长寿耐磨 · 稳定运行 · 膨润土低添加、零增加。行业唯一包保 3~6 年，六大核心技术覆盖柱钉、辊面、边部与现场修复。 Long life, stable operation and low bentonite addition with zero increase. The industry's only HPGR guaranteed for 3–6 years, with six core technologies covering studs, roll surface, edges and on-site repair.
辊压破碎通过压力穿透物料内部结构形成裂纹，比撞击破碎效率高、单耗低。但高压辊在使用中普遍存在柱钉磨损过快、辊面轴向内凹、辊面坑洼、边部坍塌等问题，必须同时从材料和结构两端解决。 Roller-press comminution drives pressure through the material's internal structure to form cracks, giving higher efficiency and lower energy use than impact crushing. Yet HPGR rolls commonly suffer rapid stud wear, axial concavity, surface pitting and edge collapse — problems that must be solved from both the material and the structural side.
发明专利 ZL 2024 1 1758990.5《一种烧结球团矿粉破碎用的耐磨长寿化高压辊辊套》，把柱钉长寿化、内凹控制、磨损同步、防坑洼、防塌边、现场修复六条技术路线写在一起。 Invention patent ZL 2024 1 1758990.5 (wear-resistant, long-life HPGR roll sleeve for sinter and pellet comminution) brings together six technical routes: stud longevity, concavity control, wear synchronization, anti-pitting, anti-edge-collapse and on-site repair.
柱钉在独立开发的疲劳磨损试验机上检测，疲劳磨损失重较德国领军企业柱钉少三分之二。这是包保 3~6 年敢写进合同的底气。 Tested on our own fatigue-wear rig, our studs lose two-thirds less mass than those of the leading German supplier. That is what makes a 3–6 year guarantee something we are willing to put in the contract.
前三项解决"磨得慢"，后三项解决"不提前下线"。只做前三项，辊子会因为局部崩块或塌边提前退出，寿命一样上不去。 The first three make wear slower; the last three keep the roll from leaving service early. Do only the first three and the roll still exits early through local spalling or edge collapse, and life does not improve.
晶粒细化 + 钴钨结合优化，匹配硬度 / 强度 / 韧性三项指标；配套预应力柱钉制造与装配技术，过盈配合装配更牢靠。 Grain refinement plus optimized cobalt–tungsten bonding balances hardness, strength and toughness; prestressed stud manufacture and interference-fit assembly hold the studs more securely.
疲劳磨损失重较德企少 2/32/3 less fatigue mass loss辊面预内凸（腰鼓形），中部较边部高 3~5mm（规范许可 10mm），提升中部柱钉性能，强化轴向内凹控制。 A pre-crowned (barrel) surface leaves the centre 3–5 mm higher than the edges against a 10 mm allowance, strengthening the centre studs and tightening control of axial concavity.
预内凸 3~5mm3–5 mm pre-crown柱钉间隙嵌入小柱钉形成匹配网面，减轻基体微动磨损，让辊面和柱钉以接近的速率磨损。 Small studs embedded in the gaps form a matching mesh that reduces fretting wear on the base body, so surface and studs wear at similar rates.
小柱钉嵌入形成网面Small studs form a mesh中低合金基体提高韧性，防异物侵入崩块；高韧性柱钉难折断、崩碎，避免局部快速磨损扩大成坑洼。 A medium-to-low alloy base raises toughness against spalling from foreign objects, while high-toughness studs resist fracture, stopping local wear from growing into pits.
中低合金钢基体，现场用自研 DSYH-2000 堆焊补强及补块，不必整套下线更换。这是中低合金路线成立的前提。 The medium-to-low alloy steel body accepts on-site DSYH-2000 hardfacing and patching, so the whole assembly need not be removed — the precondition that makes this alloy route viable.
DSYH-2000高耐磨高韧性侧板，防止侧板更换不及时、边块断裂掉落引发塌边。塌边一旦发生，整个辊面的有效寿命就被截断。 Tough, highly wear-resistant side plates prevent edge collapse caused by late side-plate replacement or fractured edge blocks. Once the edge collapses, the usable life of the whole surface is cut short.
边部是高压辊最先失效的位置。同样是拆检实拍，时间还多了 12 个月。 The edge is where an HPGR roll fails first. Both photographs are taken at teardown — ours has run twelve months longer.
