Research and development of high-temperature resistant skirted baffles: Application in rotary kilns of cement plants

I. Operational Challenges in Rotary Kilns

1. Extreme Thermal Conditions

   • Operating temperatures exceed 1,450°C during clinker formation.
   • Conventional materials degrade under thermal radiation (>500kW/m²) and thermal shock (ΔT >800°C/min).

2. Abrasive & Corrosive Environments

   • Alkaline dust (CaO content ≥40%) with Mohs hardness 3.5 accelerates wear.
   • Requires pH 12-14 resistance and <0.1% porosity to prevent chemical infiltration.

3. Dynamic Mechanical Stresses

   • Sustains cyclic loads:
     • Material gravity: 3-5kN/m&sup2;
     • Centrifugal forces: 0.5-1.2G
   • Connection strength must maintain ≥15MPa bonding under vibration (ISO 10816-3).

II. Core Technological Innovations

1. Material Advancements

• High-TPU/NR Composites:
  • Withstand continuous 280°C (short-term 320°C) while retaining 85% flexibility (ASTM D412).
  • Carbon black/aramid fiber reinforcement achieves DIN 53516 ≤100mm&sup3; abrasion loss.
• Ceramic Cladding:
  • Plasma-sprayed Al₂O₃ coatings (≥HV1,200 hardness) reduce wear rate by 70%.

2. Structural Optimization

• Dual-Seal System:
  • Primary steel-backed seal + secondary EPDM skirt ensures <0.2mm gap tolerance.
  • Auto-tracking design maintains 5-10N/cm&sup2; contact pressure across belt width.
• Modular Assembly:
  • Hot-swappable segments enable <30min replacements vs. 8hr downtime for full systems.

3. Manufacturing Breakthroughs

• Secondary Vulcanization:
  • Bonds skirt-to-base at 180°C/2.5MPa, achieving ≥18MPa peel strength (ISO 813).
• Precision Molding:
  • ±0.15mm dimensional accuracy via 800-ton injection presses eliminates edge leakage.

III. Performance in Cement Kiln Applications

Certifications: ASME B31.3, EN 1012-1, ISO 9001
ROI: 6-8 months payback period

This translation emphasizes:

• Quantifiable thermal/mechanical performance data
• Industry-standard compliance benchmarks
• ROI-focused terminology for decision-makers