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Mining Wear Ceramic Lined Part and ComponentsQMX can supply hydro cyclone replacement liners for OEM cyclones. Liners are generally composed of:Silicon CarbideAlumina orcomposite ceramic Liner In situations where ceramic materials may not be suitable, we also supply linings made from:Polyurethane orRubberPipe LiningsOur ceramic pipe linings have been used in very abrasive environments.They are produced from high purity (92% or 99.8%), high density Alumina.They exhibit around 8 - 10 times the wear life of comparative materials, ie steels, rubbers and polyurethanes.We stock various straight and elbow sections and can tailor to your needs.Wear Resistant Ceramic Lined Vortex Finder Wear Resistant 45°Pipe Bend Wear Resistant Cyclone Distributor
Pipe wyes and pipe tees:Pipe wyes are similar to pipe tees. The only difference is in that the branch line is angled to reduce friction which could hamper the flow. The pipe connection is typically at a 45-degree angle rather than a usual 90-degree angle. If a branch turns out at the end to be perpendicular to the through line, the pipe fitting becomes a "tee wye".Main Properties of CeramicCategoryHC92HC95HCT95Al2O3≥92%≥95% ≥95% ZrO2///Density≥3.60g/cm3≥3.65g/cm3≥3.70g/cm3Water Absorption≤0.1%≤0.1%≤0.1%HV 20≥950≥1000≥1100Rock Hardness HRA≥82≥85≥88Bending Strength MPa≥220≥250≥300Compression strength MPa≥1050≥1300≥1600Fracture Toughness KIc MPam 1/2≥3.7≥3.8≥4.0Wear Volume≤0.25cm3≤0.20cm3≤0.15cm3Application:Ceramic lined pipe elbows could be also applied in the parts of concrete pump owing to their advantages, especially the low weight, which helps to avoid the jam during the transport of concrete.Replace carbon steel pipe, stainless steel pipe and SDRHigh wear material dischargeMagnetite feed and drain linesTailing underflow
CERAMIC LINED COMPONENTS AND BENDSHard & Compact ; Smooth & Inert ; Withstands High-Abrasion & Corrosion ceramic wear liningsIn any of the process industries, especially steel and cement, corrosion and abrasion lead to significant downtime of the plant. Further, the useful life of the equipment itself may get impaired because of high abrasive nature of the materials being used. Thus, ‘wear mechanism’ results in shutdown, replacement, etc., which is costly, resulting in loss to the tune of millions of rupees. For resistance to wear, ceramic lined bends, straight pipes, etc., are ideal.FEATURESHigh resistance to all types of chemicalsHigh resistance to sliding abrasionNon wet ability and smooth surface results in easy flow of materialsCan withstand temperature of up to 200°CSmaller ID of 100 mm can also be manufacturedCOAL DISTRIBUTORHYDRO CYCLONES FOR COAL WASHING PLATE
Cast basalt lined steel pipe is made with lined cast basalt pipes, coat steel pipe and the cement mortar filling between the two layers, it sets the wear resistance and corrosion resistance of cast stone pipe, the toughness of the steel pipe and the consolidation of the cement mortar in one. Greatly improve the product's ability of adapting various complicated working condition. At the same time using cement mortar as filling material, can make the pipe inner surface in alkaline medium, so that the surface of the steel pipe will produce a purified film to prevent corrosion. Cast basalt lined steel pipe is not only resistant to wear and corrosion, against high pressure, but also convenient and safe to transport.Cast basalt pipe can be divided into straight pipe, elbow, three-way (four-way) pipe and variable diameter pipe, etc.The excellent performance of cast basalt lined steel pipe is that it sets tenacity of steel pipe, abrasive resistance of cast basalt pipe, concreteness of cement mortar in one.This greatly improves the products adaptive capacity in complicated operation conditions. At the same time. cement mortar is selected as the filling material and this can make the inside surface of steel pipe in alkali mediums. So the surface of steel pipe generates purifying films. These films can prevent being rusted.Technical parameters Packing: Ply-wood Carton
