Leading Technology Of Mine Equipment Leads China's Industrial Transformation And Upgrading

The Central Plains, the nine ancient capital. Every April peony flowers are blooming in Luoyang, China's industrial city. The CITIC Heavy Industry located here is one of the 156 major engineering projects in the Republic of China during the "15" period. Today it has grown into the leader of heavy equipment in the country.

Especially in the past 3 years, the heavy metal industry has generally declined, and CITIC Heavy Industries new products, complete sets of projects and foreign market orders have increased year by year. By 2013, total sales accounted for about 50% of the international market, and 60% of the total products and engineering packages, and 70% of new products sold. The transformation of manufacturing enterprises to high and new technology enterprises, transformation from mainframe suppliers to complete sets of service providers, transformation from localized enterprises to internationalized enterprises, and the new pattern of large-scale, intellectualized, complete and low carbon green products have been realized in three major transformations.

This historical change is achieved by relying on the scientific research achievements of the State Key Laboratory of heavy equipment in mines.

The State Key Laboratory of heavy equipment in mines was approved by the Ministry of science and technology in January 2011 and passed in August 2013.

It takes mine heavy equipment performance, reliability and life, manufacturing key technologies and saving and emission reduction as its four research directions. At present, there are 149 experimental researchers, and 409 sets of instruments and equipment constitute 28 experimental systems, covering the whole process of material experiment, simulation analysis, manufacture and final product testing, which form a complete chain of experimental research platform.

Over the past four years, besides undertaking more than 100 scientific research projects, we have also undertaken 13 research projects at the provincial level and above. Among these topics, there are 3 National 973 plans, 3 support plans and 1 863 projects. There are 135 authorized patents, of which 54 are invention patents. There are 24 awards for scientific and technological achievements at the provincial level and above, 2 of which are "two national science and technology progress awards". Topics and achievements cover the application of basic theory and technology research, materials and technology, as well as experimental technology, etc., to break through or break through a number of major technical bottlenecks restricting the development of heavy equipment in China's mines.

　　 Large grinding mill: forcing foreign equipment to cut domestic prices by 40%

Large, intelligent and efficient mills are the major technical equipment of the increasingly depleted mine resources. The State Key Laboratory of mine heavy equipment has established a grinding equipment experimental system and a powerful selection database, and developed a series of products of "large scale mining mills", which have completely independent intellectual property rights. They broke the blockade of foreign technology at one stroke and filled a number of domestic blanks, making CITIC Heavy Industry one of the three largest manufacturers in the world capable of producing ball mills with a diameter of 7 meters or more and 12 meters above grinding mills. At present, it has been equipped with more than 20 mining enterprises at home and abroad, with a domestic market share of 85%. Sales in the past three years amounted to 4 billion 760 million yuan, creating more profits and taxes for more than 10 billion yuan for related mining enterprises, forcing foreign equipment to reduce domestic sales by 40%.

Technology, carrying capacity of up to 3000 tons or more, has solved the problem of over load support. The developed large mill dual motor self correcting synchronous transmission technology and the multi state remote monitoring and diagnosis system have solved the technical difficulties of large power and multi machine driving, and the driving power reaches 20000 kilowatts. The manufacturing process of the multi-stage cylinder, segmental end cover and multi ring gear ring of the large-scale mill has been solved, and the problem of extreme manufacturing for large parts of large mills has been solved. A complete set of technology integration for manufacturing and assembly of super large and overweight components has been realized. The grinding equipment experiment system and type selection database have been established, and a grinding parameter calculation model based on ore characteristics has been created, which solves the problem of accurate selection of grinding process and realizes resource saving and high efficiency. The result is the pure static pressure multi oil chamber rocker inclined self tightening bearing and multi sliding bearing support. utilize 。

　 High pressure roller mill: three difficult problems to solve low grade ore

"More crushing and less grinding" and "lamination crushing". always It is the dream of China's mineral processing sector for decades, and it is also a heavy responsibility for the equipment manufacturing industry. CITIC Heavy Industry has high intellectual roller mill with independent intellectual property rights to make this dream come true. The technology has changed the traditional grinding technology routes and methods in mining, metallurgy, building materials and other fields, and solved the major technical problems of traditional technology with high energy consumption and low efficiency, which reduced the import equipment price by more than 50% in the domestic market. In the past three years, it has sold 5 billion 220 million yuan in domestic and foreign markets, which has increased 28 billion yuan for users.

According to the different mineral characteristics and grinding requirements, the results of the study are that the thickness of the grinding mill is reduced from 10mm to 3mm for the first time by using the method of layer thickness rolling. The technological indexes such as project investment, energy consumption and metal wear of mineral processing are reduced by more than 20% than that of traditional process. China's first super high pressure roller mill has a pressure of 4.5MPa. The development of the GM series high pressure roller mill can achieve 40% early dumping in metal mines, which solves the problem of low consumption, low efficiency and hard recovery of low-grade ores. The energy consumption of the system is reduced by more than 30% and the operation efficiency is increased by 15%.

