Pipe for feeding slurry
Ceramic lined pipe for feeding slurry to agitation tank
Our mild steel pipes with ceramic lining offer unparalleled resistance to wear, corrosion, and heat, making them perfect for demanding industrial applications.
Mild steel pipes with ceramic line coating are essentially different from traditional steel pipes, wear-resistant alloy cast steel pipes, cast stone pipes, and steel-plastic and steel pipes.
Download PDFEngineered with a durable alumina ceramic lining, these pipes provide a cost-effective and efficient solution for the toughest environments, including metallurgy, mining, and power generation.
The outer layer of the ceramic steel pipe is a steel pipe, and the inner layer is corundum. The corundum layer has a Vickers hardness of 1100-1500 (Rockwell hardness of 90-98), which is equivalent to tungsten-cobalt hard gold. The wear resistance is 20 times higher than that of the carbon steel pipe, and it is much superior to the corundum wheel which is usually bonded. Now the corundum grinding wheel is still the main grinding wheel for all kinds of grinding machines.
The corundum layer in the ceramic steel tube can wear away the corundum grinding wheel. The wear resistance of ceramic steel pipes is mainly due to the corundum layer with a thickness of several millimeters in the inner layer, and its Mohs hardness is 9, which is second only to diamond and silicon carbide. Its hardness is relatively high among all oxides. Only about 20% of the cast stone components are corundum, most of which are SiO2, and the Mohs hardness of SiO2 is 7.
High chromium or rare earth wear resistant alloy tube, Vickers hardness of about 400 (Rockwell hardness of about 50); less than one third of corundum hardness. Therefore, wear-resistant alloy cast steel pipe, cast stone pipe anti-wear depends on the composition and organization, but also depends on the thickness, ceramic steel pipe anti-wear ability compared with them, has a qualitative leap.
Metallurgy, power industry transportation of pulverized coal, ash, mud, limestone paste slurry, such as the annual need to consume a large number of metal pipelines. The use of ceramic composite pipe to replace other pipelines, with high wear-resistant, long life, easy installation and remarkable economic benefits. Shandong Liaocheng Chang-run thermal power plant, Liaocheng China power Plant, Beijing North New building materials group, Henan Hebi Power Plant, Gansu Pingliang Power Plant, Taiyuan Coal preparation plant, Shimen power plant in Hunan, Hebei Jinniu Energy Co., Ltd. Gequan Coal Preparation plant, Xingtai coal preparation plant and other industrial operations, its operating life is more than 10 times times or even dozens of times times more than steel pipe.
II. application in mining and coal industry
(1) Mine: mine filling, concentrate powder and tailings transportation to the pipeline of serious wear, the past use of mineral powder conveying pipelines such as Panzhihua, Daye mine, such as the service life of less than one year, the tube can increase the life expectancy by about 5 times times.
(2) Coal: Coal preparation and long-distance pipeline transportation of coal is commonly used in wet transport, the requirements of the pipe is both wear-resistant and corrosion-resistant, the use of the tube can be used as a long life transport pipe, the economic benefits are considerable.
Iii. Other
(1) The tube does not pollute and does not adhere to the molten aluminum solution. It is an ideal material to manufacture molten aluminum equipment, aluminum liquid conveying pipe and liter liquid pipe which are sensitive to iron pollution and need heavy labor for finishing and maintenance after use.
(2) The tube has good abrasion resistance and heat-resisting corrosion. It is suitable for conveying corrosive materials containing solid particles and high temperature corrosive gas and sulfur-containing hot water.
Mild steel pipes with ceramic lining are engineered to provide exceptional durability and resistance to wear, making them ideal for applications in industries such as metallurgy, mining, and power generation. The ceramic lining, typically composed of alumina or other advanced ceramics, offers significant enhancement in terms of corrosion resistance, wear resistance, and thermal stability.
The outer layer of these pipes is made of mild steel, which provides structural strength, while the inner layer of ceramic material ensures that the pipe's interior maintains a high level of resistance to abrasion and corrosion. The ceramic lining can be applied through various methods, including plasma spraying, thermal spraying, or other advanced coating techniques, resulting in a strong bond with the steel substrate.
