Preparation Before Repair
1. Determine Repair Dimensions: Refer to the new equipment drawings to determine the required dimensions of the hydrocyclone after repair.
2. Fabricate Corresponding Molds: Prefabricate suitable repair molds according to the determined dimensions to ensure that the dimensional accuracy after repair meets production requirements.
Surface Treatment of Aging Areas
Pre-treatment of aged, worn/corroded areas is crucial for ensuring the strength of the repair:
1. Welding the Frame: For rusted, thinned, or worn areas, weld a frame using steel plates/reinforcing bars of the same material as the equipment base material to fill the gaps.
2. Degreasing and Moisture Removal: Wipe the surface with cotton yarn to remove grease, then adjust the oxy-acetylene flame to a length of 10 cm and heat the workpiece surface evenly at a speed of 5 cm/minute to thoroughly remove surface grease and moisture.
3. Sandblasting and Rust Removal: Grind away the surface oxide layer until a uniform metallic color is exposed; after sandblasting, avoid touching the treated surface with greasy hands, ensure proper moisture protection, and cover areas that do not require repair in advance.
Selection and Construction of Wear-Resistant Repair Materials
Based on the location of aging and wear, select suitable specialized wear-resistant repair materials:
1. Recommended Materials: RJ-YHL-C-1.0-2.0 composite ceramic wear-resistant repair material, RJ-C-100 wear-resistant repair material, etc., can be used. These materials have excellent corrosion resistance and impact resistance in fluid environments, suitable for the working environment of starch hydrocyclones.
2. Apply the repair material according to the material usage requirements, fit it into the prefabricated mold, wait for the material to fully cure, then demold, and polish the surface to adjust to the required dimensions.
Repair Scheme Adjustment for Different Aging Conditions
1. Aging and wear only in the hydrocyclone tube: No overall repair is needed; simply replace the individual qualified hydrocyclone tube. The cost-effectiveness is far higher than repair.
2. Minor rust and aging in localized areas of the main body: Welding repair and wear-resistant coating treatment according to the above process can restore usability. If there is large-area rust and cracking, or shell deformation, and the repair cost is close to 30% or more of the cost of new equipment, it is recommended to replace the entire unit for better cost-effectiveness.
