Wear-resisting comparative table of ceramic lining pipe
| Sand injection test | 30% Transfer test of sludge with SiO2 | ||
| Material | Volume diminution (cm3) | Material | Volume diminution (cm3) |
| Ceamic lining Steel pipe | 0.0022 | Ceamic lining Steel pipe | 3 |
| Ceramic pipe Al2O397% | 0.0025 | S45C | 25 |
The liquid pipe transport has been widely used in the industries of electric power, metallurgy, coal, petroleum, chemical engineering, building materials, mechanism and so on. And it has developed rapidly. When transporting the materials with the harder abrasion (such as ash dregs, slag, coal powder, mining dregs, the rest mines, cement, etc), it will exit the problem that the abrasion of pipes is too rapid. Especially, the abrasion of bent pipes is greatly more rapid. When transporting the special abrasion materials or erosive materials, it will exit the problem that the damage of pipes is too rapid.
When transporting the materials with comparatively high temperature, it will exit the problem that the anti-hot steel pipes are very expensive. Since the ceramic steel pipe has gone into the market, the above problems have been settled down easily.
The ceramic steel pipes are widely used for the transporting of mining fillings, mining power, and the rest mines with hard abrasion; for the pipe lines of hardening slag, blast furnace dregs, steel-making red-clay, agglomerated whitewash, dust cleaning of steel & iron companies; for the pipe lines to transport powder, to clean dregs, to clean sulfides, to clean dust for the thermal power plants; for the transport pipe lines of green stock, clinker, cements, coal powder and collective dust in the industry of cement. The ceramic steel unbent pipes are also the ideal pipelines for transporting the materials with erosive matter.
The ceramic steel unbent pipes, the ceramic steel bent pipes, reducers, three-path pipes, four-path pipes, multi-path pipes and others manufactured in our factory have been used in over 200 thermal power plants, more than 50 mines and the industries of coal, building materials, mechanism, petroleum and so on. For example, in the condition of hard abrasion, the ceramic steel unbent pipes have been used for several years. But, at present, there is no any ceramic steel unbent pipe has been worn through. Even the ceramic steel unbent pipes with hardest abrasion, their use life is 10 times longer than the cast stone bent pipes and wearable alloy steel bent pipes, 15 times longer than the toughened plastic bent pipes and toughened latex bent pipes.
The ceramic steel pipe has captured the market rapidly. Besides the high quality and the wonderful capability, it's also because its capability price ratio is higher than other wearable, anti-abrasion & anti-hotness pipes.
For the pipes with the same sizes, types and length, the weight of ceramic pipe is about 1/2 of the wearable cast alloy steel pipe's, while the cost has reduced 10%~20% per meter; the weight of ceramic pipe is about 1/3 of the cast stone bent pipe's, 1/2 of the cast stone unbent pipe's.
The cost per meter is equal to the unbent pipe's, 5%~15% less than the bent pipe's.
Remarks:
1． Under the direction of the arrow diagram for the export direction.2． Bend radius is usually 1.5-5 times the diameter of steel pipe (1.5-5D).
3． Othe specifications of the compsite pipe can be manufactured accord to the user requirments.
4． The weight is caculate by theoretics, maybe have some tolerance, the real weight will be weigh in afer them finished.
Hoop strength is the resistance against radial pressure. The strength of the ceramic -lined steel composite pipe is 300 to 500MPa.
Metals have good ductility but poor resistance to abrasion - which means that abrasion prevention is required when metal pipes are used in high-temperature fluid catalyst service. On the other hand, ceramics possess great hardness and abrasion resistance, but they are brittle. Metal Ceramic double pipe is a hybrid pipe using metal as an outer pipe and a ceramic material for inner pipe segments, applied together to utilize the two materials' advantages. Hence excellent wear-resistance and good corrosion resistance of the ceramics and high strength and toughness of metal can be well combined to get a comprehensive advantage of wear-resistance, corrosion-resistance and anti-scaling. They are suitable for applications in heavy wear working conditions.
Ceramics are among the hardest materials available and provide ultimate wear resistance in piping. In high wear applications, ceramic lined pipes have been demonstrated to be cost-effective by increasing service life and reducing maintenance costs. Sunny Steel supply ceramic lined abrasion resistant steel pipes to your custom dimensions and budget. Our ceramic linings are the highest quality materials available to ensure that we provide the most cost-effective solutions for our clients.
The Ceramic Tiles could protect Industrial Components against abrasion, impact wear and high temperature of above 1000°C. Standard Flat Tiles of Square & Rectangular Shape having thickness of 6 to 50 mm, with or without central hole are available.