Alumina is a cost effective and widely used material in the family of engineered ceramics. Alumina ceramics have been developed and optimized for maximum wear resistance and corrosion resistance.
| Item | Index |
|---|---|
| Content of Alumina | ≥95% |
| Density | ≥3.5 g/cm3 |
| Rockwell Hardness | ≥80 HRA |
| Impact Strength | ≥850 Mpa |
| Bending Strength | ≥290MPa |
| Breaking Temper | ≥4.8MPa·m1/2 |
| Coefficient of Linear Thermal Expansion | 20W/m.K |
| Sand injection test | 30% Transfer test of sludge with SiO2 | ||
|---|---|---|---|
| Material | Volume diminution (cm3) |
Material | Volume diminution (cm3) |
| Ceramic lined Steel pipe | 0.0022 | Ceramic lined Steel pipe | 3 |
| Ceramic pipe Al2O397% | 0.0025 | S45C | 25 |
| Items | Index |
|---|---|
| Alumina content | 92% |
| Bulk Density | 3.62g/cm³ |
| Rockwell Hardness (HRA) | 90 |
| Compressive Strength | 850MPa |
| Fracture Toughness | 4.8MPa.M1/2 |
| Bending Strength | 290MPa |
| Thermal Conductivity 20℃ | 20W/m.k |
| Coefficient of Thermal Expansion | 7.2×10-6m/×m.k |
| Young's Modulus 20℃ | 277GPa |
| Shear Modulus 20℃ | 113GPa |
| Surface Finish: As Fired | 1.27mm |
Wear-resisting bend (wear resistant ceramic pipe)just as its name implies is a relatively traditional is more wear-resisting bend (wear resistant ceramic pipe), adopted the new wear-resistant plastic production, used in large industrial, currently occupies the market share of around 80%.
Ceramic lined is an application that provides protection for materials in environments that experience exposure to extreme chemicals and temperatures.
Ceramic lined refers to a material or surface that has a layer of ceramic applied to it. This ceramic layer provides protection against wear, corrosion, and abrasion, making it ideal for use in industrial applications where harsh conditions can cause damage to equipment over time. Ceramic lining is commonly used in pipes, tanks, and other equipment used in chemical processing, mining, and power generation industries.
Self-propagating high temperature synthesis technology of corundum ceramic composite steel pipe is that is, "SHS" technology composite, is a national High-tech "863" project, is the original national metallurgical Industry Department, the Ministry of Electricity Project focused on the promotion of new products, the tube from within to outside by ceramic (corundum) layer, transition layer and steel layer composed of three parts.
Ceramic composite pipe due to corundum ceramic (a-AL2O3), Mohs hardness of 9.0 is equivalent to more than HRC90. Therefore, it has high wear resistance for abrasive media conveyed by industries such as metallurgy, electric power, mining, and coal. It has been confirmed by industrial operation that its wear life is ten times or even several ten times that of hardened steel.
SHS ceramic composite pipe is not like a convex spiral line on the inner surface of a seamless steel pipe because the inner surface is smooth and never corrodes. The inner surface roughness and clear water resistance characteristics of the relevant test units were tested. The smoothness of the inner surface was better than that of any metal pipe. The clear drag coefficient was 0.0193, which was slightly lower than the seamless pipe. Therefore, the tube has the characteristics of small running resistance and can reduce operating costs.
Since the steel ceramic layer is (a-AL2O3), it is a neutral characteristic. Therefore, it is resistant to acid and alkali and seawater corrosion, and it also has anti-scaling properties.
Due to the corundum ceramic (a-AL2O3), it is a single stable crystalline structure. Therefore, the composite pipe can operate normally in the long-term temperature range of -50--700°C. Material linear expansion coefficient of 6-8 × 10-6/0C, about 1/2 of the steel pipe. The material has good thermal stability.
Ceramic composite pipes are light weight and affordable. It is 50% lighter than the cast stone tube with the same inner diameter; it is 20-30% lighter than the wear-resistant alloy tube, and it has good wear resistance and corrosion resistance because of its long service life, thus supporting hanger costs, transportation costs, installation fees, and Reduce operating costs. Comparing the project budget of the design institute and construction unit with the actual project, the project cost is equivalent to the cast stone. Compared with the wear-resistant alloy pipe, the project cost is reduced by about 20%.
Because of its light weight and good welding performance. Therefore, welding, flanges, quick coupling, etc. can be adopted, and the construction and installation are convenient, and the installation cost can be reduced.
