A split composite wear-resistant cone

Abstract

This utility model discloses a detachable composite wear-resistant cone, belonging to the technical field of alumina production equipment. The detachable composite wear-resistant cone of this utility model has a conical top for buffering slurry impact and an extension for embedding within a detachable base. A stepped side is formed between the conical top and the extension. The base includes a symmetrically arranged first part and a second part. When the first and second parts are assembled, they form a mating surface adapted to the stepped side and a groove adapted to the extension. The extension is embedded in the groove, and the stepped side fits snugly against the mating surface. Both the first and second parts have horizontal bolt holes at their bottoms. The first and second parts are fixed together by bolts. The base formed by the assembly of the first and second parts has a bottom surface that fits snugly against the support frame inside the flash tank. This detachable composite wear-resistant cone of this utility model has strong buffering capacity and, due to its detachable structure, is easy to replace.

Description

Technical Field

[0001] This utility model relates to the technical field of alumina production equipment, specifically to a detachable composite wear-resistant cone. Background Technology

[0002] High-pressure leaching is a key process in the Bayer process for producing alumina. The flash evaporator is the main equipment in high-pressure leaching, achieving three-phase separation of solid, liquid, and gas under certain pressure conditions. The slurry, after high-temperature and high-pressure leaching, undergoes several stages of flash evaporation, gradually reducing its temperature and pressure. The flash evaporator operates in a harsh environment involving high temperature, high pressure, high speed, and corrosive media. The slurry entering the flash evaporator contains alkaline solutions, iron oxide, silica, and other mineral particles. The slurry temperature can reach 200℃, and the pressure can reach 10MPa, exhibiting high-speed turbulent flow. This results in strong impacts, collisions, and wear on the flash evaporator tank, severely affecting its service life and directly impacting the stability and safety of the production process. To ensure normal operation, existing technologies incorporate wear-resistant cones at the bottom of the flash evaporator tank, supported by brackets. These cones buffer the strong impacts on the tank and disperse the slurry, facilitating temperature and pressure reduction and improving production efficiency. Slurry containing a large number of high-hardness, irregular ore particles enters the flash evaporator under high pressure and high speed, directly impacting the wear-resistant cone. This causes severe wear on the cone, which is also subjected to alkaline corrosion and thermal stress, resulting in insufficient service life, frequent downtime for maintenance and replacement, and low equipment operating efficiency. Furthermore, with advancements in process technology, the wear-resistant cone has been enlarged to improve leaching efficiency and effectiveness, making on-site installation or replacement extremely difficult, consuming significant manpower and resources, and further limiting the effective operating time of the equipment. Utility Model Content

[0003] The purpose of this invention is to overcome the problems in the prior art and provide a detachable composite wear-resistant cone that can buffer the direct impact on the cone, improve wear resistance, and extend the service life. At the same time, the detachable composite wear-resistant cone of this invention, with its increased structural size, is easy to install and replace, thus improving equipment utilization.

[0004] The present invention provides a detachable composite wear-resistant cone, comprising a central cone and a detachable base. The central cone has a conical top for buffering slurry impact and an extension for being embedded in the detachable base. Several protrusions are staggered on the outer surface of the conical top, and a stepped side is formed between the conical top and the extension. The base comprises a first part and a second part arranged symmetrically. The first part and the second part, when assembled, can form a mating surface adapted to the stepped side and a groove adapted to the extension. The extension is embedded in the groove, and the stepped side fits against the mating surface. The bottom of both the first part and the second part has horizontal bolt holes. The first part and the second part are fixed together by bolts. The bottom surface of the base formed by the assembly of the first part and the second part can fit against the support frame inside the flash tank.

[0005] Preferably, the boss is semi-circular or trapezoidal; the diameter of the semi-circle is 5mm~20mm; the upper base of the trapezoid is 5mm~10mm, the lower base is 10mm~20mm, and the height is 5mm~20mm. The bosses are staggered and evenly distributed along the outer surface of the top of the cone, and the distance between adjacent bosses is 10mm~30mm.

[0006] Preferably, the protrusions are integrally formed with the conical top and the extension.

[0007] Preferably, the outer surface of the conical top is the working surface, and the outer top surface of the base formed by the first part and the second part is the extension surface of the working surface.

[0008] Preferably, when the central cone is combined with the base, the working surface and the extension surface are used together to buffer the impact of the slurry, wherein the area of ​​the working surface does not exceed 2 / 3 of the total area of ​​the working surface and the extension surface.

