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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.

Ceramic-lined carbon steel pipe

Ceramic-lined carbon steel pipe

Low carbon steel pipe with ceramic

Low carbon steel pipe with ceramic

The ceramic-lined steel composite pipe

The ceramic lined steel composite pipe

Ceramic Lined Steel Pipe and Elbows
Ceramic Lined Elbows and Bends

Ceramic Lined Elbow

Ceramic Lined reducer pipe

Ceramic Lined reducer pipe

Ceramic Lined Bends

Ceramic Lined Bends

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.

Ceramic lined extension pipe draws
Principle of a wear-protected pipe elbow

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:

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.

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

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.

Self-propagating high-temperature synthesis (SHS)
Centrifugal SHS ceramic lined composite steel pipe
production process
Ceramic lined
FE2O3+2Al=2Fe+Al2O3+836KJ/mol
3FE3O4+8AL=9Fe+4AlO3+3265KJ/mol

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:

化学反应式

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.

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

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.

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

The ceramic-lined steel composite pipe can be joined by welding the steel pipe layer.

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  Customized Maximum Length Can be Achieved by Welding.
Properties of the Ceramic-lined Steel Composite Pipes >>
Ceramic (Corundum: a-Al2O3) lined abrasion resistant straight pipe and fittings are lined with highly abrasion resistant ceramic by SHS ----Characteristics of SHS self-burning ceramic composite pipe

Standard and identification of Abrasion resistant pipe


Classification and designation
of wear-resistant pipes
for power industry


Pipe elbows be Long-term
use in power plants

Because the outer surface behaves like mild steel, the product can be cut and welded with proper procedure in the field, configured into a variety of fittings, and can accept the standard end options of flanges, weld rings and couplings.

Abrasive Applications

One-hundred-twenty-nine-million tons of coal ash—a byproduct of the coal burning process—is produced every year. Most power plants transport the coal ash in liquid form to large surface impoundments or in solid form at landfills near the facility through long lengths of steel piping, which can range in length from several thousand feet to miles.

Application of Abrasion resistant pipe

Abrasion resistant pipe applied in coal-fired power plant ash and slag discharge tube, powder, powder tube, desulfurization pipeline,in addition also widely used in the following industries:

Q&A

Warranty

We are Quality Department tests and ensures all of our products are 100% inspected unreported. To an offer we customers additional corps of mind, all our products carry a 24-month warranty against defects or faulty workmanship.We fluid-flow products such as pipe and fittings, chokes, orifice plates, etc, carry a warranty against, erosion, defects, and/or faulty workmanship.

The warranty is determined to each creator and the maximum duration maximally in service. Should any of the RS fail within the warranty period, We'll replace or repair the defective product (s) at No. end user. Please contact the Sunny steel for details on the How to obtain a warranty for our products.

Inspections

As part of our quality regimen, 100% of incoming raw materials, semi-finished products, as well as finished products are thoroughly inspected prior to being entered into our inventory. We have established multiple hold points throughout fabrication as well as a comprehensive final inspection for all products.



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Our team are highly trained and experienced in servicing and producing all types of steel supplies. Whether you've got a large construction project, or need parts for industrial machinery, our team of steel fabrication consultants will ensure that your project is provided with the parts you need, when you need them.

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