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Description
Wear resistant ceramic lined pipe is a material that combines the characteristics of steel pipe and ceramic. It uses high-strength steel pipe as the base material, and protects the steel pipe through the wear-resistant ceramic layer inside the steel pipe, thereby extending the service life of the steel pipe and improving the corrosion and wear resistance.
The wear-resistant ceramic layer is usually made of high-strength ceramic materials such as alumina, ZTA (alumina and zirconium oxide mixture), SIC (silicon carbide), etc. This material is usually used in the transportation system of coal mining, steel, power and other industries, which not only increases the service life of the equipment, but also reduces the maintenance cost and downtime.
Advantages
1. Strong wear resistance: Wear-resistant ceramics are used as lining materials, which can better resist the erosion of wear and tear than composite steel pipes of general materials, and extend the service life.
2. Excellent chemical resistance: Ceramic lining materials are highly stable and not easily corroded by chemical substances, and can be used to transport a variety of chemical media.
3. High strength and high toughness: Ceramic lined steel pipes are composed of multiple layers of materials, of which the thickness of the ceramic is 3-8mm. The steel pipe shell has high hardness and high strength, and has the characteristics of high strength and high toughness.
4. Light weight and thin: Compared with traditional steel pipes of the same caliber, ceramic lined steel pipes are light in weight, slender in shape, and easy to construct and install.
5. Smooth cross section: The lining material is ceramic, and the coating is stable for a long time, which can keep the inner diameter of the steel pipe smooth, prevent dust accumulation, and flow smoothly.
6. Not easy to condense and adhere: The inner diameter of the ceramic lined steel pipe is smooth, the friction coefficient is low, and it is not easy for materials to adhere or condense in the pipe, reducing resistance and reducing load.
7. Strong oxidation resistance: The wear-resistant ceramic steel pipe lining material is chemically stable, not easily oxidized or rusted, and can be used to transport high-temperature, high-pressure liquids or gases.
Type of composite pipe
According to the fixing method of wear-resistant ceramics, ceramic pipes can be roughly divided into three types: patch-type composite pipes, weldable composite pipes and sleeve type composite pipes.
1.Patch type composite pipe
The pipeline uses high-temperature resistant strong ceramic adhesive to stick ceramic liner or tile to the inner wall of the pipeline, and then forms a firm anti-wear layer after heating and curing.
It is simple to install and replace, and the ceramic pieces can be chosen based on the pipeline's wear in different areas, allowing for maximum cost savings without sacrificing pipeline performance. Patch-type ceramic pipelines offer numerous benefits, but they also clearly have drawbacks. Ceramic adhesives are the only thing that can fix ceramics. The ceramics are prone to falling off once the adhesive viscosity diminishes or vanishes in extreme circumstances, such as high temperatures. As a result, it is essential to use ceramic adhesives that are resistant to high temperatures and to pay attention to the use temperature.
2.Weldable composite pipe
Wear-resistant ceramic pipe that has been stud-welded is created by applying a powerful adhesive to the inner wall of the pipe and then using spot welding to securely bond the ceramic lining to the inner wall of the steel pipe through tiny holes. A ceramic cap is fitted on to shield the welding points.This type of pipeline is firmly fixed, high temperature resistant, and can operate normally in a high temperature environment of 500°C.
3.Sleeve type composite ceramic pipe
Sleeve type wear-resistant ceramic pipe: The pipe is made by measuring the size of the steel pipe in advance, then sintering it as a whole, and installing and fixing it by inserting it inside the steel pipe.This type of pipe has few connection gaps and a smooth inner wall, which avoids material hanging, blocking and leakage. It is generally suitable for pipes with special requirements.
According to the shape of the pipe, it can be divided into straight pipe, elbow pipe, tee pipe, etc.
1.Straight pipe
The shape of the straight steel pipe is fixed, and no additional bending operation is required during installation. It can be docked and installed more directly, reducing the complexity and time cost during the installation process. When conveying fluids, the streamlined design of the straight steel pipe reduces the resistance of the fluid and improves the conveying efficiency.It is suitable for situations where efficient conveying of fluids and gases is required.
2.Elbow pipe
Elbows pipe have a variety of bending angles and radii to choose from to meet the design requirements of various piping systems. The connection methods of elbows are more flexible and can be welded, threaded, flanged, etc.It is suitable for situations where the flow direction of the pipeline needs to be changed.
3.Tee pipe
The tee is T-shaped with three ports that can connect three pipes. The tee has a simple structure, unified interfaces, easy installation, and does not require pipe bending, which greatly reduces the difficulty of installation. The fluid passes more smoothly, with less friction resistance, thus saving more energy.It is suitable for occasions where multiple pipelines need to be connected.