[0009] Preferably, the bottom of the extension has a first cavity, and the area below the groove is also a second cavity. The central axes of the first cavity and the second cavity are collinear with the central axis of the overall structure formed by the combination of the central cone and the base. The volume of the first cavity and the second cavity does not exceed 1 / 3 of the overall volume of the disassembled composite wear-resistant cone.

[0010] Preferably, the central axis of the integral structure formed by the combination of the central cone and the base is collinear with the central axis of the extension and the central axis of the groove.

[0011] Preferably, the central cone is made of high-chromium wear-resistant alloy material and is integrally formed by casting process.

[0012] Preferably, both the first part and the second part are made of carbon steel or low alloy steel and are formed by casting or forging.

[0013] Preferably, the fitting accuracy between the stepped side and the mating surface, as well as between the extension and the groove, is less than 1 mm.

[0014] Compared with the prior art, the beneficial effects of this utility model are: The working surface of the central cone of this invention is provided with a boss, which increases the working surface area, buffers the direct impact on the cone, and further improves wear resistance and extends the service life. The extension of the central cone can be embedded into the groove of the assembled base, and the mating surface between the stepped side of the central cone and the assembled base together achieves a stable fit between the central cone and the assembled base. Due to its split structure, the detachable composite wear-resistant cone of this invention reduces the size and weight of the individual structure. While increasing the structural size of the wear-resistant cone, it also facilitates on-site handling, installation, disassembly and replacement, saving manpower and resources and improving equipment utilization.

[0015] Since the wear of the wear-resistant cone is mainly concentrated in the central area and the wear gradually decreases in the outer area, this utility model divides the wear-resistant cone into a central cone and a base. The central cone is made of high alloy wear-resistant material to exert high wear resistance. The base is located in the outer area and wears less. It is made of ordinary carbon steel or alloy steel and mainly exerts high strength and high toughness, improving the safety and reliability of use. The performance advantages of the two complement each other, greatly improving the overall service life and reducing operating costs. Attached Figure Description

[0016] Figure 1 This is a schematic cross-sectional view of the disassembled composite wear-resistant cone according to an embodiment of the present invention.

[0017] Figure 2 This is a schematic diagram of the structure of the present invention, showing that the boss is a semi-circular conical top.

[0018] Figure 3 This is a schematic diagram of the structure of the cone-shaped top with a trapezoidal boss in an embodiment of the present invention.

[0019] Figure 4 This is a schematic diagram of the base structure of an embodiment of the present utility model.

[0020] Figure 5 This is a schematic diagram showing the position of the detachable composite wear-resistant cone inside the flash evaporator in an embodiment of this utility model.

[0021] Explanation of reference numerals in the attached figures: 1. Central cone; 101. Conical top; 102. Extension; 103. Stepped side; 104. Working surface; 105. Boss; 2. Base; 201. First part; 202. Second part; 203. Groove; 204. Mating surface; 205. Extension surface; 3. Bolt hole; 4. Flash evaporator; 5. Support frame. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the described embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0023] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the elements or objects preceding "comprising" encompass the elements or objects listed following "comprising" or "including" and their equivalents, and do not exclude other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described objects changes, the relative positional relationship may also change accordingly.

[0024] like Figure 1 As shown, the detachable composite wear-resistant cone provided by this utility model includes a central cone 1 and a detachable base 2, as... Figure 2 and Figure 3 As shown, the central cone 1 has a conical top 101 for buffering slurry impact and an extension 102 for being embedded in a detachable base 2. Several protrusions 105 are offset on the outer surface of the conical top 101, and a stepped side 103 is provided between the conical top 101 and the extension 102; Figure 4As shown, the base 2 includes a symmetrically arranged first part 201 and a second part 202. When the first part 201 and the second part 202 are assembled, they form a mating surface 204 that adapts to the stepped side surface 103 and a groove 203 that adapts to the extension 102. The extension 102 is embedded in the groove 203, and the stepped side surface 103 is in contact with the mating surface 204. The bottom of both the first part 201 and the second part 202 has horizontal bolt holes 3. The first part 201 and the second part 202 are fixed together by bolts. The bottom surface of the base 2 formed by the assembly of the first part 201 and the second part 202 can fit against the support frame inside the flash tank. Figure 5 As shown.

[0025] As a preferred embodiment, such as Figure 2 and Figure 3 As shown, the boss 105 is semi-circular or trapezoidal in shape. The semi-circular diameter is 5mm~20mm. The upper base of the trapezoid is 5mm~10mm, the lower base is 10mm~20mm, and the height is 5mm~20mm. The bosses are staggered and evenly distributed along the outer surface of the conical top 101. The distance between adjacent bosses is 10mm~30mm. In this embodiment, the boss 105 is reasonably designed, which can increase the arrangement density, effectively expand the working contact area, and improve the heat dissipation effect and production efficiency.