Ceramic steel pipe and traditional steel pipe, wear-resistant alloy cast steel pipe, cast stone pipe, as well as steel plastic, steel rubber pipe, etc. have essential differences. The outer layer of ceramic steel pipe is steel, and the inner is corundum. The Vickers hardness of corundum layer is as high as 100-1500 (Rockwell hardness is 90-98), which is equivalent to tungsten cobalt hard gold. The wear resistance is more than 20 times times higher than carbon steel pipe, it is superior to the corundum grinding wheel which is usually bonded. Now the corundum grinding wheel is still the main grinding wheel of the grinding mill. The corundum layer in the ceramic steel tube can wear away the corundum grinding wheel. The abrasion resistance of ceramic steel tube is mainly by the inner layer of several millimeters thick corundum layer, its Morse hardness is 9, second only to diamond and SIC, in all oxides, its hardness is the highest.
The inner liner ceramic wear-resisting steel pipe is made by SHS high temperature synthesis-centrifugal method, the melting point of corundum in ceramic steel pipe is 2045 ℃, the corundum layer and steel layer have special structure and stress field because of the process reason. Under normal temperature, the compressive stress of the ceramic layer, the tensile stress of the steel layer, the two opposites, into a balanced whole. Only when the temperature rises to more than 400 ℃, because the thermal expansion coefficient is different, the new stress field produced by the thermal expansion and the original stress field in the ceramic steel pipe cancel each other, so that both the ceramic layer and the steel layer are in a free equilibrium state. When the temperature rises to 900 ℃ the inner liner ceramic wear-resistant steel pipe into the water, repeatedly soaked repeatedly, the composite layer does not crack or cracking, showing the incomparable thermal shock resistance of ordinary ceramics. This performance is of great use in construction, because the outer layer is steel, in addition to heating the inner layer does not crack, in the construction, the flange, blowing, explosion-proof doors can be welded, but also can be directly welded to connect, which is more than wear-resistant cast stone pipe, wear-resistant cast steel pipe, Rare-earth wear-resistant steel pipe, bimetal composite pipe, steel pipe, Steel rubber pipe In the construction is not easy to weld or welding more than a chip. Internal liner ceramic Wear-resistant steel pipe resistance to mechanical impact is good, in transport, installation beat and the two support between the weight bending deformation, the composite layer does not break off.
At present, the practice of dozens of thermal power plants shows that the wear resistance of the inner-lined ceramic steel tube is high, and the resistance to fluid scouring is strong. In the first air duct, the bending pipe wear the most quickly, the wear resistance of the inner liner ceramic wear-resisting steel pipe is more than 5 times times higher than that of the thick wall wear-resisting cast steel elbow.
In practice, the inner liner ceramic wear-resistant steel pipe after 1-2 years to open observation and measurement, the composite layer has no obvious wear or fall off, in the same size and unit length of the pipeline, the internal liner ceramic wear-resistant steel tube weight only wear-resistant cast steel pipe or bimetal composite pipe of about 1/2, the cost of each of the meters reduced 30–40%, Only cast stone pipe and Rare-earth wear-resistant steel pipe weight of about 2/5, per meter project cost reduction of more than 20%. In the corrosive or high-temperature place to use the liner ceramic wear-resistant steel pipe, its price is only a stainless steel tube, nickel-titanium tube of a fraction of.
Fluid pipeline transportation is not only used in the power industry, but also in metallurgy, coal, petroleum, chemical, building materials, machinery and other industries. When the pipe is transported with large grinding material (such as ash residue, pulverized coal, mineral fine powder, tailings cement, etc., there is a problem of fast abrasion of pipe, especially the bending pipe wear fast; when conveying a strong corrosive gas, liquid or solid in the pipeline, there is a problem that the pipeline is corroded and destroyed quickly. When conveying the material with high temperature in the pipeline, there are some problems such as the price of heat-resisting steel pipe is very expensive. The internal liner ceramic wear-resistant steel pipe market, these problems are solved.
A ceramic lined pipe is a type of pipeline that has an inner lining made of ceramic material to provide superior resistance to wear, abrasion, and corrosion. The ceramic lining is typically made of high-grade alumina ceramics, which are known for their hardness, strength, and durability.
Ceramic 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 lining provides exceptional wear resistance, protecting the underlying steel or cast iron pipe from premature failure due to abrasion or corrosion.
