Wear Resistant Ceramic Lined Equipment

Ceramic lined hopper and chute

Chutes or hoppers are the main equipment for material conveying and loading in the crushing system in cement, steel, coal power plant, mining and so on. With continuous conveying of particle, such as coal, iron ore, gold, aluminum etc. The chutes and hoppers are suffered very serious abrasion and impact because of such big material conveying capacity and big impact. It is also applicable to Coal, Metallurgy, and Chemical industries as feeding materials equipment.

According to the abrasion, impact and temperature, we select suitable abrasion resistant ceramic wear liners or ceramic liner to install on the inner wall of the equipment, like the mining chute, hopper, silo and material feeder, So that the equipment can prolong the lifetime.

The equipment on the furnace top of the iron and steel plant includes chutes, hoppers, and material distributors, forming a material blending system. Its main function is to mix and load the raw materials and fuels required by the blast furnace into the furnace in certain proportions. The furnace top material handling equipment needs to meet the following conditions:

1. Uniform material distribution and flexible adjustment.
2. Good sealing, able to withstand high furnace top pressure.
3. Simple equipment design for ease of maintenance.
4. Smooth and safe operation, reliability.
5. Wear-resistant, impact-resistant, and long service life.

The swinging chute is an important component of the furnace top equipment, and its service life and maintenance frequency directly impact the efficiency of the blast furnace. The working characteristics of the swinging chute include a large material flow rate and strong impact. During operation, materials such as ore and pellets continuously fall from a height, causing severe wear and impact, especially at the bottom of the chute. Installing wear-resistant ceramic lining plates on the bottom and inner walls of the swinging chute can effectively improve its operational condition.

Ceramic Lined Cyclone

The material cyclone suffered serious abrasion and impact when it separated the material particle, like coal, gold, iron and ext. because of high speed material conveying. It’s very easy to wear out to leak the material from cyclone and a suitable wear protection solution for material cyclone is very necessary.

We used the ceramic liners lined into the inner wall of the cyclone to get the wear & impact protections. It has been turned out it’s a very good wear solution for material cyclones.

Also, we can design different shape and thickness ceramic liners for the cyclones according to different working conditions. Custom cyclone can be made according to client’s drawing.

Applications

• Coal
• Mining
• Cement
• Chemical
• Steel

Ceramic lined air fan impeller

The fan impeller is ideal dynamic equipment which can provide the material particle conveying by wind. The material will hit and wear the fan impeller continually Because of high speed wind .So the fan impeller suffered heavy abrasion from the high speed material and repaired frequently.

We used more than 10 kinds of shapes ceramics liners to line onto the surface of the impeller to form a solid wear protection layer to prevent the abrasion and impacts. It performs very well and saves the maintenance cost a lot in cement and power generation.

Ceramic lined air fan impellers can save maintenance costs in cement and power generation.

Coal Mill

The coal mill is common grinding and separating equipment in many industries, like cement, steel, coal-fired power plant. The inner wall of the mill is suffering from heavy wear and impact problems because of the grinding and hitting materials.

We can provide complete ceramic solutions from the bottom of mill to the cone of the mill. We use different ceramic liners and different installation methods to meet the different wear condition.

Advantages

1. Superior wear resistance;
2. Smooth inner wall;
3. Longer service lifetime;
4. Lower the weight;
5. Saving maintenance time and expenditures.

Rotary drum mixer

Rotary drum mixer is one of the main materials mixing equipment for sintering plant in steel industry. The inner wall of the drum mixer suffers from heavy abrasion when the heavy material is mixing. Kingcera will choose different ceramic liners to do the wear protections according to the drum mixer’s mixing capacity.

This solution not only solving the abrasion problems, but also solved the material jamming problems when the material is mixing ,so that it improved the efficiency of the drum mixer a lot because of the large reducing of shutdown and maintenance time.

A boiler burner nozzle is a component of a boiler burner system that is responsible for spraying fuel oil or other fuel sources into the combustion chamber, atomizing it into fine droplets to ensure efficient combustion. The nozzle plays a crucial role in the combustion process by controlling the fuel flow rate, spray pattern, and fuel-air mixture.

Functions of Boiler Burner Nozzle

1. Fuel Atomization: The primary function of the nozzle is to atomize the fuel oil or other fuel sources into fine droplets, increasing the surface area for efficient combustion.
2. Fuel Flow Control: The nozzle regulates the flow rate of the fuel, determining the amount of fuel being delivered to the combustion chamber.
3. Spray Pattern: The nozzle design determines the spray pattern of the fuel spray, ensuring proper distribution in the combustion chamber for optimal combustion.
4. Fuel-air Mixture: By controlling the spray pattern and fuel flow rate, the nozzle helps achieve the desired fuel-air mixture ratio for efficient and clean combustion.

Importance of Boiler Burner Nozzle Maintenance

Regular maintenance and inspection of the boiler burner nozzle are essential to ensure its proper functioning. Over time, the nozzle can become clogged or worn, affecting the fuel spray pattern and efficiency of combustion. Maintaining a clean and properly functioning nozzle is crucial for optimal boiler performance, fuel efficiency, and emissions control.

Boiler Burner Nozzle

The pulverized coal burner is supplied in the form of a nozzle body and a pulverized coal air duct (which can be assembled and formed), including the nozzle cover, rolling, fixing and adjusting device.

The pulverized coal burner should have high wear resistance and heat resistance. The materials for the nozzle and bluff body can be selected according to customer requirements. The windward surface of the bluff body and the support ribs are surfacing with high chromium molybdenum anti-wear alloy or pasted with ceramic sheets to prevent wear. Treatment, the thickness of the surfacing layer is greater than 5mm, and the hardness of the surfacing layer is HRC ≥ 60.

Classification of burners

• According to different boilers, the burner is divided into four-corner tangent type, front and rear wall hedging type and W type;
• Four-corner tangential burners include: primary air, secondary air, tertiary air, burnout air and other burners, including swing burners and fixed burners.

Installation and application of wear-resistant ceramic lining

Process of ceramic tile lined pipe

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.

Steel body Grinding-> Ceramic patch-> Paste-> Welding-> Detection

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.

• Use tools to clean the surface of the steel body.
• The raw material can be mixed evenly before use.
• The ceramic tube is pasted by professionals to ensure that the porcelain tube is free from the wrong side and the surface of the ceramic pipe is smooth.
• After testing qualified storage.

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.

Packaging and delivery of ceramic tile lined pipes

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.

Suggested Usage of the Ceramic Tile lined pipe

The ceramic alumina pressure has superior performance against abrasion,wich has five times more resistant than the conventional ceramic. If the objective is protection of components and reduced maintenance costs,the correct application of anti-abrasive lining led immediately to track the economy. If the objective is protection of components and reduced maintenance costs,the correct application of anti-abrasive lining led imediately to track the economy.

The ceramic pipe lining of hydraulic and pneumatic conveying transport has efficiency and economy,especially in steel tubes.Where they have great advantages, increasing the time of life.

A cross section of a steel pipe after 1 year of used

A cross section of a steel pipe after 1 year of used

The perfect choice Resistance to abrasion is superior to all material available on the market

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.