Ceramic Rubber Liner-Nylon Products-Bakelite Products-Wear-resistant Ceramics-Customized Processing

Extremely high abrasion resistance: hardness second only to diamond, can effectively resist material scouring and abrasion.
Excellent corrosion resistance: it can resist the erosion of most acids, alkalis, salts and other chemical media.
High strength and toughness: high impact resistance, not easy to break.
Light weight: density is only about half that of steel, which reduces equipment load.
Small friction coefficient: smooth surface, not easy to stick material, can reduce conveying resistance.

1. Electricity industry (coal-fired power plants)
This is one of the most widely used areas for ceramic liners, which are mainly used to solve the severe wear and tear of equipment caused by coal dust and ash.

Coal conveying system: anti-friction lining of hopper, chute, guide plate, etc.

Pulverizing system: Coal mill outlet ducts, separators, etc.

Ash removal system: dust collector hopper, air inclined chute, etc.

2. Iron and steel metallurgical industry
The industry has a large number of high-temperature, highly abrasive material conveying and handling processes.

Raw material conveying and dosing: Lining of blast furnace raw material silos, coke silos, vibrating feeders, sinter chutes.

Blast Furnace System: Piping and distributor for pulverized coal injection system, furnace top receiving hopper, pressure equalizing discharge pipe.

Steelmaking system: Dedusting ducts, flues, iron oxide powder conveying equipment.

Sintering and pelletizing: ring cooler chutes, vibrating screens, finished ore bin linings.

3. Cement and building materials industry
The entire production process, from raw materials to finished products, is accompanied by heavy wear and tear from dust and particulate matter.

Raw material preparation: Raw material mill, cement mill inlet and outlet air ducts, powder selector, V-type powder selector chute lining.

Clinker cooling and conveying: chute from grate cooler to clinker storage, clinker crusher inlet, clinker conveyor.

Pulverized coal preparation: Coal mill system piping, cyclone separator, pulverized coal silo.

4. Mining industry
Involved in the mining, crushing and conveying of ores, the wear and tear is extremely severe.

Ore crushing: Crusher chamber, impact plate, inlet liner.

Ore Conveying: Lining of chutes in ore bins, chutes, vibrating ore dischargers, belt conveyor transfer stations.

Ore sorting: heavy media sorting tank, magnetic separator chute.

5. Chemical industry
It mainly utilizes its dual properties of corrosion and abrasion resistance.

Material Conveying: Pipes, elbows and silo linings for corrosive and abrasive chemical materials (e.g. catalysts, salts, plastic granules).

6. Port Terminal and Machinery Manufacturing
Harbor loading and unloading: Hopper and chute liners for ship unloaders, ship loaders, and stacker reclaimers, for loading and unloading bulk materials such as coal, ore, and grains.

The core performance of ceramic rubber composite liner is characterized by the triple advantage combination of "high wear resistance + corrosion resistance + strong cushioning + easy to install", which perfectly balances the hardness and impact resistance of wear-resistant materials, and is suitable for all kinds of high wear and high impact industrial scenarios.
1. Core performance characteristics
Extreme wear resistance liner surface ceramic layer (such as alumina, ZTA ceramics) is the core wear-resistant components, its hardness can reach HRA 85-95 or more, the hardness is second only to diamond, far more than wear-resistant steel and stainless steel, and its wear-resistant performance is equivalent to 266 times that of manganese steel, 171.5 times that of high chromium manganese steel, in the same working conditions. At least ten times longer service life of the equipment.

2. Excellent impact resistance
The rubber layer in the middle has high elasticity and toughness, which can effectively absorb the impact force when the material falls or impacts, avoiding the ceramics from breaking due to brittleness, and at the same time, reducing the noise and vibration when the equipment is running.

3. Reliable adhesion and sealing
Through a special process, ceramic and rubber, rubber and steel plate (backing plate) are firmly combined, with strong adhesion and not easy to fall off. The elasticity of the rubber also fills the gaps in the equipment, preventing material leakage and dust overflow.

4. Lightweight and easy to install
Compared with pure ceramic liner or high chrome steel liner, it is lighter in weight and can be installed in various ways such as bolt fixing and sticking, which is easy to construct and can significantly shorten the equipment downtime and maintenance time.

5. Corrosion resistance and adaptability
Ceramics and rubber have good chemical stability, can withstand acid and alkali, humidity and other harsh working conditions, suitable for mining, metallurgy, electric power, ports and other industries, silos, chutes, pipelines and other equipment.

The completion of the installation is only the first step, scientific routine maintenance and regular inspection is to ensure long-term stable operation of the cornerstone.

