Ceramic wear protection
Mechanical wear causes wear problems, more maintenance time, more costs. Usefull wear protection will reduce these costs. we can offer you the right ceramic wear protection for several production facilities.
Castbasalt
Cast basalt is a mineral material of exceptionally high abrasionresistance, unlimited resistance to moisture, high compressive strength and resistance to virtually all acids and alkalis and is completely corrosion-proof.
Cast basalt is produced by melting selected natural basalt - broken into sizes of 20 - 50 mm - in shaft furnaces at temperatures around 1,300°C, followed by casting into the desired molds.
Cast basalt reaches a value of hardness of 8 on the Mohs hardness scale. For comparison: the highest value 10 is only attained by diamonds. By virtue of these properties, the silicate cast basalt provides outstanding protection against abrasion and scuffing. However, it is marked by a certain sensitivity to impact. Under normal service conditions, cast basalt withstands temperatures up to approx. + 350°C or - 40°C. However, cast basalt should not be subjected to temperature shocks.
Cast basalt products are manufactured as tiles, formpieces, pipes and pipe segments.
Cast basalt tiles are produced as tiles and formpieces and have been succesfully been applied in:
• bottems of chain conveyors
• pipes- and bends
• coalbunkers, cyclones
Alumina Ceramic - Al2O3
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The term "alumina ceramic" defines ceramic materials with an aluminium oxide (Al2O3) content exceeding 80%. Basically, this is a single-phase, single-component oxide of corundum crystals bonded by solid phase reaction during the sintering process. Currently, alumina is technically the most important exponent of oxide ceramic materials.
The preferred and most economical shaping process is pressing; the casting process permits a greater variety of geometric shapes than the pressing process. More complicated geometries are produced by special ceramic casting processing.
Owing to the two possible shaping processes - pressing and casting - the product program is quite varied: tiles, pipes, elbows and all kinds of special preshaped formpieces are available.
Furthermore, smaller formats are offered on backing material or vulcanized onto rubber mats; usually, these are rectangular or hexagonal platelets. With these small formats, surfaces of any curvature may be protected, as well.
The outstanding qualities of alumina ceramic are its high hardness and temperature resistance. Therefore, this material is used in areas of extreme abrasion and - owing to its high temperature resistance - to protect surfaces subjected to both extreme
abrasion and high operating temperatures at the same time. As this material is also
available in thinner versions, a thin wall liner may achieve sufficient service time
in areas where a thicker lining is not possible for weight or space limitations.
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Zirconia - ceramiek
What is zirconia ceramic?
The offered zirconia ceramic is a material of the mixed ceramic type, made by the bonding of different oxides. Oxides of aluminium, zircon and silicon are melted in an electric arc furnace at approx. 2,000°C. Mixed crystals form which provide this material with its distinctive characteristics: high density, hardness and extreme wear-resistance.
Due to its mineralogical composition (approx. 50% corundum, approx. 32% zircon and a glass phase proportion of approx. 18%) and the method of production, this material is often called fused corundum.
The smelt fused in the electric arc furnace can be cast into various moulds. Standard tiles have edge lengths of 150 to 500 mm and a thickness of 20 to 100 mm. For mechanical attachment to the base material of the plant component, these may additionally be provided with:
• a center hole, for use with a screw or damp connection onto the plant component which
• is to be protected (boltwelding technique or similar)
• with a cast bolt screw
• with cast steel bases at the bottom for direct welding onto a steel structure
• with dovetail grooves for fitting correspondingly shaped steel platelets with welded-on
• balt screws.
Furthermore, straight pipes and elbow segments are offered as standard, with wall thicknesses from 17 to 25 mm and a diameter of 50 to 600 mm. Radial tiles are used, as well. As the material is shaped by casting, special formpieces can be produced, e.g. for the lining of pumps, cyclones etc. The temperature limit is approx. 1,000 °C.
Silicon Carbide Ceramic
Silicon carbide ceramic differs from other wear-protective materials in particular by its distinctive high resistance to temperature fluctuations. Silicon carbide is therefore used as wear protective material against abrasive and impact wear in areas stressed by very high service temperatures combined with fast-changing temperature fluctuations.
Typical areas of application therefore are:
• lining of coal dust piping in vicinity of the burner;
• lining of fans in power coal station coal units;
• lining of aluminium pouring spouts;
• nozzles;
• hydrocyclone linings.
Depending on the production process, these products are available as tiles, formpieces and pipes (casting process). Plain and complex geometric shapes are possible, as are largesurface areas (sqm) and very small-scale parts. Wall thickness range from 10 to 75 mm, with a minimum of approx 6 mm.
Wearstop
WearStop is a complete new generation of wear resistant ceramics. WearStop is a mix of very hard wear resistant particles with a special binder.
WearStop can be easily mixed with water and installation can be done "on-site" (cyclone, bunker, liners, pipes). WearStop can be easily repaired .
WearStop can be applied in installations with high abrasive wear and/or velocity till 20 mtr/second (pneumatic). Temperature limit approx 1200°C.
Toepassingen
• pijp- en bochtstukken
• kolenbunkers, cyclonen en glijgoten
• silo's, seperatoren
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