Metal ceramic tubes and elbows
All problems that arise due to excessive wear out (abrasion) during transport of various materials are solved if transport surfaces are lined with high quality ceramics. It is difficult to imagine contemporary pneumatic transports without tubes and elbows lined with ceramics. Large surfaces of various forms are successfully lined with ceramic mosaics and special ceramic tiles. Ceramic mosaics and tiles are successfully fitted to surfaces that are exposed to a large rate of abrasion with the help of special adhesives (epoxy glue) or by mechanical fixing.
Ceramic for mill lining, elements for milling and mozaics
CONVEYOR NOZZLE
Conveyor nozzles are used to accelerate transport with injecting the air in very long transport pipelines. These nozzles are made from ceramic segments which have more than 30 inlets around the scope of nozzle. These inlets are directed in the centre of the tube and that provides consistent air pressure of transport media. At the moment, this is the best solution in technology of pneumatic transport
CONNECTION OF METAL TUBE AND METAL-CERAMIC TUBE
STANDARD JOINT
JOINT WITH CONNECTION FLANGE
Tubes and elbows with inner diameter of ceramic up to DN 200 mm are made from ceramic cylindrical segments, which have male and female parts (see photo up left). At assembly this assures high quality of joint and long life time.
Tubes and elbows which have inner diameter bigger than DN 200 mm are lined with panels (mosaics) or with cone ceramic plates with requested thickness. Cone plates are adjusted to diameter of the tube or elbow, which are lined with ceramic.
Photos show different positions, which are lined with ceramic, due to big exposure to abrasion.
MATERIALS
Materials that are used for protection of elbows and tubes are:
- Aluminium Oxide 95% Al2O3
- Aluminium Oxide 99,5% Al2O3
- Composite Al2O3 +10% Zr02 (Aluminium Oxide + Zirconium Oxide)
- Zirconum Oxide ZrO2
MECHANICAL PROPERTIES
The widest application of ceramics comes from its excellent mechanical properties.
High hardness and wear resistance, modulus of elasticity, comprehensive and fl exural strengths have enabled the application of ceramic parts there where high mechanical stresses are expirienced.
Such high strength of Al2O3 ceramics is maintained at high temperatures and high abrasiveness, what makes it an excellent replacement for majority of metals, glasses, plastics, etc.
APPLICATION
Elbows and tubes with ceramic lining have wide application in different industries like pneumatic and hidraulic transport. The most common applications are:
| Industry | Material |
|---|---|
| 1. Abrasive products | Grinding wheel granules |
| 2. Aluminium plants | Calcined aluminia, bauxite, electrode, carbon, crushed bath |
| 3. Iron & Steel | Sinter dust, limestone, lime injection, coal, iron carbide, alloy additives |
| 4. Mineral wool and insulation products | Perlite, stone dust, refractory fibers, production wastes, dust from sawing operations |
| 5. Foundrise | Molding sand, dust collection |
| 6. Glass plants | Batch, cullet, quartz, kaoline, feldspar |
| 7. Breweries, grain processing, feed mills | Corn, barley, soy beans, malt, cocoa beans, sunflower seeds, rice hulls, malting plants |
| 8. Cement | Clinker dust, limestone, cement, fly ash, coal, blast furnace slag |
| 9. Chemical plants | Caustic lime, fertilizers, lime dust, chrome ore, paint pigments, plastic pallets with glass fibers |
| 10. Mineral mining plants | Kiln feed, ore concentrate, coal tailings, dust |
| 11. Coal fired power stations | Coal, fly ash, pyrites, slag, ash, limestone |
| 12. Coal mines | Coal dust, mine waste for backfilling |
| 13. Technical Carbon products | Technical carbon, dust, graphite for electrodes |
AVTO G ELECTRONIC CONTROL SYSTEM OF CERAMIC WEAR IN PNEUMATIC TRANSPORT SYSTEMS
Current problems of uncontrolled wear of ceramic lining in pneumatic transport systems are over.
We have developed special Avto G electronic control system, which provides complete control of metal ceramic wear in pneumatic transport.
Avto G electronic wear control system provides you with following usefull information:
- - it informs you on time, if tubes or elbows are worn out and if they must be replaced,
- - it informs you exactly which element in the pipeline is damaged and on which place it must be replaced
- - it informs you when was this element installed and for how long time it has been working,
- - and it can provide you with many other custum made information.
The system automatically gives you a light/alarm signal, when the elbow or tube is damaged. This information can be also seen on your computer, tablet or smart phone. After the signal, you know that ceramic lining is already worn out and that you still have only metal tube left, as a protection. It means that after the signal, you still have time to order new tube or elbow. Therefore our electronic control system prevents unpredictable breakthroughs and unnecessary stopping of production.
We hope our system will help you to improve your production ef ciency and make your future easier.
In pneumatic transport systems, where exact dimensions of tubes and bends can not be de ned, ceramic lined exible rubber tubes can be used. Ceramic lining is produced according to principle male-female part in shape of joint, what makes the rubber tubes more exible and allows bending in every direction.