Materials: seamless mild steel pipe plus 95% alumina ceramics for liner
- Designed pressure: >= 0.35Mpa
- Normal operation velocity: 20-35m/s
- Normal operation temperature: -50-800
- Running medium: mixture of air and powder
- Size of the pipe: the inner diameter is between 1 to 120 or even lager
Abrasion Resistant Pipe Solutions
Wear of wear-resistant tube is a universal phenomenon, where two objects touch each other and have relative movement of the surface will occur wear.
Conveying highly abrasive materials, steel piping systems are under constant attack often over long distances. To combat abrasion and keep piping systems in service as long as possible, the industry solution has been to install abrasion resistant (AR) pipe much harder on the Scale than standard steel pipe. The harder the inner wall, studies have shown, the better it resists gouging or plowing action of abrasive sliding particle flow.
Wear of wear-resistant tube is a universal phenomenon, where two objects touch each other and have relative movement of the surface will occur wear.Pipe wear refers to the wear phenomenon caused by disconnection or transfer of the material surface when the pipe material is impacted by flowing water and small but loose particles.
The wear of industrial wear-resistant pipe has always been a factor that affects the safe and civilized production. With the continuous development of science and technology, the materials are also constantly innovative, such as cast stone, cast steel, alloy, paste ceramic and so on.Among them, the pipe lining alumina ceramics with its high wear resistance, high hardness, oxidation resistance, corrosion resistance and high resistance to high and low temperature strength performance, has become the most widely used wear-resistant materials, occupy the world special ceramics market share (wear-resistant materials) of about 80%.
The use of ideal high strength, high toughness, high plastic material wear-resistant tube is an important way to reduce abrasive wear.
Unfortunately, this type of abrasion is only one type of wear experienced within the piping system. Impact abrasion, where a slurry meets the inner pipe wall at closer to 90° such as at the bends, elbows, laterals or tees in the system, has a decidedly unwelcome effect on the inner wall of the pipe.
At sharper angles, abrasive material actively “chips” away at a more brittle inner wall, eroding the surface from the inside out. So predominant is the problem that frequent replacement, repair, and the associated maintenance expenses at the bends, elbows, laterals and tees in the system are accepted as the norm.
So, the solution would appear straightforward. For sliding abrasion, an extremely hard interior pipe wall for the straight lengths of pipe and a more ductile inner wall at the directional transitions? Not so fast. Turns out size transitions and directional changes can experience both abrasive and impact wear.
According to SumXu, the variety of considerations that need to be addressed when it comes to abrasive wear illustrates the difference between simply ordering a piece of pipe and the broader field of piping system design.
“Designing a piping system is really a balancing act and each system is different,” SumXu said. “In some cases, if the abrasive material is softer than the steel used for the bends and it’s not moving very quickly, even an impact situation will not wear away the pipe. If the abrasive material is very hard or being conveyed at a higher velocity, alternative solutions at the directional transitions are required.”
Induction Hardening of the Bends
Strength and wear resistance can be improved by the addition of alloying elements to the steel during the pipe manufacturing process. This material is commonly referred to as AR200 (abrasion resistant) piping.
Strength and wear resistance can also be increased with secondary processing of the steel, including heat treating by induction hardening. Induction hardened pipe can last up to three to eight times longer than mild steel, with only a moderate price increase.
At 600 BHN the inner wall of the pipe can withstand the sliding abrasion of most common mining slurries, while its more ductile outer surface behaves like mild steel and can be cut and welded with proper procedure in the field, configured into a variety of fittings, and can accept the standard end options of flanges, weld rings and couplings.
The same technology is used to create the bends, elbows, laterals and tees with the same hardness profile.
Based on the premise that when two objects meet the harder object wins out, induction hardened pipe for both straight lengths and directional transitions is often sufficient for slurries of “softer” material such as coal and limestone. In some cases, mild steel pipe with induction hardened bends may work as well.
Increasing the Radius of the Bends
Another legitimate technique to mitigate the effects of impact abrasion is using induction hardened pipe in long radius bends. “If there is enough room, you can design the bend with an impingement angle of less than 15°, which is a small enough angle that you no longer have impact abrasion but essentially sliding abrasion,” SumXu said. “With a large enough bend, for all intents and purposes you have made it a straight pipe.”
The use of ideal high strength, high toughness, high plastic material abrasion resistant pipe is an important way to reduce abrasive wear.
Cement industry
Cement industry raw materials, clinker, cement, coal dust, dust and other transport pipes.