Ceramic technical specifications
Series | BM92 | BMG95 | BME95 | BMZTA | BMZR |
AL2O3 (%) | 92±0.5 | 95±0.5 | 95±0.5 | ≥75 | - |
ZrO2 (%) | - | - | - | ≥21 | 94.8±0.5 |
Bulk density(g/cm3) | ≥3.6 | ≥3.65 | ≥3.7 | ≥4.1 | ≥5.9 |
Compressive strength (MPa) | ≥1050 | ≥1300 | ≥1600 | ≥2000 | - |
Bending strength(MPa) | ≥220 | ≥250 | ≥300 | ≥400 | ≥800 |
Fracture toughness (MPam1/2) | ≥3.70 | ≥3.80 | ≥4.0 | ≥4.5 | ≥7 |
Rockwel hardness (HRA) | ≥82 | ≥85 | ≥88 | ≥90 | ≥88 |
Loss bulk(cm3) | ≤0.25 | ≤0.2 | ≤0.15 | ≤0.05 | ≤0.02 |
Section Shape | Rectangular, round |
Alumina Liner Color | White |
Shape | Straight pipe |
Elbow | |
Tee pipe | |
Connection | by flange or welding |
Forming way | welding, lined |
AL2O3 | 92%,95% |
Finish | Sand blasting finished |
Usage | wear resistance |
Technique | ERW, Cold Rolled |
Temperature | less than 1700 centigrade (300-800°C) |
Certification | ISO9001 |
Special Pipe | Thick Wall Pipe |
Alloy Or Not | Non-alloy |
(Can be customized upon request)
Application
Composite pipes are mainly used for conveying media under harsh working conditions such as high wear resistance, high corrosion, high temperature, and high pressure, such as the conveying systems of the petroleum, chemical, electric power, metallurgy, mining, coal and other industries. Specifically including the following fields:
1.Gas conveying system: Gas conveying systems usually face harsh conditions such as high-speed flow, high temperature and high pressure, and corrosion. The use of wear-resistant ceramic elbows can effectively extend the service life of the pipeline.
2.Petrochemical industry: Wear-resistant ceramic elbows are widely used to convey acid and alkali slurries with particularly strong corrosiveness, which can minimize pipeline wear and corrosion.
3.Power industry: Wear-resistant ceramic elbows are also widely used in the conveying system of the power industry, especially in conveying coal powder, desulfurization ash, and limestone slurry in the desulfurization system of thermal power plants.
4.Metallurgical industry: The high-temperature and high-pressure media in the metallurgical industry have very high requirements for the wear resistance of the pipeline. The use of wear-resistant ceramic elbows can effectively avoid pipeline wear and leakage.
5.Mining industry: The conveying medium in the mining industry is usually in powder or liquid form. Wear-resistant ceramic elbows can effectively reduce wear and blockage problems and improve production efficiency.
Please note during installation
1.During the installation process, be gentle and avoid knocking or metal collision, which may cause cracks. Ceramic with cracks cannot be used anymore.
2.Align the pipe with the center line of the pipeline to ensure that the end face is connected correctly.
3. he installation of the elbow should be consistent with the flow direction of the conveying medium according to the adjustment direction of the ceramic tube.
4.When welding the flange, the end face should be flush with the end face of the steel pipe. Do not leave a gap between pipes when welding, and it is advisable to use intermittent welding with a small current.
FAQ
Q:Can the thickness and size of wear-resistant composite steel pipes be customized?
A:It can be customized according to specific construction conditions and customer requirements.
Q:What are the fixing methods of wear-resistant composite steel pipes?
A:The connection methods of composite pipes are relatively flexible, and can be connected in a variety of ways, such as welding, threading, and flange connection.
Q:What kind of packaging does the wear-resistant composite steel pipe require?
A:Wooden case packing.
Q:What factors affect the service life of wear-resistant composite steel pipes?
A:The service life of wear-resistant composite steel pipes is affected by many factors, mainly including material, manufacturing process, operating conditions, maintenance, etc.
Q:What ceramic plates can be lined in composite pipes?
A:Flat Liner,Weldable liner,Trapezoidal liner,Interlocking Liner,Mosaic Alumina Ceramic Tiles.
Q:How to test the impact strength and wear resistance of wear-resistant composite steel pipes?
A:Impact strength test:Charpy pendulum impact test and low-speed impact test.
Wear resistance test:Impact wear test.
