Performance characteristics of smoothly transitioned ceramic wear-resistant elbows
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The smoothly transitioned wear-resistant elbow uses a special high-temperature resistant adhesive to attach special corundum wear-resistant ceramic sheets to the interior of the steel pipe elbow, thereby addressing the severe wear problem in the conveying elbows used in industries such as thermal power, metallurgy, steel manufacturing, and cement production. By combining the use of steel pipe elbows with wear-resistant ceramic sheets, this solution facilitates quick replacement and simplifies construction processes. Depending on the working conditions, the manufacturing process varies; the direct bonding method, bolt clamping method, or one-piece molding method can be used. Among them, the integrated pipe formation method (RHS) involves using carefully selected alumina particles to burn and form lining pipes through various molding methods, and then pouring a special filler into the interior of the steel pipe to form the integrated pipe. The pipes formed by this method differ from the ceramic composite pipes produced using the self-igniting combustion technique, as their inner ceramic crystals are exactly the same as those in the ceramic coatings. Its advantages are a smooth inner wall of the pipeline and excellent wear resistance, making it suitable for slag transfer and ash removal systems that require high standards for pipeline material. The bolt clamping method is a ceramic assembly technique that employs triple fixation through adhesive bonding, mutual pressing and interlocking of ceramic pieces, and bolt clamping. Thanks to the triple-fixing method, the ceramic and the equipment have become one; even when operating at high temperatures above 1000°C, the ceramic does not come off. The smooth-transition type wear-resistant elbow features a scientifically sound design; its smooth transition mechanism reduces the scouring force exerted by coal powder, thereby increasing its wear resistance and offering significant advantages. Ceramic composite pipes with excellent wear resistance have an inner lining of corundum ceramic (α-Al2O3), giving them a Mohs hardness of 9.0, which is equivalent to over HRC 90. Therefore, it exhibits high wear resistance against abrasive media transported in industries such as metallurgy, power generation, mining, and coal mining. Industrial operation has proven that its wear resistance lifespan is ten times, or even dozens of times, that of quenched steel. Ceramic composite pipes with low operating resistance have a smooth inner surface; they do not rust, and unlike seamless steel pipes, they lack protruding spiral patterns on their inner surface. According to tests conducted by relevant testing institutions on the internal surface roughness and water flow resistance, the smoothness of its internal surface is superior to that of any metal pipe; the water flow resistance coefficient is 0.0193, which is slightly lower than that of seamless pipes. Therefore, this pipe features low operating resistance, which can reduce operating costs. Corrosion resistance and anti-scaling properties are achieved because the steel-ceramic layer is (a-AL2O3), which has neutral properties. Therefore, it possesses acid and alkali resistance as well as seawater corrosion resistance, along with scale prevention properties. Ceramic composite pipes have a low cost of construction, are lightweight, and come at an affordable price. 50% lighter than cast stone pipes of the same inner diameter ； It is 20-30% lighter than wear-resistant alloy pipes, and boasts good wear and corrosion resistance; its long service life reduces costs related to supports, handling, installation, and operation. Through a comparison between the project budgets prepared by the relevant design institutes and construction units and the actual costs of the project, it was found that the cost of this type of pipe is comparable to that of cast stone pipes; compared with wear-resistant alloy pipes, the cost is reduced by about 20%. Installation is convenient due to the pipe’s light weight and good weldability. Therefore, methods such as welding, flanges, and quick connections can be used, which facilitates construction and installation while reducing installation costs. http://attach01.hcbbs.com/forum/201711/02/160804ucaiiap87aajuqap.jpg
The curvature radius of ceramic wear-resistant elbows, also known as the bending radius (R), refers to the radius of a circle. The larger the radius, the greater the circle and its curvature, and thus it becomes more similar to a straight line. Therefore, the larger the radius of curvature, the less resistance there is in transporting the material; the smaller the radius, the greater the resistance. Radius of curvature size is generally determined as a multiple of the pipe diameter. For example, if it is DN100 with a radius of curvature R10D, then the radius of curvature for this elbow is R1000. For example, hot-pressed elbows typically have a bending radius of one to two times the pipe diameter, while fire-bent elbows have a bending radius of three to four times the pipe diameter. Such bending ratios are commonly used in pipes subject to low wear, such as those used for blowing processes. 1. The radius of curvature of the elbows on the boiler fuel supply pipes in power plants must be determined according to the design specifications; it is generally six to ten times the diameter of the elbow. The ash transfer pipelines suffer severe wear over time; it is advisable to use a larger radius of curvature. If the curvature is very small, the service life will be extremely short, requiring maintenance as early as every 1 or 2 days. 2. The curvature radius of the tailings slurry conveyed in mines is generally 2D to 5D. 3. The curvature radius of ceramic wear-resistant elbows commonly used in cement plants for transporting coal powder is 10D to 15D. 4. The radius of curvature of the elbows in the chemical industry’s ash transfer pipelines is 10D. If there are space constraints at the installation location of the ceramic wear-resistant elbow, we recommend a minimum radius of R3.5D; in addition, a thickened back section should be provided to increase the service life of the elbow with a small radius.