[0026] like Figure 1 As shown, in this embodiment, the working surface 104 of the middle cone 1 of the disassembled composite wear-resistant cone is umbrella-shaped, with several staggered bosses 105 on it. The middle cone 1 is installed on the base 2, which is assembled from the first part 201 and the second part 202, to form a composite wear-resistant cone. In this embodiment, the middle cone 1 is made of high-chromium alloy material and is formed in one piece by casting. The bottom mating surface 204 is machined to ensure a fitting accuracy of <1mm to avoid loosening after assembly. The base 2 is made of low-alloy steel and is formed by casting. The mounting mating surface 204 is machined to ensure a fitting accuracy of <1mm. Finally, it is divided into two parts by wire cutting or laser cutting. The middle cone 1 can be removed and replaced as a whole after the first part 201 and the second part 202 of the base 2 are disassembled.

[0027] In use, place the first part 201 and the second part 202 of the base 2 on the support frame inside the flash evaporator 4, align the middle cone 1 with the groove on the base 2, and slowly lower it into the groove on the base 2 so that it is in full contact with the base 2. Finally, use a long bolt to pass through the matching hole on the base 2 to connect and tighten the two parts, and clamp and fix the middle cone 1 to form a whole. During operation, the slurry enters the flash evaporator 4 through the feed pipe and flows directly towards the central cone 1, dispersing along the umbrella-shaped working surface 104. Because the umbrella-shaped working surface 104 of the central cone 1 has protrusions 105, the contact area between the slurry and the material is increased, reducing the direct impact of the slurry on the central cone 1. The vibration caused by the impact is also mitigated to some extent, further extending the service life. Since the base 2 has sufficient strength and toughness, it provides good protection for the central cone 1, making its use safer and more reliable. When the central cone 1 is severely worn and can no longer meet production requirements, the base 2, with less wear, remains intact. The base 2 can be removed from the support frame, the connecting bolts loosened, and the base 2 automatically separates into two parts, making it easy to remove the central cone 1 for replacement. The base 2 can also be recycled and reused.

[0028] In a preferred embodiment, several bosses 105 are integrally formed with the conical top 101 and the extension 102, resulting in better impact resistance.

[0029] In a preferred embodiment, the outer surface of the conical top 101 is the working surface 104, and the outer top surface of the base 2 formed by the first part 201 and the second part 202 is the extension surface 205 of the working surface 104.

[0030] In a preferred embodiment, when the central cone 1 is combined with the base 2, the working surface 104 and the extension surface 205 are used together to buffer the impact of the slurry. The area of ​​the working surface 104 does not exceed 2 / 3 of the total area of ​​the working surface 104 and the extension surface 205. In this embodiment, the area where the working surface 104 is located is the central area that suffers the most severe impact and wear from the slurry. High-performance wear-resistant materials are selected to improve service life. The impact and wear in the outer area is less, so low-performance and low-cost materials can be selected to save the amount of precious metal materials while meeting the usage requirements.

[0031] The bottom of the extension 102 has a first cavity, and the area below the groove 203 is also a second cavity. The central axes of the first and second cavities are collinear with the central axis of the overall structure formed by the combination of the central cone 1 and the base 2. The volume of the first and second cavities does not exceed 1 / 3 of the overall volume of the disassembled composite wear-resistant cone. In this embodiment, the non-working surface 104 is designed with a cavity structure to reduce unnecessary weight and avoid material waste. Considering the wear resistance and stability under impact of the overall structure, the cavity volume in this embodiment must not exceed 1 / 3 of the overall volume. The collinearity of the central axes of the first and second cavities with the central axis of the overall structure formed by the combination of the central cone 1 and the base 2 ensures a uniform weight distribution and improves the stability of the overall structure under impact.

[0032] In a preferred embodiment, the central axis of the overall structure formed by the combination of the central cone 1 and the base 2 is collinear with the central axis of the extension 102 and the central axis of the groove 203. This results in a symmetrical overall structure with uniform weight distribution, improving the stability of the overall structure under impact.

