Ceramic lining

In its operations, WEARTECH uses the following types of ceramic linings: zirconium corundum, alumina ceramics, and silicon carbide. Thanks to their unique properties, these materials are widely used to protect industrial equipment from various types of wear. Under conditions of predominant erosion, ceramic materials prove to be the most effective. Ceramics exhibit absolute resistance to corrosion, both at high temperatures and in conditions of dry and liquid phases of transported materials.

There are numerous materials for making ceramic linings, each with unique properties that determine their application in various situations. WEARTECH successfully uses the following materials to protect industrial equipment:

Zirconium Corundum

Zirconium Corundum (ZrO₂-Al₂O₃) is a high-strength and wear-resistant ceramic used in extreme temperatures and aggressive environments. Its key advantages include:

High thermal resistance: Withstands temperatures up to 1700°C, making it ideal for metallurgy and foundry industries.
Wear resistance: Its high hardness extends the lining's service life in abrasive conditions.
Chemical resistance: Resistant to corrosion from acids, alkalis, and molten metals.

Alumina Ceramics

Alumina Ceramics (Al₂O₃) is one of the most common lining materials due to its excellent mechanical properties and availability. Key advantages include:

High hardness and strength: Possesses exceptional hardness, enhancing resistance to mechanical wear.
Thermal resistance: Withstands temperatures up to 1600°C, allowing use in various thermal processes.
Chemical inertness: Resistant to most chemical reagents, making it suitable for the chemical industry.

Silicon Carbide

Silicon Carbide (SiC) is a ceramic material known for its exceptional hardness and thermal conductivity. Key advantages include:

High thermal conductivity: One of the highest thermal conductivities among ceramic materials, facilitating efficient heat dissipation.
Wear resistance: Its high hardness makes it resistant to abrasive wear and mechanical damage.
Corrosion resistance: Resistant to acids, alkalis, and molten metals, ideal for aggressive chemical and metallurgical processes.

Ceramic linings find wide application in various industries due to their unique properties. Here are some key industries where the use of ceramic linings is feasible and effective:

Metallurgical Industry

Furnaces and crucibles: Ceramics are used for lining furnaces and crucibles, which withstand high temperatures and aggressive environments during metal smelting.
Ladles and molds: Used for lining ladles and molds, minimizing heat loss and protecting against thermal and mechanical damage.

Mining Industry

Crushers and mills: Ceramic linings protect equipment from abrasive wear during ore grinding.
Conveyors and transport systems: Used for lining chutes and pipes, extending equipment life and reducing maintenance costs.

Cement Industry

Rotary kilns and mills: Ceramic linings provide protection against high temperatures and abrasive impact, extending equipment service life.
Heat exchangers: Ceramics help improve heat exchange and reduce wear in heat exchangers.

Chemical Industry

Reactors and tanks: Ceramics are used for lining reactors and tanks that are resistant to aggressive chemical environments.
Pipelines: Lining pipelines protects them from corrosion and chemical exposure.

Energy Industry

Boilers and heat exchangers: Ceramic linings are used to protect boilers and heat exchangers from high temperatures and chemical exposure.
Gas and steam turbines: Used to protect turbine blades from wear and high temperatures.

Glass Industry

Melting furnaces: Ceramics are used for lining melting furnaces, providing protection against high temperatures and chemical exposure from molten glass.

Petrochemical Industry

Catalytic cracking units: Ceramic linings protect equipment from corrosion and wear at high temperatures.
Heat exchangers and reactors: Used for protection against aggressive chemical environments and high temperatures.

Food and Pharmaceutical Industry

Production lines: Ceramic linings are used to protect equipment from wear and chemical exposure during the production process.

These industries demonstrate the wide range of applications for ceramic linings, highlighting their versatility and effectiveness in conditions requiring high thermal resistance, wear resistance, and chemical resistance.

Complete ceramic lining

AUTHOR SUPERVISION

DESIGN

INSTALLATION

SANITATION

Advantages of Ceramic Lining

High Hardness and Wear Resistance: Ceramics have extremely high hardness, which ensures resistance to abrasive wear and extends the service life of equipment under intense mechanical impact.
Thermal Resistance: Ceramics can withstand high temperatures, making them ideal for use in extreme temperature conditions, such as metallurgy and foundry production.
Chemical Resistance: High resistance to corrosion and aggressive chemicals allows ceramic linings to be used in the chemical industry and other environments with high chemical inertness requirements.
Low Thermal Conductivity: Ceramics have low thermal conductivity, which helps minimize heat transfer and improve thermal insulation of equipment, protecting it from overheating and thermal stress.
Erosion Resistance: Ceramic linings are resistant to erosion caused by high-speed flows of solid particles or liquids, protecting the internal surfaces of equipment.
Durability and Reliability: Thanks to the combination of all the above properties, ceramic linings significantly increase the service life of equipment, reduce the frequency of repairs, and ensure more stable and reliable operation.
Mechanical Strength: Ceramics have high mechanical strength, allowing them to withstand strong impacts and mechanical loads without damage.
Long-term Cost-effectiveness: Although initial costs for ceramic linings may be higher, their durability and low maintenance requirements make them economically advantageous in the long term, reducing operating costs and equipment downtime.

These properties make ceramic linings the preferred choice for equipment protection in various industries, providing high efficiency and reliability.

Despite numerous advantages, ceramic linings also have their drawbacks. Here are some of them:

Disadvantages of Ceramic Lining

Brittleness: Although ceramics have high hardness, they are brittle materials that can easily crack or break under impact or significant mechanical loads.
High Cost: The initial costs for installing ceramic linings can be high due to the cost of materials and the need for skilled installation.
Labor-intensive Installation: Installing ceramic linings requires specialized knowledge and experience. Mistakes during installation can lead to material damage and reduced effectiveness.
Complex Repairs: Repairing ceramic linings can be complex and costly. In case of damage, large sections often need to be replaced, increasing the time and cost of repairs.
Limited Flexibility: Ceramic materials generally have low flexibility, limiting their use in situations where significant deformation or adaptation to changing conditions is required.
Operational Requirements: Ceramic linings require specific operational conditions. Sudden temperature changes can cause cracks and material damage.
Weight: Ceramic materials can be heavy, increasing the overall weight of the equipment and potentially requiring additional structural solutions for support.

Nevertheless, ceramic linings remain one of the best solutions for protecting equipment in extreme conditions, especially where high thermal resistance and chemical inertness are required. Proper application and installation of ceramic linings can significantly minimize their drawbacks and provide long-term equipment protection.