摘要
有机硅材料具有优异的综合性能,在生产生活诸多领域得到应用,有机硅工业是国家大力发展的一个领域。生产有机硅单体装置回料系统的介质是固相为硅粉的高温气固两相流介质,气固两相流介质对输送管道上的球阀有很强的磨蚀作用,气固两相流介质的高温磨蚀特性要求球阀即要耐磨又能适应高温环境,目前的球阀无法满足要求,需要对高温耐磨球阀关键技术开展研究,开发出满足有机硅单体装置回料系统用高温耐磨球阀,以满足国家有机硅工业发展对高温耐磨球阀的需求。本文在浙江省科学技术厅科技攻关计划项目“陶瓷耐磨球阀的研制”(计划编号2004C31006)的资助下,针对有机硅装置回料系统介质的特点,对硬密封高温耐磨球阀的关键技术进行了较为深入的研究,主要包括如下内容:
(1)双层辉光离子渗钨渗碳球体密封面特性。对经双层辉光离子渗钨渗碳工艺硬化处理的2Cr13材料的渗层深度、渗层的相组成、渗层的硬度分布,以及经此工艺硬化处理的2Cr13球阀启闭件球体的变形量和球体密封面的静压寿命进行了详细的试验研究。试验结果表明经双层辉光离子渗钨渗碳工艺硬化处理的2Cr13球体密封面加工量小、硬化层厚且硬度高、静压寿命长,证实了双层辉光离子渗钨渗碳工艺是一种能使硬密封球阀2Cr13球体密封面具有优异综合性能的硬化工艺。
(2)硬密封球阀球体密封面精加工技术。提出了两种双轴转动球体密封面研磨设备结构,对基于这两种结构实现球体密封面研磨成型的原理进行了理论分析;为提高球体密封面研磨质量,对双轴转动球体密封面研磨设备双轴转速之间的关系进行了分析并确定了二者之间的关系;推导出了球体研磨速度的计算公式;提出了双轴转动球体密封面研磨设备的整体结构形式和部件结构形式;分析了工艺参数值对球体密封面研磨效果的影响,在此基础上提出了球体密封面研磨工艺参数值。对双轴转动球体密封面研磨设备样机的研磨效果进行了试验检验,试验结果表明双轴转动球体密封面研磨设备可研磨出密封性能达到零泄漏的硬密封球阀球体密封面,验证了双轴转动球体密封面研磨设备结构的可行性,以及提出的研磨工艺参数值的合理性。
(3)高温防卡阻硬密封球阀结构。提出了一种新型高温防卡阻硬密封高温球阀结构——球体预置偏心高温浮动对中硬密封高温球阀结构,分析了该结构球阀的工作原理。
(4)硬密封高温耐磨球阀密封结构。提出了一种硬密封高温耐磨球阀阀前阀座和阀后阀座都能密封的双面密封结构;在分析双面密封硬密封高温耐磨球阀阀座受力状况的基础上,推导出了阀座密封面密封比压的计算公式;针对双面密封结构的特点,提出了确定阀座密封面宽度的准则,以此准则为基础给出了确定阀座密封面宽度的方法;提出了一种阀杆锥形柔性石墨环组合填料密封结构,分析了该阀杆密封结构的工作原理和特点。
(5)硬密封高温耐磨球阀阀体内腔耐磨衬里技术。在分析阀体内腔磨损形式的基础上,给出了阀体内腔耐磨涂层的热喷涂工艺形式并确定了涂层材料。
(6)硬密封高温耐磨球阀试验研究。对硬密封高温耐磨球阀样机进行了压力试验和高温磨蚀条件下的工况试验,试验结果表明硬密封高温耐磨球阀密封性能优异,高温磨蚀条件下操作灵活、工作寿命长,验证了球体预置偏心高温浮动对中硬密封高温球阀结构和阀门密封结构的合理性,以及所确定的耐磨涂层的耐磨性。
Organic silicon material has excellent integrated performance and has been applied in numerous fields of production and living. Organic silicon industry is a field of our country for energetic development. The medium of material return system for the organic silicon monomer production device is a medium of high-temperature gas-solid two-phase flow with its solid phase as the silicon powder, the medium of gas-solid two-phase flow has very strong abrasion on the ball valve on the delivery pipeline and its high-temperature abrasion characteristics require that ball valve not only resists wear, but also can adapt to high-temperature environment, but existing ball valve cannot satisfy the requirements, it is required to research the key technology of high-temperature wear-resistant ball valve with a view to developing the high-temperature wear-resistant ball valve for material return system of organic silicon monomer production device so as to satisfy the demand of the development of organic silicon industry in our country on high-temperature wear-resistant ball valve. Under the sponsorship of the technical key problem tackling program of Department of Science and Technology of Zhejiang Province—"development of ceramic wear-resistant ball valve" (program No. 2004C31006), a deeper research is carried out on the key technology for metal-seated high-temperature wear-resistant ball valve with respect to the medium characteristics of material return system for organic silicon device in this paper, mainly including the following contents:
(1) Characteristics of sealing surface of ball by double glow plasma diffusing W and carburizing. Detailed experimental researches have been carried out on the penetration depth, phase composition of penetration layer, hardness distribution of the penetration layer of 2Cr13 subjected to double glow plasma diffusing tungsten alloying and carburizing hardening treatment as well as deformation amount of closure member—ball of 2Cr13 ball valve subjected to such hardening treatment and static pressure life of seating face of the ball, the experimental results show that the seating face of 2Cr13 ball subjected to double glow plasma diffusing tungsten alloying and carburizing hardening treatment has small processing amount, thick hardening layer, high hardness and long static pressure life, thus ascertains that the double glow plasma diffusing tungsten alloying and carburizing process is a hardening process that can make the seating face of 2Cr13 ball of metal-seated ball valve has excellent integrated performance.
