Lined Ceramic Wear-Resistant Pipe

What are Lined Ceramic Wear-Resistant Pipes?

Lined ceramic wear-resistant pipes consist of a robust metal exterior combined with a ceramic lining. This unique design provides exceptional protection against wear and corrosion, making these pipes ideal for challenging environments where traditional materials may fail.

The lined ceramic wear-resistant pipe has the characteristics of high strength, good toughness and impact resistance. Welded steel pipes and corundum ceramics have high hardness, wear resistance, corrosion resistance and heat resistance, which overcomes the problem of low hardness. Therefore, the ceramic wear-resistant pipe has excellent induction functions such as wear resistance, heat resistance, corrosion resistance, mechanical and thermal shock resistance, and good weldability.

Features

1. Longer life time, reduce maintenance costs
2. Higher cost performance
3. Reduce pollution to raw materials
4. Easy to disassemble and maintain

Benefits

• The coal will bring great impact to the equipment during transportation in the coal handing system of power station, so the alumina ceramic tiles s not available and they will fall of by large area.
• The valve in the desulfurization system can change the follow during the switching process, sot he slurry with grain at high speed will wear out the pipe at the ends of valves. The liquid in the tube contains much sulfite which is very corrosive, so usually nonmetallic pipes like rubber tubes and PVC pipes are used to avoid corrosion, but the wear resistance of these tubes are poor that the straight pipe at the ends of valves always worn out. The alumina ceramic lined tube/elbow is one piece, the slurry couldn’t permeate through it, moreover, the alumina tube/elbow has high hardness and the process by isostatic pressing dry power is favorable to the uniformity of ceramic crystal structure, so its wear resistance is better than ceramic tiles with the same materials.
• The weakest place is the gap between each sticked tiles during material handing. The material grains not only wear the pipe but also have impact on it. This is why the pipelines lined by tiles are easily worn out and fallen off.
• The experiment shows that the service life of ceramic tube/elbow is at least 5 times longer than ceramic tiles of the same thickness.

In the demanding world of industrial applications, the need for durable and efficient piping systems is crucial. Lined ceramic wear-resistant pipes have emerged as a leading solution, offering unmatched performance in transporting abrasive and corrosive materials. This article delves into the features, benefits, and applications of lined ceramic wear-resistant pipes.

Benefits

• Outstanding Abrasion Resistance: The ceramic lining in these pipes provides superior resistance to wear and tear, making them perfect for industries that deal with abrasive materials, such as mining and mineral processing.
• Corrosion Resistance: Lined ceramic pipes are engineered to withstand harsh chemicals and corrosive environments, reducing the risk of pipe failure and minimizing maintenance costs.
• High-Temperature Tolerance: These pipes can operate effectively in high-temperature conditions, ensuring reliability in power generation and manufacturing processes where heat is a factor.
• Extended Service Life: The combination of metal and ceramic results in a longer lifespan compared to standard pipes, offering significant savings in replacement costs and downtime.
• Enhanced Flow Efficiency: The smooth ceramic surface reduces friction, allowing for better flow characteristics and increased efficiency in fluid transport systems.

Applications

Lined ceramic wear-resistant pipes are versatile and find applications in various sectors, including:

• Mining and Mineral Processing: For transporting slurries and abrasive materials, minimizing wear and downtime.
• Chemical Processing: To handle aggressive chemicals safely, enhancing system reliability.
• Power Generation: In environments where high temperatures and corrosive substances are present.
• Water Treatment: To manage abrasive materials in filtration systems efficiently.

Recently 95% alumina ceramic sleeve lined pipes, elbows and T pipes have been largely applied in lithium battery material conveying system.. The main raw material of wear resistant ceramic ring is a special kind of ceramic with AL2O3 as the and the rare metal oxide as the flux, which is melted by high temperature at 1700 °C. The big diameter ceramic sleeve is always a big problem for the ceramic tube manufacturers since it’s very difficult to control the deformation rate of the ceramic sleeve after it’s sintering .Also It will also need an advanced and big isostatic pressing machine to do this .So it will not only express the company’s production capability ,but company’s technology. Right now, our factory have owned both advantages which are wear resistant ceramic pressing facilities and technologies.