　 Calcining active lime: intelligent measurement and control for the first time in China

Active lime and rare earth, also known as "industrial monosodium glutamate," can significantly reduce energy consumption and material consumption, reduce pollutant emissions and improve the quality of industrial products. steel-making Electrolytic aluminum, calcium carbide smelting, paper making and other fields.

Based on the research of key technologies and complete sets of equipment for large scale high-efficiency and energy saving active lime production line, based on the basic theory of thermal engineering, simulated calcination test and production data analysis, the active lime calcining system with low pressure loss and high heat exchange efficiency was developed through the system simulation of temperature field. Through active lime simulating calcination test and physical and chemical analysis, the database of the optimal process parameters for calcining the active lime rotary kiln system was mastered, and the design and calculation method of key equipment were obtained. The mathematical model of the OCS control system is developed, and the intelligent online detection and control software of the lime system is created to realize the fully automated central control room. Finally, the key technology and complete equipment of active lime production line with high product activity, low heat consumption and low investment and comprehensive utilization of resources were developed.

　　 Improving quality of lignite: solving theoretical problems of international equipment selection

Lignite is the coal with the lowest degree of coalification. It accounts for 50% of the total coal reserves in the world. Only the total proven reserves of lignite in China reach 1300 billion tons. It is the main fossil energy and coal chemical raw material in the future. Lignite upgrading technology for the first time explores the data conversion rule of static and dynamic pressure test, summarizes the mathematical model, and solves the theoretical foundation problem of upgrading equipment in the world. The development of the new CCDJ material roll extrusion forming selection technology can calculate the main parameters of the roll forming machine specification, line speed, installed power, work specific pressure and equipment capacity to meet the technological requirements of different material forming system.

The first forming and passivation technology solves the problem of easy crushing and easy spontaneous combustion of Hot Briquette. The first roll diameter 1400mm, the roll width 1000mm, the highest line pressure reached 25t/cm, the binder free high-pressure molding machine were developed, so that the pulverized coal can be continuously molded under high pressure and no additives. Efficient molding intelligent automatic control system, so that the ball rate increased by 10% to 30%. After the lignite is upgraded and molded, the profit of the ton product can reach more than 50 yuan. If the project is built at the pit, the profit of the ton product will be higher than 100 yuan, and the moisture content will be reduced by 30% - 60%.

　 High end high voltage inverter: breaking monopoly instead of import

High voltage frequency conversion upgrade traditional industries. Air conditioning variable frequency speed regulation has been popularized, and everyone is familiar with its energy saving everyday. However, a large number of key technical breakthroughs are needed in large heavy load equipment with huge energy consumption. Variable frequency speed regulation technology has the advantages of wide speed range, high speed accuracy and good dynamic response. It enables the motor to run at the most energy-saving speed. In many applications requiring precise speed control, frequency converters are playing an important role in improving the quality and efficiency of production and saving energy, and it is also one of the biggest areas to replace imports and save investment. Domestic market demand for high voltage variable frequency speed regulation is also increasing rapidly. High voltage inverter has huge market space in mining, metallurgy, building materials and other fields. At present, the frequency conversion speed control products developed and developed by our country are only equivalent to the 90s level of the international century, and the key technologies rely heavily on foreign companies.

At present, the high-end high voltage inverter market in domestic large-scale mine hoisting equipment, large mill, large heat and cold rolling mill, wind power converter, oil and gas pipeline erection is still monopolized by foreign brands. Although all kinds of high-voltage frequency converters are constantly appearing, so far there is no nearly uniform topology like LV inverters. Although foreign manufacturers have mature control technology, the topology of their products leads to their inability to adapt to the voltage level of China's power grid. Domestic users are forced to adjust their grid voltage through transformers to adapt to foreign products in the absence of substitute products.

The lab successfully developed CHIC1000, CHIC2000, CHIC3000, CHIC5000, CHIC6000 and other frequency converters to meet the needs of various leading products and market demands of industrial enterprises. Voltage levels include 10kV, 6kV, 4.16kV, 3.3kV, 1140V and 660V. It is widely used in many fields such as coal, mining, metallurgy, nonferrous metals, building materials, electric power, energy conservation and environmental protection.

The core breakthrough of CITIC Heavy Industry involves the development of power unit, main controller, rectifier transformer, power unit control software, general control software and vector control algorithm for high-voltage high-power inverter products. The core technology is high performance vector control, product stability, high precision and multi-function. The technology is mostly used in the field of energy saving. After industrialization, the products produced annually (according to the annual output of 500 units and the electricity saving rate of 30%) can save 400 million to 600 million kilowatt hours of electricity for users, save 15 to 200 thousand tons of coal and reduce 4 to 50 thousand tons of CO2 emissions.