Cyclones handling abrasive products such as clinker dust or raw meal are often lined with QMX abrasion-resistant alumina ceramic tiles to extend the cyclones' operating life. These pre-engineered tile linings resist wear, abrasion, and corrosion from the materials being processed, reducing maintenance and downtime. A relatively thick ceramic tile lining is critical in our Heavy-media Cyclones, as dense mineral matter can be very abrasive.We offer our pre-engineered tiles in two different grades, with 25 to 38 mm (1-in to 1.5-in) thickness, to optimise wear life.Material of the Cyclone Linings: 92% Al2O3 95% Al2O3 T95% Al2O3 ZTA(Zirconia Toughened Alumina)During their manufacture, we machine each ceramic tile in its “green” state, and then fire the lot to become interlocking, serialised liner components. Although this process is relatively expensive, the resulting increase in wear life pays for itself, and is one more reason why operations choose our Heavy-media Cyclones over other models that utilise flat tile.Cyclones Dimension can be Manufactured: 660mm/840mm/900mm/1000mm/1150mm/1250mm/1300mm/1450mm in diameterLayout of the Cyclone Tile:Packing Pictures:
QMX is able to advanced-ceramics-line different bores and lengths of pipework with the application of either alumina or silicon carbide. We are also able to design and build pipework. Advanced ceramics, with hardness ratings of 2000 Vickers, are amongst the hardest materials available. Utilising diamond-ground advanced ceramic lining systems, we are able to expertly line pipework to provide the highest level of abrasion resistance and increase the lifespan of the pipe, therefore reducing running and maintenance costs.Alumina Lined Pipe RBSiC Silicon Cabide
Products application:Alumina ceramic tube is of high wear resistance, acid and alkali resistance, effectively prolong the service life of equipment and considered to be the best choice of anti-wearing and anti-corrosion material; Wear resistance of ceramic is 10 times than that of special manganese, 10 times to high chrome cast iron; Hardness is much higher than that of wear-resistant steel and stainless steel. Application: Oil, mining, steel and power industry. Technical parameters:Alumina/RBSIC ceramic tubeMaterialAlumina&RBSiC Silicone CarbideBrandFIRSTARCountry of originZibo,ChinaColourWhiteTypeTubeSizeODIDLength70-750mm30-710mm200-500mmMolding methodIsostatic pressingBulk Density3.02 & 3.65 & 3.70g/cm3Al2O3%92% / 95% / Silicon carbide Water Absorption≤0.01Abrasion(cm3)0.1~0.25
QMX Alumina Ceramic Blocks are designed as per the requirements of the customers' engineering combined with the cost, installation and effective of application. Especially the blocks with tongues and grooves, Its obvious performance is that they could lock each other due to the tongues and grooves to increase the connectivity in whole engineering. So it is used widely in pipe lining, ceramic rubber plate in mining industry, steel plant, cement plant, port, power plant,etc.Meanwhile QMX ceramic blocks usually vulcanized with rubber, made as the ceramic rubber and steel composition ceramic liner. >>> Reputation & Experience for QualityQMX served industrial maintenance company for 17years, we earned good reputation by our believable products and sincere service , CHEMSHUN CERAMICS are the wear resistant ceramics of choice for a large variety of industries including mining, sand and gravel, coal handling, steel production, and more.>>> QMX Ceramic AdvantageAfford the standard and pre-engineered tilesProfessional technical team to afford CAD designsProfessional installation team to afford install serviceWell established process as per international standards>>> QMX Wear Resistant Materials Application Copper Mining Processing• Mill Feed Throats• Underflow Tub Liners• Material Handling Chutes• Cyclone Feed/Discharge Piping/ChuteCoal Preparation• Cyclone Distributors• Cyclone Liners• Magnetic Separator Chutes• Impact Panels• Sieve Bend Feed Boxes• Pipe Lining/ElbowsCement Industry• Chutes• Cyclone Separators• Cones>>> QMX Ceramic Product Salient PropertyExcellent wear and abrasion protection propertyLower production and maintenance costExcellent corrosion resistance propertyExcellent impact resistance propertyExcellent heat resistance propertyEasy to handle size and weightFast and safe installation