1. Limestone crushing system, pre-homogenization system of raw materials: crusher feeding chute, crusher feeding chute, belt drum wrapping, etc.;
2. Raw mill system: guide blade of powder separator, vertebral body and shell of powder separator, feed chute (inside and outside) of vertical mill, retaining ring of vertical mill, scraper of grinding disc, cylinder body of vertical mill, support rod of inner vertebral body, vertical mill to cyclone bobbin channel, cyclone cylinder, sealing ring of roller shaft of vertical mill and protective cover of roller shaft, etc.;
3. Fuel mill: guide blade of powder separator, vertebral body and shell of powder separator, powder return tube of powder separator, vertical grinding cylinder, vertebral body, chute, etc.;
4. Sintering system: humidifying tower inlet, outlet elbow, grate cooler to electric dust collector pipe, grate cooler to coal mill wind pipe, cyclone pipe, etc.;
5. Cement grinding system: vertical grinding cylinder, chute, chute of roller press, side baffle of roller press, liner of stable flow weighing warehouse, chute of v-type powder selecting machine, vertebral body and shell of powder selecting machine, impeller of circulating fan, shell, cyclone cylinder and inlet and outlet elbow, outlet elbow of ball mill, dust collecting pipe, etc.;
6. Waste heat power generation system: grate cooler to settling chamber pipeline, settling chamber wall, etc
Steel industry
Water quenching slag, blast furnace coal injection, steel red mud, sintering white ash, dust pipe.
1. Clinker system: belt head hopper, belt head hopper, belt, machine skirt board, trolley three-way bucket, receiving hopper, etc.;
2. Batching system: mixing bin, primary mixing cylinder, secondary mixing cylinder, mixing disk, pelletizing plate, etc.;
3. Sinter conveying system: feed chute, shaker bottom dressing hopper, cyclone dust collector and pipeline, blast furnace hopper, trolley, blast furnace charging tank, fan impeller, etc.;
4. Coking system: coke hopper, funnel, coke operating chute, anti-impact coke receiving funnel, coal transfer chute, gripper screen, etc.;
5. Iron-making coal injection system: cone hopper, separator baffle, outlet pipe, pulverized coal pipe, burner cone, outlet pipe, thick and fine powder separator, pulverized coal pipe, elbow, inner shell of pulverized coal exhausting machine, impeller, etc.;
6. Dedusting and ash discharging system: dedusting pipeline, dedusting elbow, dedusting tee, tail dedusting pipe, ash falling pipe, ash discharging pipe, etc.
Thermal power industry
Thermal power industry, feed powder, slag, sulfur, dust, mud, lime gypsum slurry and other pipelines.
1. Coal conveying system: coal scuttle, coal scuttle pipe, bucket turbine disk, drum coating, raw coal bunker, air lock;
2. Pulverizing system: medium-speed coal mill cylinder, outlet pipe of separator, branch pipe and elbow, vertebral body in separator, guide blade, etc.;
3. Desulfurization system: limestone conveying pipeline and slurry conveying pipeline;
4. Powder feeding system: duster shell, duster impeller 'duster pipe, thermometer protection sleeve, duster mixer, throttling shrinkage cavity, etc.;
5. Dust removal system: air preheater support rod, air preheater baffle, air preheater cylinder wall, induced fan shell, flue tube wall, etc.;
6. Jet combustion system: pulverized coal concentrator vertebral body and pulverized coal concentration separator;
7. Ash discharge system: ash discharge pipe, dry ash fan housing, dry ash fan impeller, air valve valve plate and cylinder wall, slag transport pipe;
Steel ball coal mill: mill outlet pipe, sawdust separator, coarse and fine powder separator, return pipe, etc.
Diggings industry
It is mainly used in the transportation of fillings, concentrate powder and tailings in the mining industry.
Suitable for all kinds of mining equipment anti - grinding, such as coal, copper, tungsten, molybdenum, iron ore and other mining plant, and washing plant.For example, hopper, chute, bin, magnetic separator, slurry pump, drum coating, bucket turbine disk, heavy medium cyclone, etc.
Coal conveying system: chute, hopper and silo;
Coal washing system: cyclone, three products without pressure heavy media cyclone, four products without pressure heavy media cyclone, concentrated cyclone set;
Feeding system: pipes, elbows, hoppers, silos, distribution ports, etc.
Lithium battery industry
Lithium battery industry
Stainless steel lined wear-resistant ceramic pipe plays an important role in lithium battery material transportation
In fact, the integral wear - resistant ceramic - lined tube has been widely used in the lithium production line of Japan and Korea.The integral wear-resistant ceramic lining bend has the characteristics of ultra-wear-resistant, anti-corrosion and high-temperature resistance. At the same time, as a non-metallic lining material with ultra-high hardness, the ceramic lining bend can effectively prevent the contact between the powder and iron and other harmful substances, reduce the content of iron and other impurities in the cathode material, thus improving the safety performance of the battery.The raw material conveying pipeline of lithium battery industry is seriously worn by the wind powder mixture, especially the elbow, because the airflow changes the flow direction at the bend, which is very serious for the outside of the elbow.
