Sunny Steel Enterprise Ltd.
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The Wear ResisThe ceramic lined pipe is a high performance pipe consisted of ceramic ring,seamless steel tube and adhesion agent.
After the heating and curing, it forms a strong anti-friction layer. The production process of this product is relatively simple, the production cycle is short, the cost is relatively low.
Technical details of theWear Resistant Ceramic lined Pipe
| 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 |
Features & Benefits:
Application:
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%.
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.
1.1 The Manufacturing Process of Ceramic Lined Steel Pipe and Elbows:
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.
The composite pipe is composed of three layers: ceramic, intermediate, and steel layers. The ceramic layer is formed by molten alumina at a temperature above 2500 degree. The molten alumina produced from the reaction Fe2O3+2Al=2Fe+Al2O3 spreads on the inside wall of the steel pipe under the influence of a centrifugal force, then solidifies, so the ceramic layer has high density and smooth surface and bonds to the steel pipe. They are widely used to convey highly abrasive material such as fly ash and any other fine powder material in mine, thermo power generating, coal processing plant, metallurgy, construction, etc. The service life is 10 to 20 times longer than normal steel pipe.
1.2. Features and Advantages:
a). High Abrasion Resistant:
Vickers hardness of the corundum lining is HV1100 to1500, as high as that of tungsten-cobalt hard alloys, and the abrasion resistance is 20 times as carbon steel pipes. A composite elbow was used in a mining plant for about fifty thousands hours.
The general service life of common steel elbow is about 700 hours.
b). Corrosion Resistant:
Corundum is a neutral material, and is acid-proof and fouling -free.
c). Heat Resistant:
Ceramic-lined composite steel pipe can work under circumstances of -50 to 800 degrees Celsius.
d). Lower Weight and Convenient Installation:
The ceramic-lined steel composite pipes are lighter than alloy pipes, cast iron pipes, and cast stone pipes and can be welded or connected through flanges, which reduces the expense of transportation and makes the pipes easier to install.
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 lined steel pipe is about 1/3 of the cast stone bent pipe´s, 1/2 of the cast stone straight pipe´s.
e). Lower Cost:
Ceramic-lined composite steel pipe can take place of expensive stainless steel, titanium, nickel, cast stone or alloy pipes. Extended service life can also reduce maintenance cost.
Designed to match standard pipe flanges for easy installation in high-wear areas of the pipeline only. Maximum long-term cost-savings in replacement parts and downtime.
Size range:
SHS (Self-propagating High-temperature Synthetic process) ceramic lined steel pipe and elbow create a new generation of abrasion and corrosion resistant engineering pipeline.The composite steel pipe is composed of three layers: ceramic, intermediate, and steel layers. The ceramic layer is formed by molten alumina at a temperature above 2500 degree.
A well-known example of SHS reaction is the thermite reaction given below:
The molten alumina produced from the reaction Fe2O3+2Al=2Fe+Al2O3 spreads on the inside wall of the steel pipe under the influence of a centrifugal force, then solidifies, so the ceramic layer has high density and smooth surface and bonds to the steel pipe. Self-propagating high-temperature synthesis (SHS) is a method for producing inorganic compounds by exothermic reactions, usually involving salts. A variant of this method is known as solid state metathesis (SSM).
Since the process occurs at high temperatures, the method is ideally suited for the production of refractory materials with unusual properties, for example: powders, metallic alloys, or ceramics with high purity, corrosion–resistance at high–temperature or super-hardnessity.
The ceramic lined pipe transport has been widely used in the industries of electric power, metallurgy, coal, petroleum, chemical engineering, building materials, mechanism and so on.
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).
(cm3)MaterialVolume diminution
(cm3)Ceamic lined
Steel pipe0.0022Ceamic lined
Steel pipe3Ceramic pipe
Al2O397%0.0025S45C25
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 structure and superior mechanical strength are the unique properties that make it the material of choice for a wide range of demanding applications. 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
1). High Abrasion Resistant:
Vickers hardness of the corundum lining is HV1100 to1500, as high as that of tungsten-cobalt hard alloys, and the abrasion resistance is 20 times as carbon steel pipes. The composite ceramic lined steel elbow was used in a mining plant for about fifty thousands hours. The general service life of common steel elbow is about 700 hours.
2). Corrosion Resistant:
Corundum is a neutral material, and is acid-proof and fouling -free.
3). Heat Resistant:
Ceramic lined composite steel pipe can work under circumstances of -50 to 800 Celsius degree .
4). Lower Weight and Convenient Installation:
The ceramic lined steel pipes are lighter than alloy pipes, cast iron pipes, and cast stone pipes and can be welded or connected through flanges, which reduces the expense of transportation and makes the pipes easier to install. 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 lined steel pipe is about 1/3 of the cast stone bent pipe´s, 1/2 of the cast stone straight pipe´s.