In addition to their excellent wear properties, ceramic lined pipes may also provide benefits such as improved flow rates, reduced downtime, and lower maintenance costs. They may also be used in applications where hygiene is important, as the ceramic lining is non-toxic and does not react with most chemicals.
Ceramic 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 lining may be adhered to the inner surface of the pipe using specialized adhesives, and may be installed using conventional welding or mechanical joining techniques.
While ceramic 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 lining and specialized manufacturing processes.
There are probably hundreds of different methods for packing a abrasion resistant pipe and Elbows, and most of them have merit, but there are two principles that are vital for any method to work prevent rusting and Sea transportation security.
Wear-resistant ceramic composite pipe, full name ceramic liner composite steel pipe, is a kind of ceramic composite steel pipe.
Ceramic (Corundum: a-Al2O3) lined abrasion resistant straight pipe and fittings are lined with highly abrasion resistant ceramic by SHS -------Self-propagating High-temperature Synthetic process.
A small amount of iron also remains in the ceramic layer. There is a thin equiaxed grain area of alumina near the steel pipe wall, and then alumina was grown in form of dentrite to the surface of ceramic layer.
When abrasive material is transported through steel pipe in mining applications, typically as pumped slurry, the pipe can quickly be eroded from the inside out, which in more extreme cases can result in pipe leaks and even failure, or significant maintenance costs and downtime for pipe replacement.
Section of the composite pipe
Microstructure of ceramic layer
FeAl2O4 distributes among alumina dentrite. Although the ceramic layer was solidified from one end to another end of a pipe, the microstructure of ceramic layer was almost uniform throughout the whole length of the pipe.
Resistance to thermal shock
A composite elbow was used
in a mining plant for about
fifty thousands hours.
Hoop strength
Hoop strength is the resistance against radial pressure. The strength of the ceramic -lined steel composite pipe is 300 to 500MPa.
Compression-Shear strength
Compression-shear strength is the bonding strength at the interface between the ceramic layer and the steel pipe. The compression-shear strength of the ceramic-lined composite pipe is 15 to 20MPa.
Resistance to mechanical shock
The ceramic layer does not crack or flake off when the composite pipe receives a mechanical shock.
Resistance to thermal shock
The ceramic layer does not crack or flake off when heated to 800℃ and then quenched.
Resistance to abrasion
The ceramic-lined steel composite pipe has exceptional resistance to abrasion. Its service life in materials transportation with hard abrasives is more than 20 times longer than in common steel pipe.
For these abrasive applications, mild steel pipe is not tough enough to stand up to the abuse for more than a year or two. As a result, maintenance engineers are seeking superior piping alternatives to reduce maintenance and prolong system life, at a price point that will not significantly impact the budget.
The general servicelife of common steel elbow is about 700 hours.
The ceramic-lined steel composite pipe can be joined by welding the steel pipe layer.
The ceramic-lined steel composite pipes are lighter than alloy pipes, cast iron pipes, and cast stone pipes, which reduces the expense of transportation and makes the pipes easier to install.
Good weld ability
The relative weight of the
composite pipe is about
40-50% lighter than that of the
caststone pipe
The ceramic-lined steel composite pipes can be easily connected by welding, or with flanges and soft easy connectors.
Convenient installation
The composite pipes have good corrosion-resistant. There is no evidence of corrosion filling the composite pipes with bitter for one year (left), but the common steel pipe under the same condition is corroded seriously (right).
Ceramic liner composite pipe is different from traditional seamless steel pipe, wear-resisting alloy cast steel pipe, cast stone pipe, steel plastic pipe and steel rubber pipe.
Ceramic lined pipe is made through self-propagating high-temperature synthesis (SHS) technique.
Cast basalt lined steel pipe is composed by lined with cast basalt pipe, outside steel pipe and cement mortar filling between the two layers.
Ceramic tile lined pipes have very uniform coating of specially formulated ceramic material that is affixed to the inner of the pipe.
The material of the rare earth alloy wear-resistant pipe is ZG40CrMnMoNiSiRe, which is also the grade of rare earth alloy steel.
Tubes Erosion Shields are used to protect boiler tubing from the highly erosive effects of high temperatures and pressures thereby greatly extending tube life.
The ASTM A213 T91 seamless tubes are primarily used for boiler, superheater, and heat-exchanger.