Lithium battery transportation problems:
However, the cathode material of lithium battery is mostly micron powder material, because the powder is not very fine, it is easy to dust, the production environment is extremely harsh, and it is not easy to operate and transport, the labor cost is greatly increased.However, the airflow transportation enables the transportation of lithium battery anode materials to achieve automatic production and unmanned workshop management. It is just like setting up a highway, and the materials can run safely and efficiently between various production processes.
1. Current lithium battery transportation adopts 304 stainless steel + glass;
2. The glass is not wear-resistant, and the powder is continuously scoured and worn under pressure, with a service life of about 6 months;
3. There are a lot of elbows in the conveying system, because the flow direction of airflow changes at the outside of the bend, the elbow is particularly badly worn;
4. Frequent use and replacement of the conveying system leads to lower output and higher production costs;
The integral wear - resistant ceramic ring is used as the lining anti - wear layer
The integral wear-resistant ceramic lining bend has the characteristics of ultra-wear-resistant, anti-corrosion and high-temperature resistance. At the same time, as a non-metallic lining material with ultra-high hardness, the ceramic lining bend can effectively prevent the contact between the powder and iron and other harmful substances, reduce the content of iron and other impurities in the cathode material, thus improving the safety performance of the battery.
1. The service life of wear-resistant ceramics is more than 5 times that of glass;
2. Abrasion resistance, the lining ceramic can resist acid and alkali corrosion;
3. Smooth inner wall, smooth air flow, prevent material hanging and blocking;
4. Low specific gravity of ceramics, reducing system equipment load;
5. Reduce maintenance frequency and cost;
6. The wear-resistant ceramic tube can operate in the temperature environment of 150-300 degrees for a long time;
Chemical industry
Wear-resistant tubes are mainly used in the chemical industry for conveying coal powder, silicon powder and other raw materials.
1. Coal conveying system: coal scuttle, coal scuttle pipe and coal bunker;
2. Pulverizing system: medium-speed coal mill cylinder, outlet pipe of separator, primary air pipe and elbow;
3. Powder feeding system: powder discharging machine shell, pulverized coal pipeline, pulverized coal mixer and expansion joint;
4. Steel ball grinding system: mill outlet pipe, sawdust separator, coarse and fine powder separator, return pipe;
5. Ash discharge system: ash discharge pipe, dry ash fan housing, air valve valve plate and cylinder wall, slag transport pipe;
6. Desulfurization system: limestone conveying pipeline and slurry conveying pipeline;
7. Dust removal system: dust removal pipeline, dust removal elbow, dust removal tee, etc.
Coal industry
Wear-resistant pipe is mainly used for coal preparation and long-distance pipeline in the coal industry.
Coal preparation and long-distance pipeline coal transportation generally adopt wet method, which requires wear-resistant ceramic pipeline to be wear-resistant and corrosion-resistant.
What kind of pipeline should be used for tailings filling
Tailings are usually filled with bimetallic wear-resistant pipes.
Pipes is used in a lot of convenient, it is not only a very broad term, and also very useful: used in power plant coal mining, mining equipment, coal industry, metallurgical equipment and other industries, the types of pipe are many: double metal pipe, rare earth alloy wear resistant pipe, ceramic pipes, sintering ceramic pipe, ultra-high molecular wear-resisting pipe, etc, general customers in the consulting products, we all want to ask which used in industry, what is it used for?
Smelting industry
Wear-resistant ceramics are used in coal conveying, powder making and powder feeding systems in smelting industry.
Metallurgical and electric power industries need to consume a large number of metal pipes every year to transport coal powder, ash, mud, lime gypsum slurry, etc.Ceramic composite pipe is adopted to replace other pipes, which is characterized by high wear resistance, long service life, convenient installation and remarkable economic benefit.
Application of wear-resistant ceramics in smelting industry:
1. Coal conveying system: coal scuttle, coal scuttle pipe, bucket turbine disk, drum coating, raw coal bunker;
2. Pulverizing system: medium-speed coal mill cylinder, outlet pipe of separator, primary air pipe and elbow, vertebral body in separator, guide blade;
3. Powder feeding system: shell of powder discharging machine, impeller of powder discharging machine, pulverized coal pipeline, protective sleeve of thermometer, pulverized coal mixer and expansion joint;
4. Steel ball grinding system: mill outlet pipe, sawdust separator, coarse and fine powder separator, return pipe;
5. Ash discharge system: ash discharge pipe, dry ash fan housing, dry ash fan impeller, air valve valve plate and cylinder wall, slag transport pipe;
6. Desulfurization system: limestone conveying pipeline and slurry conveying pipeline;
7. Dust removal system: guide impeller of induced draught fan, shell of induced draught fan, dust removal pipeline, dust removal elbow, dust removal tee, etc.