Our ceramic lined exible tubes can also be produced with electronic control system, so you can successfully monitor wear of ceramic on computer, iPad or mobile phone.
The advantage of our ceramic lined exible tubes is, that the complete inner surface of rubber tube is covered with ceramics. The rubber tube is reinforced with wire net and can withstand the pressure until 10 bar.
In aggressive and heavy industrial environments where high temperatures, strong vibrations, impacts and abrasion are present during the material transport, the best product to be used is combination of rubber and ceramic.
We have the possibilities to vulcanize all types of ceramic mosaics with rubber thicknesses from 2 mm to 10 mm and hardnesses in range from 40 to 65 Shore [ShA], depending on the application requirements of the end products.
Where it is not possible to glue the rubber to the base liner, we can make a metal housing into which the ceramic will be vulcanised. Metal housing can be with different sizes or shapes. We can also produce custom made designs. On the metal housing we can weld bolts and threads or we can weld rods for xing to the base liner, which must be protected against abrasion.
It is very easy and fast to assembly the vulcanized ceramic items onto the required surface.
Ceramic custom made wear protection products on augers against high abrasion.
Wear protection of big diameter pipelines.
Ceramic custom made wear protection for stators, rotor parts and other components in sand mixers and sand pumps, which are used for sand distribution in pneumatic pipelines.
Ceramic cylinders and cones are produced by isostatic pressing and they provide long lifetime of different pipelines, dosage machines for powder materials, different nozzles and other products.
Here are some basic reasons, why you should use our ceramic-lined tubes and elbows:
- - Because we are the only manufacturer producing metal ceramic elbows with an inner diameter of DN 200 using a bending technology and segments welding technology;
- - Because we are the first and the only manufacturer that produces ceramic segments according to the principle male-female segment, where we prevent the possibility of the elbow material wearing down at the joint of two ceramic segments;
- - We are the only manufacturer with our own line of ceramic production, while we also produce complete metal-ceramic products ourselves;
- - All our products are made using a minimum blend of 95% Al2O3 up to 99,7%Al2O3 in relation to the rate of abrasion of the transported material.
WEAR TESTS ON DIFFERENT MATERIALS
| SAMPLE | CERAMICS 99,5% Al2O3 | CERAMICS 95% Al2O3 | MELTED BASALT | RUBBER | STEEL |
|---|---|---|---|---|---|
| Density: (g/cm3) | 3,85 | 3,7 | 2,95 | 1,18 | 7,85 |
| Mass wear: (gr) | 0.007 | 0,009 | 0,12 | 0,2 | 1,51 |
| Volume wear (cm3) | 0,0026 | 0,0028 | 0,04 | 0,17 | 0,19 |
Test is made under folowing conditions:
- Radiation angle: 30 deg
- Pressure: 5 bar
- Time: 5 minutes
- Abrasive material: SiO2
CERAMIC LINING FOR LARGE SURFACES
For lining of large surfaces as well as for different shape of surfaces, we use different ceramic tiles (plates) and different mozaics. Materials that we use are 92% Al2O3, 95% Al2O3 and 99,5% Al2O3.
We make ceramic tiles (plates) in different sizes and thicknesses; it depends on operating conditions and place where they are mounted. Tiles are fi xed with special epoxy glue that has very good properties of fi xing.
Photos show plates with different shapes for linning of surfaces, which are exposed to abrasion.
At lining of surfaces, which are exposed to high temperatures and vibrations, epoxy glue is not enough to assure the quality of metal-ceramic. Plates with holes are beside glue, additionaly fi xed to surface with steel ferrule, which is welded on it, or it is adjusted to surface with screw and nut. Some plates can be adjusted mechanically, because they have swallows tale.
ADJUSTING OF CERAMIC PLATE ON SURFACE WITH WELDING OF STEEL FERRULE
ADJUSTING OF CERAMIC PLATE ON SURFACE WITH SCREW AND NUT
Besides standard panels (mosaics) we produce also special panels, on which ceramic has special shape (different convex parts, nipples). According to customers request we can also vulcanize panels in rubber, which makes the usage of panels bigger, on surfaces which are exposed to different vibrations and punches.
Ceramic mozaics are very suitable for lining of large surfaces, silos, irregular surfaces and many other shapes.
We produce following mozaics:
SQUARE TILES:
Ceramic tiles are glued on special acetat-silk material. The panel is 500 x 500mm large and we make them from following tiles: 10 x 10 mm, thickness: 2mm, 3mm 20 x 20 mm, thickness: 4mm to 12mm
HEXAGONAL (SIX-ANGLE) TILES:
Ceramic hexagonal tiles are glued on special acetat-silk material. The panel is 508 x 490mm large (696 psc of tiles). Type of tiles: SW 20 mm, (SW = distance between 2 sides), thickness: 4mm to 12mm