A cyclone is a specially designed system used to separate materials using centrifugal forces. The materials fed into a cyclone are typically hard and the environment within a cyclone is inherently highly abrasive. Hence wear inside a cyclone is an operational hazard. QMX Ceramic Engineering have the materials and expertise to be able to minimize wear of your cyclone linings and thus reduce downtime and increase efficiency.The main body of the cyclone consists of a reducer or a cone shaped liner tapering from a larger diameter to a smaller one down its length.Wear Resistant Solutions for CyclonesSince the materials separated in a cyclone are highly abrasive, it is important to have a cyclone lining that stands up to rigors of the job. Ultra High Purity Alumina can be used to increase cyclone working life and performance and can be custom shaped to suit all geometries; from the pipe work leading to the inlet, the vortex finder and apex outlet, to the conical heart of the cyclone.Cyclone Components Commonly Subject to WearThere are many components within a cyclone assembly that are subject to high wear conditions. Taylor Ceramic Engineering can supply many of these in wear resistant materials to extend component life. Some of the parts that we typically supply include:· Cylindrical & Reducing Liners· Inlets· Outlets· Spigots· Inserts· Upper, Mid & Lower Cone Sections· Vortex finders· Virtually any surface that undergoes wear!Wear Resistant Lining FormatsA range of wear resistant lining techniques can be used; from monolithic inserts to tiled sections.Monolithic SectionsQMX is uniquely positioned to be able to manufacture small and large monolithic shapes in short time frames. These sections can be custom made to suit your precise requirements.Monolithic sections have the advantage that they are much faster to install, thus reducing downtime.Tiled SectionsBecause most surfaces associated with a cyclone assembly are curved, Taylor Ceramic Engineering is able to engineer tiles that conform to the exact shape required.Flat tiles on curved surfaces often leave a series of flats radially around the internal surface of the cyclone. This not only interrupts material flow but increases wear on the tiled surfaces and thus reduces equipment life. However, using engineered curved tiles that conform to the required shape reduces the discontinuities and increases material flows and hence the equipment efficiency.CategoryHC90HC92HC95HCT95HC99HC-ZTAZrO2Al2O3≥90%≥92%≥95% ≥ 95%≥ 99%≥75%/ZrO2/////≥21%≥95%Density≥3.50g/ cm3≥3.60g/cm3≥3.65g/cm3≥3.70g/cm3≥3.83g/cm3≥4.10g/cm3≥5.90g/cm3Water Absorption≤0.1%≤0.1%≤0.1%≤0.1%≤0.1%≤0.1%≤0.1%HV 20≥900≥950≥1000≥1100≥1200≥1350≥1100Rock Hardness HRA≥80≥82≥85≥88≥90≥90≥88Bending Strength MPa≥180≥220≥250≥300≥330≥400≥800Compression strength MPa≥970≥1050≥1300≥1600≥1800≥2000/Fracture Toughness KIc MPam 1/2≥3.5≥3.7≥3.8≥4.0≥4.2≥4.5≥7.0Wear Volume≤0.28 cm3≤0.25cm3≤0.20cm3≤0.15cm3≤0.10 cm3≤0.05cm3≤0.02cm3Layout of Drawing：
Product introduction:Wear-resisting ceramic-lined pipe can be applied to the pipeline transport of materials, in the long-term pipeline transport, the pipe wear is serious, especially pipe elbow, often because of long-term wear and tear caused by the pipe damage, pipe elbow impact force is large, wear is serious.Ceramics have excellent impact resistance and super wear resistance, usually used in the inner wall of the pipe and equipment, to protect the pipe, reduce wear, impact resistance.The wear-resisting ceramic lining is installed in the inner wall of the pipeline in the form of pasting, welding, dove-tail and so on to form a firm anti-wear layer. With its super wear resistance, it is widely used in pneumatic conveying and hydraulic conveying systems in industrial enterprises.It is widely used especially in the environment with severe impact corrosion.Advantage:Longer service lifeTemperature resistance and aging resistanceLight weightThe surface is smoothCeramic staggered joint installationEasy installation
