Ceramic Tile Lined Pipe Reducer

The ceramic tile lined reducer is the use of high temperature, strong adhesive will be used to paste alumina ceramic plate in the pipe reducer wall, after the heat curing to form a solid anti-wear layer.

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Ceramic Tile Lined Pipe Reducer

The Ceramic tile lined pipe bend is the use of high temperature, strong adhesive will be used to paste alumina ceramic tiles the pipe wall, after the heat curing to form a solid anti-wear layer.

Ceramic tile lined elbow fabrication technology principle, special corundum ceramics, made from Al2O3 as raw material, with rare metal oxides as solvents, and sintered at high temperature by 1730 ℃, are combined with wear-resistant ceramic pieces and block bricks in the pipe wearing surface through bonding, welding, inlay, riveting and socket technology. Thus forming a surface with excellent abrasion resistance, and the matrix still uses the composite pipe of the ordinary metal material.

According to different needs of the choice of wear-resistant ceramic patches, to meet the special needs of users of technical conditions. Compared with the traditional all-metal high alloy pipe fittings, the working face has higher abrasion resistance, which can make the whole wear-resistant and anticorrosion service life of the pipe increase several times to dozens of times times. Overall weight of the first mate down, reduce the amount of steel, reduce the cost of equipment and maintenance costs, improve economic efficiency.

Advantage

Application Guidance

In various industrial applications, the transportation of abrasive materials or fluids with high velocity can lead to rapid wear and tear of standard piping components. This not only affects the efficiency of the system but also incurs substantial maintenance costs. To combat these issues, ceramic tile lined pipe reducers are employed as a highly effective solution to enhance wear resistance and prolong the lifespan of piping systems.

Ceramic tile lined pipe reducers are commonly used in industries and applications such as:

What is a Ceramic Tile Lined Pipe Reducer?

A ceramic tile lined pipe reducer is a specialized component used in piping systems where the reduction in pipe diameter is required. What sets it apart is the interior lining, which consists of small, high-density ceramic tiles. These tiles are usually made from materials like alumina, silicon carbide, or zirconia due to their exceptional hardness and wear-resistant properties.

Ceramic Tile Lined Pipe Reducer
Ceramic Tile Lined Pipe Reducer
Ceramic Tile Lined Pipe Reducer

Installation and maintenance

Proper installation and regular maintenance are essential to maximise the benefits of ceramic tile lined pipe reducers. Regular inspections will ensure that any damaged or worn tiles are replaced promptly, preventing excessive wear of the underlying pipe.

In conclusion, ceramic tile lined pipe reducers are a valuable asset in industries where wear and corrosion are significant challenges. Their ability to improve wear resistance, extend service life and maintain the integrity of piping systems makes them a preferred choice for critical applications.

Physical properties of ceramic tile lined pipe

Flexure strength Tensile strength Elongation Cross section stretch Ratio Impact toughness Hardness of wearable layer Hydrostatic testing pressure
MN/㎡ MN/㎡ % % J/c㎡ HRC Mpa
>610 >700 5 5.1 >15 >38 5.6-12.9

To achieve the best abrasion-resistant solutions, thicken ceramic liners can be used in the elbow which has serious abrasions.

Characteristics And Production Technology Of Ceramic Tile Lined Pipe

Ceramic tile lined pipe using ceramic-metal composite production technology principle, with Al2O3 as raw material.

Ceramic tile lined pipe process welding sturcture

Ceramic tile lined pipe process welding sturcture

Item Thickness Material Special points
Steel 6mm-10mm Carbon steel Seamless forming, high impact
Glue 0.5-1mm High temperature inorganic glue No aging when working under high temperature/td>
Ceramic 5mm-12mm 95% alumina ceramic High density,super wear

Special Corundum ceramics made of rare metal oxides as solvents and sintered at high temperature by 1730 ℃ through bonding, welding, mosaic, riveting and socket technology, a variety of wear-resistant ceramic pieces, block brick materials in the pipe wear surface, so as to form a surface with excellent wear resistance, and the matrix is still using the composite pipe of ordinary metal.

According to different needs of the choice of wear-resistant ceramic patches, to meet the special needs of users of technical conditions. Compared with the traditional all-metal high alloy pipe fittings, the working face has higher abrasion resistance, which can make the whole wear-resistant and anticorrosion service life of the pipe increase several times to dozens of times times. Overall weight of the first mate down, reduce the amount of steel, reduce the cost of equipment and maintenance costs, improve economic efficiency.

Alumina Ceramic – Abrasion Resistant Linings

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. A high density, diamond like hardness, fine grain structured and superior mechanical strength are the unique properties that make it the material of choice for a wide range of demanding applications.

Alumina Ceramic has uses similar to cast basalt but it has greater resistance to wear in high velocity applications and impact resistance in extreme dynamic systems.

Sunny Steel provides its customers with the full range of abrasion resistant lined pipe work including straight pipe, bends and elbows, reducers, tees and y-pieces. Sunny Steel offers a comprehensive range of lining materials designed to combat erosion.

