and the stirring time is 20~22 min.

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