Abrasion resistant ceramic tile lined elbows

Alumina Lining Ceramic Tile Burners for power plants

Wear resistant ceramic lined elbow

Wear resistant ceramic lined elbow is a type of piping component that is designed to resist wear and abrasion in high-stress industrial environments.

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Category: Ceramic tile lined pipes Tag: Abrasion resistant elbow

Description

Wear resistant ceramic lined elbow is a type of piping component that is designed to resist wear and abrasion in high-stress industrial environments. it typically consists of a steel elbow that has been lined with wear-resistant ceramics such as alumina, zirconia or silicon carbide.

Wear resistant ceramic lined elbows are used in applications where the transported material is abrasive, such as in mining, chemical processing, power generation, and cement manufacturing. the ceramic lining provides superior resistance to abrasion, erosion, and corrosion, which helps to extend the life of the elbow and prevent costly downtime.

The selection of a wear resistant ceramic lined elbow should be based on factors such as the diameter, bend angle, and thickness of the ceramic lining. the material being conveyed and the operating temperature and pressure must also be taken into consideration.

In addition to providing excellent wear resistance, ceramic lined elbows also offer good thermal shock resistance and can withstand high temperatures. they provide a reliable and cost-effective solution to reduce maintenance costs and increase productivity in harsh industrial settings.

At present, the common ceramic sheets lined with ceramic composite pipes are: ceramic block, dovetail mutual pressure, welding type, mosaic, card slot and so on.It has the characteristics of wear resistance and long service life.

Abrasion resistant ceramic lined pipe, Abrasion Resistant Lined Pipe and Elbow, Wear Resistant Alumina Ceramic Cone

The integral ceramic tube is the ceramic pipe fittings as a whole after firing, with a special filling material will be poured in the steel pipe internal assembly. The pipe wall is smooth, good sealing, with good wear resistance, corrosion resistance.

Abrasion resistant ceramic tile lined steel pipes are composed by steel pipe, adhensive and abrasion-resistant ceramic, we use 20 # seamless steel pipes shaping with hot bending (it is different from centrifugal casting or steel plate rolling), the ceramic tiles bonding with GWJ-350 high temperature-resistant inorganic adhesive which was developed by TsingHua University and to affix abrasion-resistant ceramic in the steel pipes, we use miss match installation instead of directly bonding (this technology was used in the bridge building a thousand years ago), and forms a firm wear-resistance layer after heating solidification. Abrasion resistant ceramic tile lined steel pipes are applicable for the pneumatic powder-feeding, and can be used under a temperature of 350℃without aging and peeling for long life. The service life is 4-5 times than the normal abrasion-resistant pipes.

Advantage

Super wear-resistant, high density: we use 95% of chromium corundum, 100 tons dry-pressing.
Elbows formed by hot-bending, the outside of the bending part are seamless which is wear-resistant and can prolong the service life.
Firmly bonding without pealing: we use epoxy adhesive and miss-match installation technology, so that there is no straight-seam.
High temperature and ageing resistance: we abandon the traditional organic bond, and use inorganic bond which is ageing resistance.
High pressure resistance: We use 20# seamless steel pipe, which is high pressure resistance and avoiding welding leakage.
The pipe with smooth inner wall which can make the materials flow smoothly: we use seamless steel pipes which have a smooth inner wall that can reduce weariness, and the height tolerance of ceramics is below 0.5mm.

Application Guidance

Avoid welding on site, the welding layer should be 30mm above the ceramic layers; according to our experiences, if you need a shot welding (for example spot welding) or must welding, watering after welding, which will reduce the damage of adhesive layer.
Avoid striking and throwing the pipes during transportation and installation.
To achieve the best abrasion-resistant solutions, thicken ceramic liners can be used in the elbow which has serious abrasions.

Features

Ceramic tile lined pipe is our company to absorb similar products at home and abroad on the basis of advanced technology developed a shell for the steel body, within the wear-resistant ceramic tube of the new composite pipe products, with high wear resistance long service life And so on

The use of anti-off porcelain tube, porcelain tube mosaic, so that paste more flat, more solid with a strong inorganic adhesive paste, wear-resistant steel bowl welding, porcelain and steel body combined to form a double reinforcement to ensure that the porcelain tube does not fall off. The installation of flexible, high wear resistance, processing convenience, the cost is moderate.

High hardness
Rockwell hardness of high alumina ceramics is up to HRA80-90 which is second only to diamond and far exceeds wear-resistant steel stainless

Excellent wear resistance
The wear resistance of high alumina ceramics is 266 times that of manganese steel and 171.5 times that of high chromium cast iron. According to our investigation & follow-up to the clients, the service life of equipment can be prolonged over 10 times under the same working conditions.

