Allis-Chalmers - double roll tooth crusher hardfacing study

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NOTICE

The information contained in this report is regarded as con fidential and proprietary. It is provided subject to the provisions regarding confidential, proprietary information contained in the Research Agreement among the Participating Parties.

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R-e-h.;·~ t() fne

Indicated

OCT }1967

I.fOBIL RESEARCH AND DEVELOPMENT CORPORATION RESEARCH DEPARTMENT

TECHNICAL MEMORANDUM, NO. 67-24

ALLIS-CHALl4ERS - DOUBLE ROLL TOOTH CRUSHER HARDFACING STUDY

ANVIL POINTS OIL SHALE RESEARCH CENTER Rifle, Colorado September 29, 1967 Authors: Approval: R. E. Smith

w.

S. Bergen

~1-)~\~'

R. H. Cramer Program Hanager

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The primary object of the Anvil Points Oil Shale Research Center TECHNICAL MEMORANDUM is to advise authorized personnel employed by the Participating Parties(l) that various

activities are in progress or that certain significant data have been obtained within the Research Center.

These TECHNICAL MEMORANDA have been prepared to provide rapid, on-the-spot reporting of research currently in progress at Anvil Points. The conclusions drawn by project personnel are

tentative and may be subject to change as work progresses. The TECHNICAL MEMORANDA have not been edited in detail.

(l)Mobil Research and Development Corporation, Project Manager Continental Oil Company

Humble Oil and Refining Company Pan American Petroleum Corporation Phillips Petroleum Company

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ALLIS-CHALMERS - DOUBLE ROLL TOOTH CRUSHER HARDFACING STUDY

TABLE OF CONTENTS

I. Introduction • • • • • • • _• _• _{• • •} _{• •} _• _• _{• •} _• _• II. Summary and Conclusions _• _{• • •} _• _• _{• •} _• _• _{• • •} _• III. Discussion • • • • • • • _{• •}

· .

.

_• _• _{• •} _• _• _• _• •

A. Selection of Hardfacing Material _• _• _• _• _• B. Evaluation of Hardfacing l~terials _• _{• •}

·

_• _•

C. Tooth Hardfacing Procedures _• _• _• _{• • •}

_·

_• _• _• D. Hardfacing Schedule

_·

_• _{• •} _{• •} _{• • •}

_·

_• _• _• _• E. Tooth Life - Capacity _• _{• •}

_·

_• _• _{• •} _• _{• •} _{• •} F. Tooth .t.~aintenance Data and Costs

_·

_• _• _•

_{· ·}

_•

TABLE

1 Hardfacing, Capacity and Power Data FIGURES

1 Secondary Crusher noll (Toothed Double Roll Crusher) 2 Secondary Crusher - Harcifacing Hethods

3 Secondary Crusher - Tooth Template - Basic Tooth Shape Templates - 108 Teeth Rolls

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ALLIS-CHALMERS - DOUBLE ROLL TOOTH CRUSHER HARDFACIHG STUDY

I. INTRODUC'l'ION

A pair of small toothed rolls were supplied by the Allis-Chalmers Company for the double roll crusher being evaluated at Anvil

Points. This crusher was used as a secondary crusher prototype. These rolls were designed to produce efficiently shale ranges from 1/4 to 1 inch and larger. They were installed during the early part of November, 1966, and remained in service throughout the remainder of Stage II of the project. During February of 1967, a hardfacing program was instituted with the objectives of maintaining crushing efficiency and obtaining data relating

hardfacing requirements to shale production for a double roll, tooth-type crusher.

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II. SUMMARY AND CONCLUSIONS

Operations on Retort No. 3 made a precise quantitative

evaluation of hardfacing needs impractical. However, several hardfacing materials were evaluated and an approximate value of productive tooth capacity determined:

1. For a full range crushing operation, 1/4 to 2 1/2 inch shale, the productive life of a tooth approximates 12.5 tons with the roll and tooth configuration installeU:- 2. Hardfacing maintenance, tooth and roll, must be performed

routinely.

3. Crushing efficiencies falloff rapidly if tooth sharpness and shape are not maintained.

4. Dull or rounded teeth are a direct cause of crusher choking. 5. Tooth wear accelerates rapidly after initial wear.

6. A ma~or tooth rebuilding or complete replacement may be

requ1red after teeth have been repaired or resurfaced approximately five or six times.

7. Wear of the roll surface between the teeth has an adverse effect on crusher operation comparable to that of the teeth. 8. Wear of the roll surface between the teeth is quite rapid,

and requires routine maintenanoe comparable to that of the teeth.

9. Crusher designs must accommodate easy access to the rolls for hardfacing procedures.

10. Crusher design must accommodate easy roll replacement.

11. For crushing shale, the hardfacing material must have good abrasion and impact resistance. Amsoo 60 was found satisfactory for this service.

