Comparison between wear-resistant interpressed ceramic patches and arch-shaped ceramic patches

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(1) Performance comparison: 1. Wear resistance – The ceramic patches with interpressure design exhibit excellent wear resistance; 10mm ceramic patches can be used continuously for over 15 years. Tests have shown that the wear resistance of our company’s special ceramics is 200 times that of manganese steel and 150 times that of high-chromium cast iron, indicating extremely good wear resistance. The use of wear-resistant elbows in the powder grinding system significantly reduces equipment wear. Based on over a decade of field operation experience, the annual wear amount is 0.5 mm, with a service life of at least 15 years, thereby reducing the frequency and costs of maintenance. 2. The ceramic lining has high strength, high hardness, and low weight. It has been determined that the Rockwell hardness of this wear-resistant ceramic is between HRA80-85, which is much higher than that of wear-resistant steel and stainless steel. With a density only half that of steel, ceramic elbow pipes weigh only 1/3 as much as wear-resistant steel elbow pipes, making them easier to install and replace. Pipes made of interpressed ceramic tiles can be fabricated using elbows with smooth transitions, **which reduces the impact force of coal powder, minimizes wear on the pipes, and extends the service life of these wear-resistant pipes. Arched ceramic tiles can only be used in the shrimp-shaped design; coal powder exerts significant force on the outer curve of the elbow, which easily leads to wear and leakage. Moreover, an increased thickness of the ceramic tiles **increases the weight of the wear-resistant pipe**. 3. It is firmly attached, with good heat and corrosion resistance; the interlocking ceramic tiles are bonded to the inner walls of pipes and elbows using high-strength structural adhesives. High-strength structural adhesives feature high bonding strength, heat resistance, and aging resistance; many boiler manufacturers use this adhesive for attaching ceramics inside burners. Moreover, the ceramic patches are pressed together and welded to the steel bowl for fixation, providing a dual-layer reinforcement effect; the installation process is simple, and the reliability is extremely high. Ceramics are inorganic materials that do not oxidize or rust, and they are resistant to acid and alkali corrosion. Ceramic tiles pressed together in an arch shape are more secure than those pressed together in a different manner. 4. The inner wall is smooth; the interpressed ceramic tiles, which are free from clogging, are sintered at high temperatures, resulting in a dense structure. After grinding and deburring, the surface becomes smooth. The installation process is carried out strictly in accordance with the operation instructions, to ensure a smooth transition between ceramic tiles with a height difference of no more than 0.5 mm. After the ceramics are installed, the inner surface of the bent pipe remains smooth and free from blockages caused by powder material. (II) In terms of price, the thickness of interpressed ceramic tiles is only 10 mm, whereas that of arch-shaped ceramic tiles is 25 mm. The arch-shaped ceramic tiles used for wear-resistant pipes require more material by over half compared to interpressed ceramic tiles, which indirectly increases the cost of the pipes; therefore, interpressed ceramic tiles offer a better price advantage. In summary, whether in terms of performance or price, the wear-resistant interpressed ceramic patch is the most cost-effective option among both the interpressed ceramic patches and the arch-shaped ceramic patches!