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The ceramic-lined steel composite pipe

The ceramic-lined steel composite pipe has exceptional resistance to abrasion. Its service life in materials transportation with hard abrasives is more than 20 times longer than in common steel pipe.

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.

Download Abrasion resistant The ceramic-lined steel composite pipes, Bends and elobws specifications & size range

Ceramic Lined Steel Pipe and Elbows

Cearmic lined pipe elbows

ceramic-microstructure
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.

1.3.Features of Alumina Ceramic:
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

Usage of The ceramic-lined steel composite pipe

Usage of  lined for The ceramic-lined steel composite pipe 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 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).

Wear-resisting comparative table of The ceramic-lined steel composite pipe:
Sand injection test 30% Transfer test of sludge with SiO2
Material Volume diminution
(cm3)
Material Volume diminution
(cm3)
Ceamic lined
Steel pipe
0.0022 Ceamic lined
Steel pipe
3
Ceramic pipe
Al2O397%
0.0025 S45C 25
Features and Advantages of The ceramic-lined steel composite pipe:

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.

Main Properties of The ceramic-lined steel composite pipe

Item

Index

Content of Alumina

95%

Density

3.5 g/cm3

Rockwell Hardness

80 HRA

Impact Strength

850 Mpa

Bending Strength

 290MPa

Breaking Temper

4.8MPa·m1/2

Coefficient of Linear Thermal Expansion

20W/m.K

Self-propagating high-temperature synthesis (SHS)

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.

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.

Specifications & size range of The ceramic-lined steel composite pipe

Size

76mm-1020mm

Wall Thickness

9mm-27mm

Outside Housing Material

Carbon Steel Seamless Pipe 

Inner Material

Alumina Ceramic

Ceramic Lining Thickness

(Including Transition Layer)

3mm to 6mm

Normal Operation Temperature

-50 deg. C ---- 800 deg. C

Normal Operation Velocity

20-35m/s

Length 

1.     1M, 2M, 3 M

2.   Customized Maximum Length Can be Achieved by Welding.

can be joined by welding the steel pipe layer. The ceramic-lined steel composite pipes can take place of expensive stainless steel, titanium, nickel, cast stone or alloy pipes. Extended service life can also reduce maintenance cost.

The ceramic-lined steel composite pipe PDF

The recommended Abrasion resistant pipe

This is because hardness is one of the most important factors when trying to increase abrasion resistance.

Please view the recommended Abrasion resistant pipe, bend, elbow, tee, reducers as below:


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