Abrasion Resistance Ceramic Lining PipeAbrasion resistance ceramic lining pipes are designed and lined with high quality alumina ceramic material like alumina rings. The abrasion resistance ceramic lining pipe as a whole part, and then assemble it into the steel pipe with our high-strength-temperature-resistant epoxy adhesive. The pipe consists of three layers: smooth ceramic lining (compact corundum), ceramic and metal transition layer and the outer steel pipe. We can produce abrasion resistance ceramic lining pipe as per customer’s requirement and application.Alumina ceramic specificationsChemical Composition and Physical PropertiesCompositionAl2O3≥92%≥95%Specific Density(g/cm3)≥3.60≥3.65HV Hardness HV20 N/mm2(MPa)≥980≥1000Rock Hardness HRA≥82≥85Bending Strength (MPa)≥220≥220Compressive strength (MPa)≥1050≥1300Fracture Toughness MPam 1/2≥3.70≥3.8Wear Volume(cm3)≤0.25≤0.20cPackingCtn box with palletsCustomized Tiles can be made.The most common applications of ceramic sleeve lined pipesIndustryMaterial1. Abrasive productsGrinding wheel granules2. Aluminium plantsCalcined alumina, bauxite, electrode, carbon, crushed bath3. Iron & SteelSinter dust, limestone, lime injection, coal, iron carbide, alloy additives4. Mineral wool & insulation productsPerlite, stone dust, refractory fibers, production wastes, dust from sawing operations5. FoundriesMolding sand, dust collection6. Glass plantsBatch, cullet, quartz, kaoline, feldspar7. Breweries, grain processing, feed millsCorn, barley, soy beans, malt, cocoa beans, sunflower seeds, rice hulls, malting plants8. CementClinker dust, limestone, cement, fly ash, coal, blast furnace slag9. Chemical plantsCaustic lime, fertilizers, lime dust, chrome ore, paint pigments, plastic pallets with glass fi bers10. Mineral mining plantsKiln feed, ore concentrate, coal tailings, dust11. Coal fired power stationsCoal, fly ash, pyrites, slag, ash, limestone12. Coal minesCoal dust, mine waste for backfi lling13. Technical carbon productsTechnical carbon, dust, graphite for electrodes
Material of Cyclone liner 1. Alumina2. RBSiC silicon carbide3. ZTA Dimensions can be customized by client’s request. Apart from the standard alumina ceramic tile, we can also manufacturer the pre-engineering ceramics to suit different equipment. Product Introduction: Seperator cyclone equipment is mainly abrasive damaged by handling material, QMX can design ceramic cyclone liners according to customer's cyclone size and wear resistance requirement. ceramic tile liner cut and then composed . Product Application: Apart from the standard alumina ceramic tile, we can also manufacturer the pre-engineering ceramics to suit different equipment. We have our technical team who can help the client to choose the suitable wear resistant ceramic products ,and also we have the ability to design and make the CAD drawings according to the client’s wear application. The Tailor-made ceramics had the advantage of low wear, high hardness and impact resistance , it widely used for the chutes, hoppers, bunkers , pipelines in the mining, power generation, steel plant, steel plant industries, it make cost effective performance and reduce the maintenance cost and down-time for the clients
RBSiC ( SiSiC ) silicon carbide sic cyclone parts / cyclone lining with high hardness with high strength,high wear resistance, corrosion resistance, high temperature resistance, which has been widely used as the liners or parts in corase particles classification, concentration, paper making, chemical, electronics, washing and mineral processing industry. Property:*Superior wear resistance, impact resistance and corrosion resistance*Excellent flatness and temperature resistance up to 1380℃*Excellent oxidation resistance* Good dimensional control of complex shapes*Easy installation* Longer service life ( about 5 times more than that of alumina ceramic and 6 times more than that of polyurethane) Applicaion of RBSiC ( SiSiC ) silicon carbide sic cyclone parts / cyclone lining with high hardness :RBSiC ( SiSiC ) silicon carbide sic cyclone parts / cyclone lining with high hardness has high hardness, high temperature, abrasion resistance, oxidation resistance, acid and alkali resistance characteristics,which is widely used for wear-resisting lining of hydraulic cyclones, flue gas desulphurization pipes and coal slurry conveyor pipelines.Thickness available: 4mm - 25mmShape available: Tubes , Tee pipes, Elbows, Cones, Rings and so on. Other RBSiC / SiSiC reaction bonded silicon carbide products:The main products of reaction bonded silicon carbide ceramics are: cross beams, rollers, coling air pipe,burner nozzles,thermocouple protecting tubes,temperature measuring parts, radiant tubes, desulfurization nozzles, crucible,batts, wear resistant lining materials,plates, seals, rings and special shaped structural parts.