Description
Wear resistant ceramic lined pipe is a material that combines the characteristics of steel pipe and ceramic. It uses high-strength steel pipe as the base material, and protects the steel pipe through the wear-resistant ceramic layer inside the steel pipe, thereby extending the service life of the steel pipe and improving the corrosion and wear resistance.
The wear-resistant ceramic layer is usually made of high-strength ceramic materials such as alumina, ZTA (alumina and zirconium oxide mixture), SIC (silicon carbide), etc. This material is usually used in the transportation system of coal mining, steel, power and other industries, which not only increases the service life of the equipment, but also reduces the maintenance cost and downtime.
Advantages
1. Strong wear resistance: Wear-resistant ceramics are used as lining materials, which can better resist the erosion of wear and tear than composite steel pipes of general materials, and extend the service life.
2. Excellent chemical resistance: Ceramic lining materials are highly stable and not easily corroded by chemical substances, and can be used to transport a variety of chemical media.
3. High strength and high toughness: Ceramic lined steel pipes are composed of multiple layers of materials, of which the thickness of the ceramic is 3-8mm. The steel pipe shell has high hardness and high strength, and has the characteristics of high strength and high toughness.
4. Light weight and thin: Compared with traditional steel pipes of the same caliber, ceramic lined steel pipes are light in weight, slender in shape, and easy to construct and install.
5. Smooth cross section: The lining material is ceramic, and the coating is stable for a long time, which can keep the inner diameter of the steel pipe smooth, prevent dust accumulation, and flow smoothly.
6. Not easy to condense and adhere: The inner diameter of the ceramic lined steel pipe is smooth, the friction coefficient is low, and it is not easy for materials to adhere or condense in the pipe, reducing resistance and reducing load.
7. Strong oxidation resistance: The wear-resistant ceramic steel pipe lining material is chemically stable, not easily oxidized or rusted, and can be used to transport high-temperature, high-pressure liquids or gases.
Type of composite pipe
According to the fixing method of wear-resistant ceramics, ceramic pipes can be roughly divided into three types: patch-type composite pipes, weldable composite pipes and sleeve type composite pipes.
1.Patch type composite pipe
The pipeline uses high-temperature resistant strong ceramic adhesive to stick ceramic liner or tile to the inner wall of the pipeline, and then forms a firm anti-wear layer after heating and curing.
It is simple to install and replace, and the ceramic pieces can be chosen based on the pipeline's wear in different areas, allowing for maximum cost savings without sacrificing pipeline performance. Patch-type ceramic pipelines offer numerous benefits, but they also clearly have drawbacks. Ceramic adhesives are the only thing that can fix ceramics. The ceramics are prone to falling off once the adhesive viscosity diminishes or vanishes in extreme circumstances, such as high temperatures. As a result, it is essential to use ceramic adhesives that are resistant to high temperatures and to pay attention to the use temperature.
2.Weldable composite pipe
Wear-resistant ceramic pipe that has been stud-welded is created by applying a powerful adhesive to the inner wall of the pipe and then using spot welding to securely bond the ceramic lining to the inner wall of the steel pipe through tiny holes. A ceramic cap is fitted on to shield the welding points.This type of pipeline is firmly fixed, high temperature resistant, and can operate normally in a high temperature environment of 500°C.
3.Sleeve type composite ceramic pipe
Sleeve type wear-resistant ceramic pipe: The pipe is made by measuring the size of the steel pipe in advance, then sintering it as a whole, and installing and fixing it by inserting it inside the steel pipe.This type of pipe has few connection gaps and a smooth inner wall, which avoids material hanging, blocking and leakage. It is generally suitable for pipes with special requirements.
According to the shape of the pipe, it can be divided into straight pipe, elbow pipe, tee pipe, etc.
1.Straight pipe
The shape of the straight steel pipe is fixed, and no additional bending operation is required during installation. It can be docked and installed more directly, reducing the complexity and time cost during the installation process. When conveying fluids, the streamlined design of the straight steel pipe reduces the resistance of the fluid and improves the conveying efficiency.It is suitable for situations where efficient conveying of fluids and gases is required.
2.Elbow pipe
Elbows pipe have a variety of bending angles and radii to choose from to meet the design requirements of various piping systems. The connection methods of elbows are more flexible and can be welded, threaded, flanged, etc.It is suitable for situations where the flow direction of the pipeline needs to be changed.
3.Tee pipe
The tee is T-shaped with three ports that can connect three pipes. The tee has a simple structure, unified interfaces, easy installation, and does not require pipe bending, which greatly reduces the difficulty of installation. The fluid passes more smoothly, with less friction resistance, thus saving more energy.It is suitable for occasions where multiple pipelines need to be connected.