Corrosion resistance
High alumina ceramics are inorganic oxides with extremely stable molecular structure and no electrochemical corrosion, thus they can resist erosion of acid, alkali, salt solutions and organic Solvents.

Thermostability
Working temperature of high alumina ceramics can be as high as 1400℃.

Good self-lubricity
High alumina ceramics have the properties of self-lubricity and in adhesion, the roughness is only 1/6 that of steel pipes thus less flow Resistance.

Light weight
The density of high alumina ceramics is about 3.6g/cm3, which is only half that of steel, thus easy for construction and installation.

Technology and structure of ceramic tile lined pipe

Ceramic tile lined pipe is composed of three layers: outer steel pipe layer, corundum layer, and ceramic glue layer. The inner ceramic layer is white from the surface. The ceramic is generally 95% ceramic, and the temperature is generally below 200°C.

At present, the common ceramic sheets lined with ceramic composite pipes are: ceramic block, dovetail mutual pressure, welding type, mosaic, card slot and so on. It has the characteristics of wear resistance and long service life.

Performance

Large hardness
Rockwell hardness HRV 80-90
High wear resistance
Wear resistance is equivalent to 20-30 times of high manganese steel.
Light weight
Its density is 3.9g/cm³, which is only half that of steel, which can greatly reduce the equipment load
Imported glue
Magbao imported glue, bonding strength: 10Mpa, working temperature: -60℃ to +250℃, welding type, wear resistance up to 800℃.

Specifications

Pipe diameter: ≥DN100
Steel pipe thickness: ≥4mm
Steel pipe material: Q235 or stainless steel
Ceramic thickness: 4mm, 6mm, 8mm, 10mm, etc.
Connection method: flange, welding, casing, V-connector
Working pressure: ≤1.0 MPa (other pressures need to be communicated with customer service)

Ceramic tile technical indicators

Ceramic marking: 92-95
Bulk density: 3.9g/cm³
Tensile strength: 1030MPa
Flexural strength: 212MPa
Hardness HRV: 80-90

Process

The ceramic tile is pasted on the steel pipe with high temperature wear-resistant glue to play a wear-resistant role, and the pipe is generally white. Generally used for large diameter pipes.
Bends and other profile sections can be clad in whole and this process has changed the traditional practice to fabricate bend and other profile sections by drawing polyline without changing flow pattern of material inside piping, greatly reducing conveyance resistance of material.

Production requirements for the process of pasting tiles on the inside of steel pipes

The ceramic tiles are pasted to the inner wall of the steel pipe with high temperature wear-resistant glue to play a wear-resistant role.

No.	Process	Standard	Inspection
1	Cleaning the inner surface of the fitting	Clean up all the rubbish and floating ash on the inner surface of construction equipment and pipe fittings.	Checked by the construction supervisor.
2	Rust removal, oil removal, paint removal	The rust, grease, and paint on the bonding surface must be completely removed without leaving any traces. Use iron sand skin, angle grinder, and soft sand skin to polish to see the metallic luster. After cleaning, wipe the surface with a cloth until there is no trace of dirt.	After the inspection and acceptance by the quality inspector, the construction of the next process can be carried out.
3	Formulated Adhesives	It must be measured in strict accordance with the prescribed proportion, and how much should be used; it must be stirred evenly, and the overall mixing should not be less than 4 times; if the mixed embedded material is added, the binder must be mixed well before adding the mixture and mixing Not less than 3 times.	Assigned by designated personnel.
4	Repair of the adhesive surface	If there are potholes on the pasting surface, especially if there are large potholes on the pasting surface of the old equipment, the wear-resistant ceramic sheet must be gradually filled with embedded materials.	After the inspection and acceptance by the quality inspector, the construction of the next process can be carried out.
5	Paste wear-resistant ceramic tiles	There should be no dust or dirt on the surface of the ceramic tiles. The surface of the repaired inlay material must be leveled. The pasting surface must be wiped again. Scrape the adhesive on the pasting surface for 1-2 times and scrape it flat. Scrape the back of the ceramic sheet for 1 It is necessary to ensure that there is a certain thickness of uniform adhesive available for pasting.	Checked by the person in charge of the construction of the pasted ceramic tiles.
6	Repair of gaps and corners between ceramic tiles	The gaps exceeding 3 mm must be repaired with wear-resistant and anti-corrosion fillers, the edges and corners must be neat, and the bevels must be trimmed with special ceramic tiles and then filled with fillers.	After the repair, the person in charge of the construction and the quality inspector will conduct a comprehensive quality inspection, and submit it to Party A for acceptance after passing the inspection.
7	Maintenance time	After construction and repair are completed, it can be put into use after natural maintenance for more than 12 hours after acceptance by Party A.