Core Strategies for Scenario-Based Application of Wear-Resistant Steel Plates
1. High-Impact Solution for Mine Crushing Systems
Mine crushers face multi-angle gouging wear and high-frequency impact loads. Recommended solution: Bimetal composite plate structure with Q345 base + T90 wear-resistant layer. Impact zones thickened to 30mm, non-impact zones maintained at 20mm. Honeycomb bolt array fixing enhances shear strength by 40%. At a copper mine, liner lifespan extended from 9 to 28 months with 62% reduction in cost per ton ore.
2. Anti-Corrosion Scheme for Coal-Fired Power Plants
Coal chutes suffer micro-cutting wear and acidic corrosion (pH 4-6). Solution: High-chromium alloy overlay plate (Cr content 27%-32%) with micro-dot embossing to reduce friction coefficient. 15° sloped modular splicing extends material clearing cycles to 6 months. At Huaneng Power Plant: Annual maintenance costs reduced by CNY 830,000 with 99.2% equipment availability.
3. High-Temperature Erosion Protection for Cement Raw Mills
Cement raw mills endure quartz sand erosion (30-60° impact angle) and 300°C thermal degradation. Solution: TiC-reinforced ceramic composite plate (HV≥1800) with dovetail groove embedded installation resisting vibration detachment. Millimeter-wave thickness monitoring enables predictive replacement. Conch Cement case: Roller sleeve lifespan exceeded 36,000 operating hours with 75% reduction in unexpected downtime.
4. Compound Wear Solution for Port Machinery
Grapples face simultaneous river corrosion and sand abrasion. Solution: Superhydrophobic stainless composite plate (contact angle >150°) with serrated edge design improving grabbing efficiency by 25%. Ningbo Port results: Maintenance interval extended from 4 to 24 months, cutting annual cost by CNY 410,000 per unit.
5. Five-Step Scenario Adaptation Protocol
Step 1: Condition diagnosis – Measure Mohs hardness of abrasives and peak impact energy
Step 2: Damage mapping – Analyze wear morphology and failure rate
Step 3: Material system design – Match plate type to impact/corrosion/temperature parameters
Step 4: Structural topology optimization – 3D contouring to fit stress distribution
Step 5: Digital O&M integration – Install wear sensors for predictive replacement
6. Key Selection Parameters
High-stress impact: Cemented carbide composite plate (3.2-3.8x lifespan gain)
Micro-particle erosion: High-chromium cast iron overlay (★★★★★ cost-performance)
Corrosion-abrasion: Stainless steel composite (4x+ acid resistance improvement)
Validation Case: Shaoguan Iron Mine Gyratory Crusher Retrofit
Original homogeneous plates required 5 replacements/year. New solution: 35mm ceramic composite in impact zones + 22mm bimetal plate in non-impact zones with preload hydraulic bolting. Achieved 34-month service life, reducing cost per ton ore from CNY 1.85 to 0.61 with annual savings of CNY 2.17 million.