1. Daily inspection "look and feel"
Expectations: Observe the surface of the liner on a regular basis to check for unusual cracks, large areas of peeling or signs of severe wear.
Smell: listen to the sound of the equipment running, if there is an abnormal sound of material flushing, may indicate that the local liner has fallen off.
Cut: When shutting down for maintenance, use a small hammer to gently knock on the liner, and judge whether there is any hollow drum or delamination by the sound.

2. Focusing on "critical areas"
The material facing surface: the area of direct impact of the material is the most serious wear and tear, and should be the top priority of the inspection.
Welds and interfaces: Check for cracks in welds and loose bolts at welded fastening points.
Equipment elbows, tees and other changes in direction: these parts of the flow rate and impact angle changes, wear and tear increased.

3. Timely "quick fixes for minor ailments"
Localized Repair: When a single piece or small area of liner is found to be damaged, it should be shut down in time for localized replacement. Remove the old rubber and residual boards and repair according to the original installation method.
Avoid running with disease: a small piece of liner falling off may trigger a "domino effect", resulting in accelerated damage to the surrounding liner by material washout.

4. Establishment of "maintenance files"
Record the time, location, cause and method of each installation, inspection and repair. This helps analyze wear patterns and provides data to support the next overhaul and spare parts procurement.

I. Core installation process: localized, solid as gold

Ceramic liners can be installed in a variety of ways, depending on the equipment conditions, shape and temperature and other factors to choose the most suitable program.

1. Bonded fixation - the most common and economical choice

• Applicable Scenarios: Flat or large curvature equipment surfaces, such as silos, chutes, flat plates, etc., at room temperature or low to medium temperatures (generally <100°C).

• process::

  • surface treatment: Thoroughly clean the surface of the substrate to remove rust, oil and old coatings and wash with acetone or alcohol to ensure dryness, cleanliness and roughness.

  • Gluing and gluing: Choose special high-strength ceramic-metal adhesive and mix it evenly according to the proportion. The adhesive is applied to the back of the ceramic liner and the equipment substrate by "spot coating" or "full coating".

  • compact: Fit the liner tightly to the substrate, press firmly and tap gently to make the adhesive layer even and full and to expel air.

  • Curing maintenance: Maintain at the specified curing time and temperature, during which movement or vibration is strictly prohibited.

• dominance: Easy construction, lower cost, uniform stress distribution.

• crux: Surface preparation is at the heart of success or failure, and the choice of bonding agent is critical.

2. Welding fixation method - dealing with high temperatures and strong impacts

• Applicable Scenarios: Highly wear-resistant, heavy shock load conditions, such as coal mill outlets, high-temperature air ducts, sintering equipment and so on.

• process::

  • Substrate preparation: Pre-drilled or welded bolts in the equipment substrate or ceramic liner.

  • Liner in place: Slip the ceramic liner over the pre-welded bolts or punched holes.

  • weld fastening: Use special welding rods to securely weld the bolt caps or grommets on the back of the ceramic liner to the equipment substrate.

• dominance: Extremely high connection strength, excellent heat resistance and high impact resistance.

• crux: It needs to be operated by professional welders to ensure the quality of welding and avoid false welding.

3. Tongue & groove (mosaic liner) - ideal solution for complex surfaces

• Applicable Scenarios: Elbows, reducers, cyclone separators and other curved equipment with complex shapes.

• process::

  • Liner in placeThis liner consists of numerous small ceramic pieces connected by a special rubber or fiber backing to form a flexible "blanket".

  • fixed installation: It can be fixed directly to the equipment by pressing strips, bolts or direct bonding, and can easily fit all kinds of complex curved surfaces.

• dominance: Flexible and convenient installation, no installation dead angle, good resistance to impact and thermal shock.

• crux: Installation needs to ensure that the liner fits tightly to the substrate to avoid gaps.

The Universal Golden Rule of Installation::

• logical layout: Pre-layout should be carried out before installation, staggered paste, as in the case of masonry walls, to avoid through-joints, in order to disperse the stress.

• gap control: Leave a gap of 0.5-1cm between boards to cope with thermal expansion and contraction.

II. Guidelines on scientific maintenance: prevention and long-term stability

The completion of the installation is only the first step, scientific routine maintenance and regular inspection is to ensure long-term stable operation of the cornerstone.

1. Daily inspection "look and feel"

• towards: Observe the surface of the liner periodically to check for unusual cracks, large areas of peeling, or signs of severe wear.

• auscultation: Listen to the sound of the equipment running, if there is an abnormal sound of material flushing, it may indicate that the local liner has fallen off.