Relevant technical introduction of wear-resistant ceramic ring

The wear resistant ceramic ring is a special kind of ceramic with Al2O3 as the main raw material and the rare metal oxide as the flux, which is melted by high temperature at 1700 oC.

Features

1. The wear-resistant ceramic ring has the characteristics of smooth interior wall and super wear resistance. Widely used in chemical, fine powder conveying pipelines and other industries, with high wear-resistant and anti-corrosion functions.
2. In accordance with the traditional process, the production of wear-resistant ceramic ring is mainly the use of hot-pressing casting or grouting molding. Adopting isostatic pressing forming technology, the ceramic ring with isostatic pressing is better in compactness and more accurate in ceramic size.
   
3. At present, our ceramic ring lining pipeline in the silicone industry, chemical industry, fine powder conveying industry has been widely used.

What is ceramic sleeve lined pipe?

Ceramic sleeve lined pipe has a continuous ceramic liner covering the inner surface of the pipe. The ceramic liner, or sleeve, is typically made of high-quality alumina ceramics, which provides excellent resistance to wear, abrasion and corrosion.

Ceramic sleeve lined pipes are commonly used in industrial applications where the pipeline is exposed to harsh conditions, such as in mining, power generation, oil and gas, and chemical processing. The ceramic sleeve provides superior wear resistance and protects the underlying steel pipe from premature failure due to abrasion or corrosion.

In addition to their excellent wear properties, ceramic sleeve lined pipes may also provide benefits such as improved flow rates, lower maintenance costs, and longer service life. They may also be used in applications where hygiene is important, as the ceramic sleeve lining is non-toxic and does not react with most chemicals.

Ceramic sleeve lined pipes may be manufactured in various sizes and shapes, including elbows, tees, and reducers, to meet the specific requirements of each application. The ceramic sleeve may be bonded to the steel pipe using specialized adhesives and may be installed using conventional welding or mechanical joining techniques.

While ceramic sleeve lined pipes can offer significant benefits in terms of wear resistance and longevity, they are typically more expensive than traditional steel pipes due to the cost of the ceramic liner and specialized manufacturing processes.

What are Ceramic pipe sleeves?

Ceramic pipe sleeves are a type of ceramic lining designed to protect metal, plastic or composite piping systems from wear and abrasion caused by high-velocity flows of abrasive materials. They are typically made of highly engineered ceramic materials such as alumina or silicon carbide, which provide excellent resistance to wear, corrosion, and erosion.

Ceramic pipe sleeves are widely used in industries such as mining, power generation, and chemical processing where the harsh environment can cause significant wear and damage to the piping systems.

The advantages of using ceramic pipe sleeves include:

1. Exceptional wear resistance: The ceramic material used for the sleeve provides excellent resistance against wear and abrasion caused by abrasive media, improving the lifespan of the piping system.
2. Corrosion resistance: Ceramic materials are highly resistant to corrosion, making them ideal for use in corrosive environments.
3. High-temperature resistance: Ceramic pipe sleeves can withstand high temperatures without losing their mechanical properties, making them ideal for use in high-temperature applications.
4. Reduced friction and turbulence: The smooth surface of the ceramic pipe sleeves reduces friction and turbulence, resulting in reduced pressure loss and increased flow rates.
5. Improved safety and reliability: Ceramic pipe sleeves can significantly reduce the likelihood of equipment failure, enhancing the safety and reliability of industrial operations.
6. Easy installation: Ceramic pipe sleeves are easy to install and can be tailored to fit specific sizes and shapes required by the application.