[0033] Currently, commonly used wear-resistant cones are integrally cast and machined, typically made of materials such as Cr12MoV alloy steel and high-chromium cast iron. Cr12MoV alloy steel has high strength and good toughness, as well as some wear resistance. However, due to compositional limitations, it produces fewer hard carbide phases within its microstructure, resulting in limited wear resistance. Under high-speed impact wear, it is difficult to guarantee a reasonable service life, and the complex heat treatment process increases manufacturing costs. High-chromium cast iron, due to its high C and Cr content, contains a large number of hard carbide phases within its microstructure, exhibiting good wear resistance. However, its toughness is poor, making it prone to cracking and premature failure, and it is also difficult to machine. As the structural size of wear-resistant cones increases, integral casting from a single material is no longer suitable for installation and replacement on the production site. Furthermore, the wear of wear-resistant cones is uneven, with the largest wear in the center and gradually decreasing wear from the inside out. Integral casting from a single material also leads to ineffective resource waste, increases operating costs, and directly impacts the company's economic benefits.

[0034] Therefore, in this embodiment, the central cone 1 is made of high-chromium wear-resistant alloy material and is integrally formed using a casting process. In another preferred embodiment, both the first part 201 and the second part 202 are made of carbon steel or low-alloy steel and formed using casting or forging processes. Since wear is mainly concentrated on the surface of the central cone 1, the central cone 1 in this embodiment uses a high-alloy wear-resistant material, while the base 2 uses ordinary materials. This avoids the waste of precious metals caused by integral manufacturing and reduces manufacturing costs. Because the base 2 experiences less wear during operation, when the central cone 1 is severely worn and cannot meet production requirements, only the central cone 1 needs to be replaced, and the base 2 can still be reused, saving production costs and improving economic efficiency.

[0035] In a preferred embodiment, the fitting accuracy between the stepped side surface 103 and the mating surface 204, as well as between the extension 102 and the groove 203, is less than 1 mm.

[0036] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A split composite wear cone characterized in that, The device includes a central cone and a detachable base. The central cone has a conical top for buffering slurry impact and an extension for embedding within the detachable base. Several protrusions are staggered on the outer surface of the conical top, and a stepped side is formed between the conical top and the extension. The base includes a symmetrically arranged first part and a second part. When the first and second parts are joined, they form a mating surface adapted to the stepped side and a groove adapted to the extension. The extension is embedded within the groove, and the stepped side fits against the mating surface. Both the first and second parts have horizontal bolt holes at their bottoms. The first and second parts are fixed together by bolts, and the base formed by the joining of the first and second parts has a bottom surface that fits against a support frame inside the flash tank.

2. The disassembled composite wear-resistant cone as described in claim 1, characterized in that, The protrusion is semi-circular or trapezoidal; the diameter of the semi-circle is 5mm~20mm; the upper base of the trapezoid is 5mm~10mm, the lower base is 10mm~20mm, and the height is 5mm~20mm. The protrusions are evenly distributed and staggered along the outer surface of the top of the cone, and the distance between adjacent protrusions is 10mm~30mm.

3. The disassembled composite wear-resistant cone as described in claim 1, characterized in that, Several bosses are integrally formed with the conical top and extension.

4. The disassembled composite wear-resistant cone as described in claim 1, characterized in that, The outer surface of the conical top is the working surface, and the outer top surface of the base formed by the first part and the second part is the extension surface of the working surface.

5. The disassembled composite wear-resistant cone as described in claim 4, characterized in that, When the central cone is combined with the base, the working surface and the extension surface are used together to buffer the impact of the slurry, wherein the area of ​​the working surface does not exceed 2 / 3 of the total area of ​​the working surface and the extension surface.

6. The disassembled composite wear-resistant cone as described in claim 1, characterized in that, The bottom of the extension has a first cavity, and the area below the groove is also a second cavity. The central axis of the first cavity and the second cavity is collinear with the central axis of the overall structure formed by the combination of the central cone and the base. The volume of the first cavity and the second cavity does not exceed 1 / 3 of the overall volume of the disassembled composite wear-resistant cone.

7. The disassembled composite wear-resistant cone as described in claim 1, characterized in that, The central axis of the overall structure formed by the combination of the central cone and the base is collinear with the central axis of the extension and the central axis of the groove.

8. The disassembled composite wear-resistant cone as described in claim 1, characterized in that, The central cone is made of high-chromium wear-resistant alloy material and is integrally formed using a casting process.

9. The disassembled composite wear-resistant cone as described in claim 1, characterized in that, Both the first and second parts are made of carbon steel or low alloy steel and are formed by casting or forging processes.

10. The disassembled composite wear-resistant cone as described in claim 1, characterized in that, The fitting accuracy between the stepped side and the mating surface, as well as between the extension and the groove, is less than 1 mm.

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