Ceramic roller usage tips

1、 Selection of roller rod:

1. The suitable type of roller should be selected based on the maximum firing temperature of the roller kiln, taking into account different working zones (temperature zones), rotational speeds, loads, roller center spacing, kiln atmosphere, possible erosion, and cost factors.

2. New kiln: Customers should inform us of the roller bars used for the new kiln, so that they can be selected according to the new kiln standards.

2、 Before using the roller, it should be placed next to or on top of the kiln for preheating and drying. After removing the adsorbed moisture, it can be loaded into the kiln for use.

3、 Installation of roller bars: The process of inserting the roller bars into the kiln should be completed as soon as possible to avoid prolonged heating of the roller bars in a non rotating state. In the case of a warm kiln, when the kiln temperature rises to 300-400 ℃, put in the roller bar and then steadily increase the temperature.

4、 The use of roller bars: During normal use, the kiln temperature should be kept stable to avoid local temperature fluctuations; Regularly check the operation of the roller and handle any abnormalities promptly.

5、 Replacement of roller: When there is adhesive on the surface of the roller, it should be replaced in a timely manner. When removing the roller rod under high temperature conditions, attention should be paid to avoiding bending of the roller rod. The removed roller rod should be immediately placed on a support with insulation material and continuously rotated until it cools down to below 600 ℃; Alternatively, place the roller on a flat insulation material and cover it with insulation cotton to gradually cool it down.

6、 Protection of Roller Rod: It is recommended to use roller rod protection coating in the working section of the roller rod to effectively reduce the erosion of the kiln atmosphere and molten substances. Please refer to "Ceramic Roller Rod Anti Corrosion Protection Coating" for details. Ceramic rollers should be avoided from use in alkaline atmospheres. Hot rollers should avoid contact with the ground or cold metal.

7、 Cleaning of roller: When adhesive appears on the surface of the roller, it should be removed and cleaned. Do not use hard tools to strike the roller rod when removing surface adhesive. If roller protection coating is used, new coating should be applied after cleaning.

8、 Stop kiln cooling:

1. When the kiln is turned off and cooled down, continue to turn on the smoke exhaust fan, turn off other fans, maintain a slight positive pressure in the firing zone, and keep the rollers running normally. When the kiln temperature drops below 500 ℃, the rollers can be removed.

2. When cooling down a kiln using water gas as fuel, the smoke exhaust fan and residual hot air fan should be adjusted according to the specific situation of the kiln pressure and cold air leakage, to ensure that there is no cold air leakage in the burning zone, and the temperature should be steadily cooled to below 500 ℃ before removing the roller bars.

3. For kilns using heavy oil as fuel, the fan should be adjusted throughout the entire cooling process when stopping the kiln to maintain the balance of the original suction force inside the kiln and avoid negative pressure causing cold air leakage. By reducing the airflow velocity inside the kiln, stable cooling can be achieved. When the temperature drops below 500 ℃, the roller bars can be removed

9、 Other: It is recommended to insert insulation fiber cotton or other insulation materials into the 50-60mm holes at both ends of the roller rod.

Ceramic roller anti-corrosion protective coating

Ceramic roller anti-corrosion protective coatings are generally composed of two types of coatings: bottom coating and surface coating, which need to be used in combination. At high temperatures (1000-1250 ℃), the bottom coating does not react chemically with the surface of the ceramic roller and the surface coating, while the surface material can quickly sinter and harden, forming a hard protective layer that protects the surface of the ceramic roller from contamination and corrosion by corrosive waste gases and impurities such as brick glaze in the kiln.

1、 The use of paint

Before use, the bottom and top coatings should be stirred evenly and the impurities on the surface of the roller should be cleaned to make it smooth and clean.

When brushing, first apply the bottom layer of coating with a thickness of about 0.2-0.3mm. Wait for natural drying for more than 30 minutes before brushing the surface layer of coating with a thickness of about 0.4-0.6mm. Customers can determine the number of sizing times according to their actual situation.

After painting, the roller can be placed next to or on top of the kiln for drying.

When changing the rod, the roller must be fully dried and directly inserted into the high-temperature belt to prevent the coating from falling off.

When replacing the rollers in the kiln during the normal usage cycle, gently tap or peel the surface coating after the rollers have cooled down. At this time, the surface coating will peel off like a cooked eggshell. After slightly cleaning the surface of the roller, apply the bottom and top coatings in sequence. After drying, the roller can be reused.

2、 Special Reminder

Due to the fact that the bottom and top layers are two different types of coatings, the sizing bucket and tools should be separated during sizing and should not be mixed.

Both the bottom and top layers of the coating are prone to precipitation from materials with high specific gravity. Therefore, before each use, the coating should be thoroughly stirred and the specific gravity range of the bottom and top layers should be controlled. The specific gravity of the bottom coating should be controlled between 1.35-1.45, and the specific gravity of the top coating should be controlled between 1.50-160.

3、 Parameter comparison

Compare content	Use roller coating	Using a traditional roller bar grinder
Usage effect	The protective coating can effectively protect the roller rod from glaze corrosion, making it easy to peel off, and most effectively extend the service life of the roller rod. Invisibly reducing the cost of using the roller rod.	After polishing, the surface of the roller rod will not be smooth. Frequent polishing will cause the diameter of the roller rod to be reduced and increase the structural damage of the roller rod, thereby reducing its service life.
processing time	Each one takes 2-3 minutes	Each one takes 5-8 minutes
Handling method	Peel off the coating after the roller bar cools down	Heat and polish inside the polishing machine
Handling losses	No	The mechanical wear caused by polishing is about 10-30%
Processing cost (taking 400 pieces of diameter 40 * 300 as an example)	No specialized equipment required, with a cost of only 200-300 yuan per use	Special equipment needs to be purchased, and without considering the investment, depreciation, and power consumption of the equipment, the loss per use is about 1000-2000 yuan