Overall, ceramic pipe sleeves are an effective and reliable solution for protecting piping systems from the harsh effects of abrasive materials. They offer superior wear resistance, corrosion resistance, and improved efficiency compared to traditional materials, reducing maintenance costs and improving system performance.

Alumina ceramic specifications

The combination of high rigidity of ceramic and high elasticity of steel gives the pipe unmatchable features as an abrasion resistant, heat resistant and corrosion resistant material for use in the fields of power generation, metallurgy, mining, and chemical industry etc. It has many advantages over steel pipes, cast stone pipes, and steel-plastic compound pipes.

Layer size of ceramic sleeve lined pipe

304 Stainless Steel Plate has very good formability and can be readily welded by all common methods.

Packaging and delivery of Ceramic sleeve lined pipe

Abrasion resistant pipe using steel skeleton packaging, and the two ends of the pipe with plastic head, to prevent dust and rain into the pipeline inside, to ensure the beauty of the product.

Process of ceramic sleeve lined pipe

For different production environments, our company has developed a wear-resistant pipe for a variety of media, based on the temperature, wear and corrosion requirements of the field media, and for the initial application of the scene, our company to provide wear-resistant ceramic ring for the Lined composite straight pipe design to meet the on-site wear resistance, heat resistance and corrosion resistance requirements, in view of this program for the new design (formerly ceramic chip technology, there are many gaps, easy to wear).

Paint process

After the ceramic ring in the pipe is installed and the thread is processed, the dirt outside the pipe is cleaned, and the outer surface of the pipe is treated with three layers of anticorrosive paint to meet the export requirements.

For the convenience of customers, are to provide a more specific process is as follows:

1. Removing rust and decontamination process of outer-layer steel pipe;
2. Must be in strict accordance with the prescribed ratio, the binder a\b accurate measurement, with how many, must be stirred evenly, full stir-mixing must not be less than 4 times, such as adding a mixture of the embedded feed should be mixed with the binder and then add the mixture to stir up not less than 3 times;
3. The binder is applied evenly on the inner wall of the steel tube to ensure the thickness is not less than 0.5mm thickness. Then apply the binder on the outer surface of the ceramic ring to ensure the thickness between the 0.5mm-1mm. Also in the ceramic ring side (with the ceramic ring contact with the corresponding surface) Daub 0.5mm Adhesive, to ensure that after the installation of the ring and the seal between the ring;
4. After the installation of the ceramic ring in place, it is necessary to repair the gap between the assembled ceramic rings and mend the joints to ensure the sealing between the ring and the ring;
5. According to the NPT standard, we process the two pipe ends of male and female thread processing. The end of the pipe processing, and processing 1x45° groove, to prevent on-site installation in the process of cutting the hands of construction workers, do a good job of safety protection measures, thread processing, need to brush oil to protect the thread;
6. After installing the ceramic ring, check the internal surface of the ceramic ring of the formation, finishing in place, cannot move the position of the pipe, because the binder is not dry, vibration is easily caused by the displacement of ceramic rings, affect the use of the effect of cold weather in winter, binder drying time is longer, need to ensure more than 48 hours.

Ceramic sleeve lined manufacture details

Technical index of binder

Item	Data	Characteristics of binder
Density (g/cm3)	1.32	We use the Australian Megapoxy high strength structural adhesive, this structural glue is modified epoxy resin polymer, anti-aging ability, and wear-resistant ceramic bonding to form a strong and cushion of the anti-wear layer, cured water, anti-corrosion performance is excellent, toughness, displacement-resistant effect is remarkable.
Compressive strength (MPa)	40
Shear Strength MPa	26
Impact toughness Kj/m2	10
Hardness HB	9.5
Elastic Modulus GPa	2.2
Expansion coefficient 10-6/℃	20.1
Softening temperature℃	263
Coking temperature℃	335
Acid resistance（24H）	Stability	Test solution : 15%H2SO4
Alkali resistance（24H）	Stability	Test solution: NaOH