(2) Precision machining technology of seating face of ball of metal-seated ball valve. Two structural models have been proposed for the lapping equipment with two rotary shafts for seating face of ball, and the principle of lapping and forming of seating face of ball realized based on these two structural models have been analyzed; in order to improve the lapping quality of seating face of ball, the relation between the rotational speeds of the two shafts of the lapping equipment for seating face of ball has been analyzed and the relation between them has been determined; the calculation formula for lapping speed of lapping ball has been derived ; the integral structural style of the lapping equipment for seating face of ball and structural style of components have been proposed; the effect of process parameter values on lapping effect of seating face has been analyzed and process parameter values for lapping of seating face of ball have been given based on this. Test has been conducted on the lapping effect of prototype of the lapping equipment with two rotary shafts for seating face of ball, and the test results show that the lapping equipment with two rotary shafts for seating face of ball can lap out a seating face of ball of metal-seated ball valve whose sealing performance achieves zero leakage, thus verifies the structural feasibility of the lapping equipment with two rotary shafts for seating face of ball and reasonability of values of lapping process parameters.
(3) Structure of high-temperature anti-seizure metal-seated ball valve. A new type of structure of high-temperature anti-seizure metal-seated ball valve - structure of high-temperature floating centering metal-seated ball valve with preset eccentric ball is proposed, and the operating principle of this structure of ball valve is analyzed.
(4) Sealing structure of high-temperature metal-seated wear-resistant ball valve. A double-side sealing structure that can seal the seat before and after a type of metal-seated high-temperature wear-resistant ball valve is proposed; calculation formula for specific sealing pressure of seating face of valve seat is derived based on the analysis of stress condition of the double-side metal-seated high-temperature wear-resistant ball valve seat; criteria for determining width of valve seating face is proposed with respect to the features of double-side sealing structure and based on this methods for determining the width of valve seating face is given; a structure of combined packing seal of conical flexible graphite rings for valve stem is proposed, and operating principle and features of the sealing structure of this valve stem is analyzed.
(5) Wear-resistant lining technology for internal chamber of metal-seated high-temperature wear-resistant ball valve body. Hot spray coating process type of wear-resistant coating for the internal chamber of valve body is given and coating material is determined based on the analysis of wear type of internal chamber of valve body.
(6) Experimental research on metal-seated high-temperature wear-resistant ball valve. Pressure test and operating condition test under high-temperature abrasion condition have been carried out on the prototype of the metal-seated high-temperature wear-resistant ball valve, the test results show that the metal-seated high-temperature wear-resistant ball valve has excellent sealing performance, flexible operation under high-temperature abrasion condition and long service life, and verify the structural reasonability of high-temperature floating centering metal-seated ball valve with preset eccentric ball and valve seal as well as wear resistance of the wear-resistance coating determined.
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