New wear-resistant materials: break through the high temperature and pressure exclusion zone

The compressor is the heart of petrochemical equipment and its key components are all dynamic seals. Although the dynamic sealing element is small, it is an integral part of the core technology of the equipment, and the high-temperature and high-pressure oil-free lubrication compressor represents the equipment level of a country. Traditional dynamic seals often require oil lubrication, which not only has high operating costs but also contaminates subsequent media. The research group led by Prof. Lu Xiaohua of Nanjing University of Technology focused on this challenge by inventing a new manufacturing technology for ultra-fine wear-resistant titanate (TBF), and developing an internationally advanced, high-performance, long-life, high-temperature, high-pressure, oil-free lubrication seal. The components have promoted the simultaneous development of China's compressor industry and advanced countries.
Compared with traditional materials, a new generation of wear-resistant materials will increase the limit temperature from 160 °C to 185 °C, limit pressure from 20MPa to 32MPa, breaking the international tradition of carbon fiber reinforced polytetrafluoroethylene (PTFE) composites can not be used for high temperature The restricted area of ​​high pressure, and can prepare different performance TBF according to different needs. The high wear-resistant and sealed small components are used in advanced high-temperature and high-pressure compressors to meet the needs of manufacturers, solve the major problems of modern process industries, improve the competitive advantages of China's oil-free compressors, and make important contributions to the West-East Gas Transmission. contribution.
At present, compressors using TBF sealing materials have been used normally for more than 5 years at natural gas filling stations. Comparative tests showed that the service life of new products is 4 to 12 times that of domestic products, and the cost performance is 4.7 to 20 times that of foreign advanced products. At present, the product has been successfully promoted to high-temperature blower, high-pressure nitrogen (32MPa), hydrogen (27.1MPa), propylene, cracked gas, air and other gas compressors, resulting in economic benefits of 230 million yuan, It not only replaced imported products but also earned 13 million U.S. dollars in export earnings, creating billions of dollars in economic benefits for end users.
Compressed natural gas is a clean vehicle fuel. At present, China's compressed natural gas filling stations are growing geometrically. According to the plan, by 2015 there will be more than 6,000 natural gas filling stations in China, and high-temperature and high-pressure compressors are the key to gas filling stations. part. According to Lu Xiaohua's introduction, because the compressor outlet pressure is as high as 25 MPa, the sealing elements are easily worn. The service life of the existing domestic oil-free lubricating elements is only 800 to 1500 hours, which means that they need to be replaced within 2 to 3 months. Foreign sealing components are extremely expensive, cost accounts for 10% to 20% of the total cost of the compressor, and cannot be completely oil-free. At present, most companies use oily metal sealing elements that can easily cause pollution, which not only increases the cost of the compressor, wastes energy, but also has certain risks.
The reporter learned from the interview that friction materials produced using this technology have been applied to the automotive brake pad industry in China. The operating temperature of the automotive brake pads is above 300°C. The traditional brake pads will fail due to thermal degradation in long-term high temperatures. TBF brake pads using this technology can effectively avoid high-temperature thermal degradation. Currently, they are already in cities such as Nanjing and Shanghai. Installed on the bus. Road conditions experiments show that this product can completely replace high-priced foreign products, and the price is only 1/4 of similar products. It is estimated that China needs 80 million sets of brake pads every year. The demand for wear-resistant TBF in the domestic brake pads market is at least 2,000 tons per year. The value of the high-performance brake pads developed can reach 3 billion yuan.
Lu Xiaohua believes that the traditional PTFE material is suitable for oil-free lubrication of medium and low pressure equipment. It wears extremely high and has a very short life at high temperatures and pressures. In order to solve the problems in PTFE applications, Lu Xiaohua proposed using TBF to enhance PTFE to solve the new ideas of dynamic sealing under harsh conditions. This concept breaks through the traditional thinking of improving the wear resistance of the resin blindly and adopts the reverse thinking of reducing frictional heat from the source. By filling the titanate fiber, the poor fiber area that cannot be filled with carbon fiber is reinforced, and the coefficient of friction of the material is reduced. . Lu Xiaohua led the research group to invent the new high temperature and high pressure TBF reinforced PTFE material based on this idea, and realized the industrial scale production of new products with long life and no oil lubrication and sealing components under harsh conditions.
The ultra-fine wear-resistant TBF material developed with new technology has the characteristics of stable chemical properties, corrosion resistance, heat and heat resistance, abrasion resistance, lubricity, electrical insulation and high infrared reflectivity. Multipurpose advanced materials. The technical invention has not only developed a new type of high-temperature, high-pressure, oil-free dynamic sealing components, but also solved problems in many fields such as corrosion resistance, catalysis, friction, and high-temperature insulation, and many achievements have entered the stage of industrial production. The project has been granted 8 patents for inventions, forming patent family protection, and publishing 45 related papers.
Lu Xiaohua said that the application of TBF in the field of energy conservation and environmental protection in the future is also very broad. Due to the high temperature radiative heat transfer, it is difficult to avoid. At present, the high-temperature furnace kiln in industrial production consumes the most energy and the heat loss is also high. The potassium hexatitanate fiber in TBF has the characteristics of high infrared reflectivity and very low thermal conductivity at high temperature, and is a new type of heat insulation material, which can save about 20% of high grade energy. If the kiln adopting this technology can be popularized, it will save the power generation of two Three Gorges power stations. In addition, by adjusting the pore size and porosity of TBF porous materials, TBF porous materials can also be used as catalyst carriers to greatly reduce the desulfurization cost of Euro IV gasoline.

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