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III. DISCUSSION

A. Selection of Hardfacing Material

The teeth on the rolls as supplied by Allis-Chalmers were hardfaced ''lith six different hardfacing materials.

See Figure 1. An equal number of teeth (18 per roll) were surfaced wi~h each of the materials. The following materials were tested?

1. Arkos - Diamond 49

A hot \-lork tool steel to resist wear and impact at elevated temperatures.

2. Victor Cru.sher Rod nC il

Rock'lle11 hardness 54 to 48, resists abrasion high impact - not forgeable - not machineable. 3. McKay Chrome - Manganese

Extreme abrasion and impact work hardness 50 to 55 RC. 4. Amsco Economy Hard-Face No. 60

Abrasion - severe impact - Brinell hardness - 500 Composition 0.50% C, 3.0% Cr, 1.7% of rio.

s.

Airco 388 Self Hardening

Excellent abrasion and heavy impact. resistance smooth arc action - good weldability.

6. Arcos - Diamond No. 63

High speed tool steel to resist abrasion oxidation and light impact to 1000 F.

B. Evaluation of Hardfacing Materials

'l'he wear of eac!1 of these materials ''las evaluated during the initial use of the rolls. No hardfacing maintenance was performed, and the condition of the teeth ',las allowed to degenerate be1ml normal standards. From this evaluation, the Amsco No. 60 hardfacing was selected as the best.

Uateria1s softer than Amsco No. 60 deformed too easily. Tl:.e harder materials were too brittle and broke away on impact.

Except for some screening tests of other hard facing rods such as the Eutectic No. 61 and Stoody No. 2134, the

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-Amsco No. 60 was used throughout the remainder of the program. The Stoody rod appeared too brittle. The

Eutectic rod appeared to be generally equal to the Amsco in impact resistance and abraded at a slightly slower rate.

110re detailed specifications of the Amsco No. 60 rod are as follows:

Brinell 500

Chrome 3%

Molybdenum 1.75%

Carbon 0.5%

While none of these hardfacing materials were tested, the following rods are listed by various manufacturers as direct substitutes for the Amsco No. 60:

1. Alloy Rods - Wear Arc 61.10

2. Haynes Stellite - fIascrome

3. Lincoln - Alraso Weld

4. _{Metal and Thermit - Hardex} 40

5. Rankin - Ranite BX

6. Stoody - 1030

c.

Tooth Hardfacin2 Procedures

Figure 2 illustrates the two basic methods of tooth repair employed on the crusher teeth. Where no significant loss in tooth shape had occurred, a repair procedure illustrated as Type I was used. A cut throat or carbon rod was used to remove old hardfacing and a single pass with the hard facing rod was made. Maintenance time for this procedure was approximately 7 :~ minutes per tooth.

Occasionally a new layer of hardfacirlg was applied over existing hardfacing without removing the existing hard

facing_ The manufacturer states that one of the advantages of the Amsco No. 60 rod is the fact that it can be applied over existing Amsco 60 rod. Our experience showed that the hardfacing life is reduced by approximately 50% by this technique since spalling rates are excessive by comparison. The repair technique, Type II, was used when a loss of tooth shape had occurred. This type of repair work is the most difficult and tooth damage progresses very rapidly beyond this point. Before new hardfacing can be applied, the

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_I FIGURE 2

SECONDARY

CRUSHER

HARDFACING

METHODS

TYPE I

HARDFACING ONL.Y EI)GE WITH

, BASIC TOOTH SHAPE IN TACT. ONL.Y HARDFACING

OF THE TOOTH CUTTING E.DGE· IS REQUI RE.D.

GOIJGE IS FIL..I-E.O WtTH ONE:. L.1GHT PASS

OF HARDENING.

TYPE-IT

TOOTH RESHAPING PLUS HARDFAC ING

MUL TI PLE PASSES WlTH

CINE HARDFAGlt,iG MANGANESE ROD

PASS ~~~~..:y:n.r----~

. LOSS OF TOOTH SHAPE HAS OCCURE'P. SHAPE

IS REBUIL.T WITH MANC1ANESe: ROD AND EDGE

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proper tooth shape must be established using a bare manganese rod. Care must be exercised to prevent a dilution of the tooth base metal (manganese) with the hardfacing metal remaining on the tooth. If dilution becomes excessive, the tooth \lTill lose'its ability to

resist impact. .

Establishing the original tooth shape is not easy.

