Wear-resistant Ceramic Liner

The excellent wear resistance of wear-resistant ceramic liners stems from the inherent properties of the ceramic materials themselves:

1.Ultra-high Hardness

The Mohs hardness of alumina ceramic liners can reach Grade 9, second only to diamond. Its hardness is 10 times that of ordinary carbon steel and 3–5 times that of wear-resistant steel plates, making it capable of withstanding the scouring and abrasion of most materials.

2.Low Friction Coefficient

The friction coefficient of the ceramic surface is as low as 0.1–0.2, which reduces frictional resistance during material conveying and helps avoid material adhesion and accumulation on the inner wall of equipment.

3.Strong Corrosion Resistance

Inorganic ceramic materials are inert to chemical media such as acids, alkalis, and salts, meaning they do not rust or degrade. They are suitable for harsh corrosive working conditions.

4.Excellent High-Temperature Stability

Ceramic liners maintain stable performance at working temperatures of 800–1000°C, without deformation, softening, or other issues caused by high temperatures, thus meeting the protection requirements of high-temperature equipment.

According to application scenarios and installation requirements, wear-resistant ceramic liners are mainly divided into the following four types:

Standard Flat Ceramic Liners

Shape: Mostly square (e.g., 100×100×10 mm, 150×150×20 mm) or rectangular, with chamfered edges to avoid stress concentration.

Application Scenarios: Protection of the inner walls of material chutes, hoppers, and pipelines under low-impact conditions.

Special-shaped Ceramic Liners

Shape: Customized into arc, trapezoidal, or irregular shapes according to the contours of equipment such as rotary kilns and mixer drums.

Application Scenarios: Designed to adapt to the curved surface structure of equipment, ensuring a full fit between the liner and equipment surface without any protection blind spots.

Composite Ceramic Liners

Structure: Features a three-layer composite design, consisting of a ceramic wear-resistant layer, an adhesive layer, and a steel plate base layer. The steel plate base layer facilitates welding and installation, while the ceramic layer provides the wear-resistant function.

Application Scenarios: Suitable for high-impact working conditions, such as crusher discharge ports and belt conveyor transfer points.

Ceramic Mosaic Liners

Structure: Small ceramic pieces are spliced together with high-strength adhesive and then fixed onto the equipment surface.

Application Scenarios: Used for local repairs of equipment or protection of small-area vulnerable parts.

The installation firmness of liners directly affects their service life. There are three main installation methods commonly used:

Adhesive Bonding Installation

Apply a high-temperature-resistant and high-strength epoxy resin adhesive to the back of the ceramic liners, then attach them to the pre-treated (derusted and degreased) equipment surfaces. This method is suitable for flat surfaces under low-impact conditions.

Mechanical Fastening Installation

Drill holes in the ceramic liners and fix them to the equipment using bolts and pressure plates. This method is suitable for high-impact working conditions where adhesive bonding may fail.

Welding Installation

Weld the steel plate base layer of composite liners directly to the equipment body. This method offers the highest level of firmness and is suitable for harsh working conditions with long-term heavy loads and high impacts.

Cement industry: Protection of inner walls of raw material chutes, cement mill feed pipes, cyclone separators and kiln hoods.

Thermal power industry: Protection of inner walls of coal conveying pipelines, ash discharge pipelines and boiler air preheaters.

Metallurgical industry: Protection of inner walls of ore chutes, blast furnace slag discharge pipes and dust removal pipelines of steelmaking converters.

Mining industry: Protection of ore hoppers, vibrating screen baffles and mine filling pipelines.

Compared with traditional wear-resistant materials such as wear-resistant steel plates and rubber liners, ceramic liners have distinct advantages:

Long Service Life

The service life is 5–10 times that of wear-resistant steel plates, generally reaching 3–8 years, which greatly reduces the frequency of equipment maintenance and downtime losses.

Light Weight

The density of alumina ceramics is about 3.6g/cm³, only half that of steel, which can reduce the additional load of equipment and lower equipment operation energy consumption.

Environmental Protection and Energy Saving

The smooth and flat ceramic surface can reduce material conveying resistance, cut down the power consumption of conveying equipment, and meet the production requirements of environmental protection and energy saving.

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