Ceramic technical specifications
Series | BM92 | BMG95 | BME95 | BMZTA | BMZR |
AL2O3 (%) | 92±0.5 | 95±0.5 | 95±0.5 | ≥75 | - |
ZrO2 (%) | - | - | - | ≥21 | 94.8±0.5 |
Bulk density(g/cm3) | ≥3.6 | ≥3.65 | ≥3.7 | ≥4.1 | ≥5.9 |
Compressive strength (MPa) | ≥1050 | ≥1300 | ≥1600 | ≥2000 | - |
Bending strength(MPa) | ≥220 | ≥250 | ≥300 | ≥400 | ≥800 |
Fracture toughness (MPam1/2) | ≥3.70 | ≥3.80 | ≥4.0 | ≥4.5 | ≥7 |
Rockwel hardness (HRA) | ≥82 | ≥85 | ≥88 | ≥90 | ≥88 |
Loss bulk(cm3) | ≤0.25 | ≤0.2 | ≤0.15 | ≤0.05 | ≤0.02 |
Section Shape | Rectangular, round |
Alumina Liner Color | White |
Shape | Straight pipe |
Elbow | |
Tee pipe | |
Connection | by flange or welding |
Forming way | welding, lined |
AL2O3 | 92%,95% |
Finish | Sand blasting finished |
Usage | wear resistance |
Technique | ERW, Cold Rolled |
Temperature | less than 1700 centigrade (300-800°C) |
Certification | ISO9001 |
Special Pipe | Thick Wall Pipe |
Alloy Or Not | Non-alloy |
(Can be customized upon request)
Application
Composite pipes are mainly used for conveying media under harsh working conditions such as high wear resistance, high corrosion, high temperature, and high pressure, such as the conveying systems of the petroleum, chemical, electric power, metallurgy, mining, coal and other industries. Specifically including the following fields:
1.Gas conveying system: Gas conveying systems usually face harsh conditions such as high-speed flow, high temperature and high pressure, and corrosion. The use of wear-resistant ceramic elbows can effectively extend the service life of the pipeline.
2.Petrochemical industry: Wear-resistant ceramic elbows are widely used to convey acid and alkali slurries with particularly strong corrosiveness, which can minimize pipeline wear and corrosion.
3.Power industry: Wear-resistant ceramic elbows are also widely used in the conveying system of the power industry, especially in conveying coal powder, desulfurization ash, and limestone slurry in the desulfurization system of thermal power plants.
4.Metallurgical industry: The high-temperature and high-pressure media in the metallurgical industry have very high requirements for the wear resistance of the pipeline. The use of wear-resistant ceramic elbows can effectively avoid pipeline wear and leakage.
5.Mining industry: The conveying medium in the mining industry is usually in powder or liquid form. Wear-resistant ceramic elbows can effectively reduce wear and blockage problems and improve production efficiency.
Please note during installation
1.During the installation process, be gentle and avoid knocking or metal collision, which may cause cracks. Ceramic with cracks cannot be used anymore.
2.Align the pipe with the center line of the pipeline to ensure that the end face is connected correctly.
3. he installation of the elbow should be consistent with the flow direction of the conveying medium according to the adjustment direction of the ceramic tube.
4.When welding the flange, the end face should be flush with the end face of the steel pipe. Do not leave a gap between pipes when welding, and it is advisable to use intermittent welding with a small current.
FAQ
Q:Can the thickness and size of wear-resistant composite steel pipes be customized?
A:It can be customized according to specific construction conditions and customer requirements.
Q:What are the fixing methods of wear-resistant composite steel pipes?
A:The connection methods of composite pipes are relatively flexible, and can be connected in a variety of ways, such as welding, threading, and flange connection.
Q:What kind of packaging does the wear-resistant composite steel pipe require?
A:Wooden case packing.
Q:What factors affect the service life of wear-resistant composite steel pipes?
A:The service life of wear-resistant composite steel pipes is affected by many factors, mainly including material, manufacturing process, operating conditions, maintenance, etc.
Q:What ceramic plates can be lined in composite pipes?
A:Flat Liner,Weldable liner,Trapezoidal liner,Interlocking Liner,Mosaic Alumina Ceramic Tiles.
Q:How to test the impact strength and wear resistance of wear-resistant composite steel pipes?
A:Impact strength test:Charpy pendulum impact test and low-speed impact test.
Wear resistance test:Impact wear test.
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