原装 / 进口备件辊使用 16 个月起轴向内凹 >10mm、开始换钉，约 3 年整体更换；国产修复辊使用 9 个月轴向内凹即 >10mm；两者均每 6 个月更换侧衬板。 Original and imported spare rolls showed axial concavity over 10 mm from 16 months, requiring stud replacement and full replacement at about three years; a domestic refurbished roll passed 10 mm within nine months. Both needed side-plate replacement every six months.
包保 3 年，轴向内凹 <5mm，柱钉凸出辊面仅 4~7mm。全程未更换侧衬板，压力由 69bar 升至 88bar、膨润土用量稳定，助力同等球团品质下降低对铁矿原料的要求。 Guaranteed for three years, with axial concavity under 5 mm and studs protruding only 4–7 mm. No side plate was replaced throughout; pressure rose from 69 to 88 bar with bentonite dosage stable, helping achieve the same pellet quality from less demanding iron ore.
现状：2024 年 5 月起包保 6 年，2026 年 3 月过程检查状态理想。 Status: on a six-year guarantee since May 2024; the March 2026 interim check found the condition ideal.
原装 1 套 + 备件 2 套，每套使用约 2 年；47mm 高柱钉磨损量 >30mm、轴向内凹 20~25mm，每 6 个月更换侧衬板。 One original set plus two spares, each lasting about two years; 47 mm studs wore by more than 30 mm with axial concavity of 20–25 mm, and side plates were replaced every six months.
高精度辊运行期间，22mm 柱钉磨损仅 5~7mm、内凹仅 4~5mm；全程侧衬板完好未更换，压料与膨润土用量稳定。 Over the run of our high-precision roll, 22 mm studs wore only 5–7 mm and concavity reached just 4–5 mm; side plates stayed intact and unreplaced, with compaction and bentonite dosage stable.
现状：2025 年 3 月我司修复辊上线，2026 年 4 月检查柱钉磨损仅 3mm。 Status: our refurbished roll entered service in March 2025; an April 2026 check found stud wear of only 3 mm.
两个现场的共同点：全周期内膨润土等低添加、零增加，侧衬板不用中途更换。合作模式为功能包保、新制与修复三种，均可按现场条件组合。 What both plants share: low bentonite addition with zero increase across the full cycle, and no mid-life side-plate replacement. We work through functional contracting, new-build and refurbishment, combined to suit site conditions.
我们解决了宝武湛江、粤裕丰等球团厂使用的进口原装高压辊破损修复的技术难题，确保生产作业率、降低成本。 We resolved the technical challenge of repairing damaged imported HPGR rolls at pelletizing plants including Baowu Zhanjiang and Yueyufeng, protecting production availability while lowering cost.
| 用户Customer | 规格 (mm)Size (mm) | 投运时段Service period | 备注Terms |
|---|---|---|---|
| 宝钢湛江球团Baosteel Zhanjiang | Φ2000×1500 | 2025.03 起from 2025.03 | 质保 2 年2-yr warranty |
| 宝钢湛江球团Baosteel Zhanjiang | Φ2000×1500 | 2022.10–2025.03 | 质保 2 年2-yr warranty |
| 粤裕丰裕嘉球团Yueyufeng Yujia | Φ1400×800 | 2024.05 起from 2024.05 | 包保 6 年6-yr guarantee |
| 粤裕丰裕嘉球团Yueyufeng Yujia | Φ1400×800 | 2021.01–2024.05 | 包保 3 年3-yr guarantee |
| 粤裕丰裕嘉球团Yueyufeng Yujia | Φ1400×800 | 2018.01–2021.01 | 包保 3 年3-yr guarantee |
| 昆钢球团Kunming Steel | Φ1200×600 | 2016.05–2019.10 | 质保 2 年2-yr warranty |
给出辊子规格、物料类型、当前柱钉磨损量与轴向内凹量、侧衬板更换周期，我们会给出新制或修复方案，并附可写入合同的包保年限。 Send us the roll size, material type, current stud wear and axial concavity, and side-plate replacement interval. We will return a new-build or refurbishment proposal with a guarantee period we can put in the contract.
索取包保方案Request a guarantee proposal