Cyclone mainly handles different sizes of dust particle.and suffer heavy wear damage during long time operation .which inevitably cause cyclone equipment ,even whole equipment working link stop to work and kinds of maintenance cost . Engineered Alumina ceramic lining tile design lined cyclone maximum efficiency of separation. QMX can design wear ceramic liner for any size cyclone , no matter wet or dry application.
Ceramic Lined Cyclone parts provides exceptional wear resistant property and are used highly wear prone areas like apex, cone, vertex finder etc area. In the industries like coal production, power generation, mineral processing and many other application entire cyclones are lined with ceramic liner.Features of our Ceramic Lined Cyclones:· The ultimate in alumina tiled cyclone engineering design· Maximum efficiency of separation· Cost-effective· Superiority of design confirmed by Computational Fluid Dynamic Analysis· Minimized turbulence· Engineered tiles are designed specifically for your application· Long lasting wear surface· Reduced energy usage
The material cyclone suffered serious abrasion and impact when it separated the material particle, like coal, gold, iron and ext. because of high speed material conveying. It’s very easy to wear out to leak the material from cyclone and a suitable wear protection solution for material cyclone is very necessary.ULTRAMING used the ceramic liners lined into the inner wall of the cyclone to get the wear & impact protections. It has been turned out it’s a very good wear solution for material cyclones.Also, we can design different shape and thickness ceramic liners for the cyclones according to different working conditions. Custom cyclone can be made according to client’s drawing.Applications：·Coal·Mining·Cement·Chemical·Steel
The material cyclone suffered serious abrasion and impact when it separated the material particle, like coal, gold, iron and ext. because of high speed material conveying. It’s very easy to wear out to leak the material from cyclone and a suitable wear protection solution for material cyclone is very necessary. ULTRAMING used the ceramic liners lined into the inner wall of the cyclone to get the wear & impact protections. It has been turned out it’s a very good wear solution for material cyclones.Also, we can design different shape and thickness ceramic liners for the cyclones according to different working conditions. Custom cyclone can be made according to client’s drawing.Applications：· Coal· Mining· Cement· Chemical· Steel
As wear resistant ceramics lined pipe supplier, QMX ceramics can meet customized design and product kinds of alumina ceramic linings for lined steel pipelines. Several ceramic liner pipe wear solutions ways can be offered for client’s options. Solution 1: Lined with Trapezoidal/pipe tiles with size 150*23/21*20mm, 150*33/27*25mm, or other dimensions per the drawing. Advantage:Lower cost Solution 2: Lined with alumina sleeve/tubes&Elbow pipe tiles, with Dia.100-300mm, Length 100-500mm. Advantage: Easy to Fix & few gaps Solution 3: Lined with Mosaic lining pieces Mosaic pieces sizes: 17.5*17.5mm or 20*20mm, Thickness 3-20mmAdvantages: Suitable for Lining the small diameter Steel pipes.
Material of Cyclone liner 1. Alumina2. RBSiC silicon carbide3. ZTA Dimensions can be customized by client’s request. Apart from the standard alumina ceramic tile, we can also manufacturer the pre-engineering ceramics to suit different equipment. Product Introduction: Seperator cyclone equipment is mainly abrasive damaged by handling material, QMX can design ceramic cyclone liners according to customer's cyclone size and wear resistance requirement. ceramic tile liner cut and then composed . Product Application: Apart from the standard alumina ceramic tile, we can also manufacturer the pre-engineering ceramics to suit different equipment. We have our technical team who can help the client to choose the suitable wear resistant ceramic products ,and also we have the ability to design and make the CAD drawings according to the client’s wear application. The Tailor-made ceramics had the advantage of low wear, high hardness and impact resistance , it widely used for the chutes, hoppers, bunkers , pipelines in the mining, power generation, steel plant, steel plant industries, it make cost effective performance and reduce the maintenance cost and down-time for the clients.