Te~plates illustrated in Figure 3 were used with some suc

cess depending on the particular mechanic. Generally the use of these templates is recommended since they represent the best method tested for maintaining a standard tooth

sha~e. ~1aintenance time for this procedure was approximately

20 _~o minutes per tooth. D. Hardfacing Schedu~

A systematic hard facing routine \-las employed throughout the service life of the 108 teeth rolls after Februaiy 1967. This schedule was based on needs of the prior three months service. Figure 4 illustrates the tooth coding layout used for each roll. Seven teeth were . designated for rehardfacing each day, five days a 'Vleek, on each roll such as the seven shaded teeth in Figure 4. Each day a ne", alternate diagonal rO't>l of teeth "las

designated for repair. These seven teeth each day were so called mandatory teeth and were repaired regardless of their condition.

In addition, the mechanic was allowed to select three

optional teeth for repair on each roll. The teeth selected were the ones which, in his opinion, were the three most badly damaged. This procedure was repeated continuously during the program except for several occasions where

crus.hing plant do\l7n tinle or roll condition made a complete roll refurbishing advisable.

Table I summarizes roll maintenance, production data and pO't',er data.

E. Tooth Life - Capacity

The data was examined to ascertain the productive capacity and har6facing maintenance material needs for one life cycle of the roll teeth when producing \ldde range shale. If this information is valid for larger tooth type rolls, it is possible to project onstream factors, and maintenance costs and schedules for a similar type co~mercial secondary crusher.

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T]\.BLE ·W_' 1 __ ________ ._ ____ ___ _ (CONTInUED) ~ P,age 4 " Hl\RDFACING, CAPACITY AND '\~'JER DATA ___ .' ___ _ ;iIOA?TN

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- 9

As noted earlier, rolls tested were those s~pplied by Allis-Chalmers to produce higher rates of 1/4 to 1 inch

shale. These rolls have smaller teeth than the original rolls supplied by Allis-Chalmers for the production of 1/4 to I, 1/4 to 2 1/2, and 1 to 2 1/2 inch shale fractions. The production of the 1/4 to 2 1/2 inch shale fraction at Anvil Points best represents operation of a commercial crushing scheme. OVersize shale from a primary screener passed through the secondary crusher with no recirculation. During this operation, approximately 45 to 50% of the plant production is processed by the secondary roll crusher.

Tooth life, productive capacity, and hardfacing needs for this operation were examined.

The crushing plant produced 1/4 to 2 1/2 inch shale for a 19-day period fram June 17 to July 5. During that interval, an estimated 2291 tons of shale were crushed in the double roll crusher. The roll teeth were hardfaced once during this period. A test was also conducted with Eutectic 61 and Stoody 2134 at that time. During half of this period, only a low rate of production was required because of the retort needs. Therefore, under normal conditions an

estimated total production of 2700 tons could have been realized.

From this data the productive life of one tooth of this crusher is approximately

12.5

tons of shale.

A review was made of the overall crusher throughput and hardfacing for the period of February 27 to August 5 to check this conclusion. Throughput was approximately 18,000 tons and six maintenance cycles can be projected. Tooth life or capacity is 14 tons on this basis.

It is the judgment of the authors that the maintenance period could not have been extended for a significantly longer period.

F. Tooth Maintenance Data and Costs

Details of maintenance records were examined to formulate costs and schedules. Manpower and materials used at

Anvil Points form the basis of this evaluation. 1. Tooth Reshaping

Tooth reshaping versus hardfaeing tequirements averaged one in six.

(28)

10

-2. Tooth Maintenance Data and Costs

Iiethod I Method I I Procedure Material Diameter cost*

Hardface

onl~ Reshape and Bardface

Rods Cost¢ Air Arc Copperclad 1/4 in. 11¢/ROd 1/3 4 1 11 Tooth

Rebuilding LH 7018 5/32 in. 2 1/2¢/Rod 3 7 1/2 Hardfacing Amsco 60 3/16 in. 8¢/ROd 1 8 2 16

rUnutes r.1inutes Maintenance Labor - Minutes 10¢/Min.

5

50

15

150 Cost Per Tooth For

Each Maintenance Method 62 184 1/2

Average Cost Tooth Maintenance**

(.17 Reshape + .83 Bardface) 83 cents

e

*Costs

1/4 inch Copperclad Air Arc rod - ll¢ Rod. 5/32 inch LH 7018 rod - 22¢/lb; 9 rods/lb. 3/16 Amsco 60 rod - 66¢/lbJ

a

rods/lb. Labor Costs - $6.00/Hr; 10¢/min.

**These costs do not include cover plate disassembly and reassembly, or hardfacing t~surface of the rolls.

Relating the maintenance cost of a tooth to its productive life, a cost factor of 6.6¢ per ton of shale processed by the crusher is realized. (Only

45 to 50% of the retort shale.) This is a significant cost factor approximating 6.6¢ per barrel of retort oil produced. Manufacturer efforts to develop

materials to increase the productive life of the roll teeth and maintain the roll surface appears mandatory.