The wear resistance of hammer plates is crucial when crushing limestone in cement production. One of the most significant factors influencing the hammer’s lifespan is the silicon content in the limestone. Higher silicon content leads to shorter hammer life, as it accelerates wear. Ideally, the silicon content should be below 2% in limestone. Additionally, the compressive strength of the limestone plays a significant role—higher compressive strength results in greater brittleness and a reduced hammer lifespan.
Traditionally, cement industries with hammer crushers opted for high manganese steel casting, such as ZGMn13Cr2. This material, after heat treatment, reaches a hardness of HRC 23. However, most limestones contain higher silicon levels, which severely shorten the hammer’s working life. For example, some hammer plates, like the 2022 model, may fail after processing fewer than 100,000 tons of material.
With advancements in technology, the industry has now moved toward using ultra-high manganese steel or double composite wear-resistant alloys for casting hammer plates. The ultra-high manganese steel, ZGMn18Cr2MoRe, is an improvement over ZGMn13Cr2, with an increased manganese content. This change improves the heat treatment hardness of the hammer, enhancing wear resistance and overall durability. However, increasing manganese content and other alloying elements beyond certain limits may also decrease the hammer’s toughness.
The best choice today is the double composite wear-resistant alloy hammer, which includes several innovative features:
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The work surface is overlaid with a hard alloy to improve abrasion resistance.
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The hammer’s main alloying element, chromium, is optimized during the casting process to improve performance.
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In some designs, carbide rods or alloy ingots are embedded into the hammer’s working surface.
The overall quality of the hammer plate depends on factors such as alloy composition, material content, heat treatment, hardness depth, and many other variables. In addition to these, the crushing conditions, limestone particle size, water content, clogging of the crusher discharge grate, and operational downtime all influence hammer life.
HIGHCR Casting has extensive experience in producing high-quality, wear-resistant hammer plates tailored to your needs. If you have an inquiry, feel free to reach out to us for the best solution.
Key Features of HIGHCR Hammer Plates:
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Enhanced Silicon Resistance:
Silicon content in limestone directly affects hammer plate wear. Higher silicon content results in accelerated wear and a shortened lifespan. Our hammer plates are designed for optimal performance with limestone that has less than 2% silicon content, ensuring a longer lifespan and higher efficiency. -
Superior Manganese Steel:
Traditional hammer plates made from ZGMn13Cr2 steel have limited wear resistance, especially with high-silicon limestone. At HIGHCR, we use ZGMn18Cr2MoRe ultra-high manganese steel that improves the hardness of the hammer plates after heat treatment, providing superior wear resistance and extended life. -
Double Composite Wear-Resistant Alloy:
Our double composite wear-resistant alloy hammer plates are the ultimate choice for maximum durability:-
Hard Alloy Surface Layer: We overlay the hammer’s working surface with a hard alloy to significantly improve abrasion resistance.
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Optimized Alloy Content: The chromium content in the hammer alloy is carefully selected to maximize wear resistance and improve overall hammer performance.
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Carbide Rods and Inlaid Alloy Ingots: For enhanced impact resistance, we embed carbide rods or alloy ingots into the hammer’s working surface.
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Custom Solutions for Your Needs:
At HIGHCR, we understand that each crushing application is unique. Our team customizes hammer plates based on the specific particle size, water content, and other variables in your limestone. We work closely with you to create a hammer plate that fits your crusher and extends operational life.
Why Choose HIGHCR Hammer Plates?
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Longer Hammer Life: Our advanced materials and heat treatment techniques result in hammer plates that last longer, reducing downtime and maintenance costs.
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Enhanced Crushing Efficiency: The wear-resistant properties of our hammer plates ensure consistent crushing performance, even in demanding conditions.
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Customized Solutions: We offer tailored solutions based on your limestone’s characteristics and your crushing needs.
Industries Served:
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Cement Production
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Mining
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Aggregate Processing
Contact HIGHCR for High-Quality Hammer Plates
HIGHCR is a global leader in the manufacturing of wear-resistant hammer plates. With years of expertise, we provide solutions that increase operational efficiency and reduce costs. If you’re looking for durable and reliable hammer plates for limestone crushing, get in touch with us today for a customized solution.
Contact Us for a Quote
Reach out to our sales team for a free quote or more information on how our hammer plates can improve your limestone crushing process.