Basalt and alumina ceramic are the two generally accepted lining materials. Other linings which complement the basalt and ceramic include Eucor, AZS, silicon nitride bonded silicon carbide, and ceramic filled epoxy coatings.

Main properties of ceramic tile lined pipe

Ceramic tile lined pipe wear good: wear-resistant ceramic pipe lining ceramic layer for wear-resistant engineering ceramics, its hardness (HRA) ≥84, its wear resistance is high chromium wear-resistant cast iron alloy pipe fittings more than 10 times times. The use of 5mm thick ceramic layer, its actual wear-resistant life will be equivalent to 50mm thick wear-resistant cast steel.

Ceramic patch Composite pipe corrosion resistance: the use of different wear-resistant ceramic materials, for different corrosive medium has excellent anti-corrosion properties, acid, alkali, salt and other strong corrosive medium and brine corrosion characteristics.

Ceramic tile lined pipe high temperature performance: wear-resistant ceramic itself with 1200 degrees Celsius above the high-temperature capacity, through reasonable design and use of different composite methods, wear-resistant ceramic pipe fittings can be in-50 ℃ to 800 ℃ humidity range of long-term operation, especially for high-temperature burners and other equipment lining.

Ceramic tile lined pipe to reduce project cost: wear-resistant ceramic pipe is mainly used for conveying particles of liquid-solid two-phase flow and corrosive media, for the replacement of expensive stainless steel tubes, high chromium cast steel pipe, carbide wear-resistant pipe, can directly reduce the project cost, while prolonging the service life. Products cost-effective, can save maintenance, replacement material costs and time.

Ceramic Patch Composite pipe is our company to draw on the domestic and foreign advanced technology of similar products developed on the basis of a shell for steel, wear-resistant ceramic tube of new composite pipe products, with high wear resistance, long service life and so on.

Characteristics of ceramic tile lined pipe

The use of anti-fall porcelain tube, porcelain pipe inlay, so that the paste more flat, more solid.

The use of strong inorganic adhesive paste, wear-resistant steel bowl welding, porcelain tube and steel combined to form a double reinforcement to ensure that the porcelain tube does not fall off.

The surface of the porcelain tube is smooth, the running resistance is small, the scaling is unfavorable.

Flexible installation, high abrasion resistance, convenient processing and moderate cost.

What is the temperature of the wear-resistant tube with ceramic patch technology? How about the paste strength?

As a result of the use of paste technology, the main use of high-temperature, high-strength adhesives for pasting ceramic patches, and most of the use of high polymer adhesive temperature is not higher than 200 degrees, and the higher the temperature, adhesive strength is lower, aging speed also increased rapidly.

Therefore, the use of paste ceramic technology, the workpiece temperature is generally not higher than 150 ℃, under this temperature, the general ceramic and metal paste strength can reach 200 kg/cm. For higher than this temperature components, can be used ceramic composite wear-resistant process treatment, so that the use of temperature can reach 500 or more than 700 degrees.

What are ceramic tile lined pipes?

Ceramic tile lined pipes are a type of steel pipe that have been lined internally with ceramic tiles to provide superior resistance to wear, abrasion, and corrosion. The ceramic tiles are typically made from high-grade alumina ceramics, which are known for their hardness, strength, and durability.

Ceramic tile lined pipes are commonly used in applications where the pipes are exposed to harsh environments, such as in mining, power generation, and chemical processing. The ceramic lining provides superior wear resistance, protecting the underlying steel pipe from premature failure due to abrasion or corrosion.

In addition to their excellent wear properties, ceramic tile lined pipes may also provide benefits such as reduced friction, improved flow rates, 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 tile 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 tiles may be bonded to the steel pipe using specialized adhesives, and may be installed using conventional welding techniques.

While ceramic tile 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.

Production details of the wear resistant alumina ceramic tiles

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.

Production details of the wear resistant alumina ceramic tiles

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

Specifications

Ceramic tile technical indicators

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.

【H】 Ceramic lined pipe

Ceramic lined pipe is made through self-propagating high-temperature synthesis (SHS) technique.

【H】 Cast basalt lined steel pipe

Cast basalt lined steel pipe is composed by lined with cast basalt pipe, outside steel pipe and cement mortar filling between the two layers.

【H】 Ceramic Tile Lined Pipes

Ceramic tile lined pipes have very uniform coating of specially formulated ceramic material that is affixed to the inner of the pipe.

【H】 Rare earth alloy wear-resistant pipe

The material of the rare earth alloy wear-resistant pipe is ZG40CrMnMoNiSiRe, which is also the grade of rare earth alloy steel.

【H】 Tubes Erosion Shields

Tubes Erosion Shields are used to protect boiler tubing from the highly erosive effects of high temperatures and pressures thereby greatly extending tube life.

【H】 ASTM A213 T91 Alloy Tube

The ASTM A213 T91 seamless tubes are primarily used for boiler, superheater, and heat-exchanger.

Ni-Hard Wearback Pipes Ni-Hard Wearback Pipes
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