• grind: When shutting down for maintenance, gently tap the liner with a small hammer to determine whether there is any hollowing or delamination by the sound.

2. Focusing on "critical areas"

• facing the material (e.g. the front face of a building): Areas of direct material impact are where the most wear occurs and should be a top priority for inspection.

• Welds and interfaces: Check for cracked welds and loose bolts at welded fastening points.

• Equipment elbows, tees, and other redirections: These areas are subject to large variations in flow velocity and angle of impact and increased wear.

3. Timely "quick fixes for minor ailments"

• local repair: When a single piece or small area of liner is found to be damaged, stop the machine in time for partial replacement. Remove the old rubber and residual boards and repair them according to the original installation method.

• Avoid running with disease: The loss of a small piece of liner can trigger a "domino effect", resulting in accelerated damage to the surrounding liner as material is washed over it.

4. Establishment of "maintenance files"

• Record the time, location, cause and method of each installation, inspection and repair. This helps analyze wear patterns and provides data to support the next overhaul and spare parts procurement.

1. Large-scale construction machinery and mining equipment

This is the primary and most demanding application area for large nylon dust rings.

• Large Mining Excavator(e.g. Liebherr R 9800, Caterpillar 6090): the bucket cylinders and bucket rod cylinders are huge, and the dust rings are correspondingly huge.

• Ultra-large hydraulic supportIn coal mining, the hydraulic support columns that support the roof plate have huge cylinder diameters and require large dust rings to withstand the high dust and humidity of the underground environment.

• Large mining dump truck(e.g. Buellas, Komatsu 930E): the huge lifting cylinders that lift the carriages, working on the bumpy, dusty roads of the mines, the dust rings are vital.

• Tunnel boring machines (shield machines): Its main propulsion cylinder group and cutter shield cylinder, working in the harsh environment of mud, water and slag, the reliability of the dust ring is directly related to the digging efficiency.

2. Large-scale water conservancy and hydropower and gate opening and closing equipment

• Giant hydraulic cylinder for sluice gate/boat gate openerFor example, the hydraulic cylinders of the Three Gorges Dam locks are huge in size and are exposed to the outdoors for a long period of time, which requires the dust ring to have excellent weather resistance and durability.

• Large hydraulic dams: The hydraulic cylinders that control the lifting of the dam surface are immersed or exposed to water for a long period of time, and need dust rings to effectively prevent the intrusion of mud and sand.

3. Heavy metallurgical equipment

• Hydraulic cylinders for rolling mill press down device: Working in a high temperature, iron oxide filled environment, the dust ring needs to be resistant to high temperatures and effective in scraping away hard particles.

• Hydraulic cylinders for steel furnace tilting mechanism: Withstand high temperatures and heavy loads in extreme working conditions.

4. Marine and offshore engineering

• Hydraulic cylinder for ship's rudder: The rudders of large ships are so powerful that hydraulic cylinder dust rings need to resist marine salt spray corrosion.

• Hydraulic Cylinder for Offshore Platform Lifting System: e.g. hydraulic cylinders for lifting and lowering the pile legs of jack-up drilling rigs, exposed to harsh marine environments.

• Synchronized lifting hydraulic system for ship locks and floating docksThe

5. Special equipment and heavy vehicles

• Large military equipment: e.g. suspension and turret hydraulics for tanks and armored vehicles.

• Special Transportation Vehicle: e.g. hydraulic suspension systems for heavy hydraulic flatbed trucks (SPMT) carrying rockets, bridge modules.

I. Core performance advantages (why use nylon slider)

• Self-lubricating and low friction: Nylon itself has a low coefficient of friction, allowing it to operate with no or little oil lubrication and reduced maintenance.

• High abrasion resistance: Withstands frequent sliding and vibration and has a long service life.

• light weight: The density is only about 1/7 of that of metal, which effectively reduces the inertia of the moving parts of the equipment.

• Impact resistance and vibration absorption: It can effectively absorb vibration and noise, making the equipment run more smoothly and quietly.

• corrosion resistance: Good resistance to most chemicals such as alkalis, alcohols, oils and fats.

• Easy Installation: Easily machined into a variety of shapes and at a low cost.

II. Main applicable categories of equipment

1. Material handling and conveying equipment

This is one of the most widely used areas for nylon sliders.

• belt conveyor: Used asGuide Chute SlidemaybeSweeper sliderIt protects the conveyor belt from abrasion and effectively scrapes away adhering material.

• chain conveyor: Acts as a sliding block in the rail, reducing metal friction between the chain and the rail, reducing noise and wear.

• forklift trucks: For sliding pads on the gantry to make fork lifting and lowering smoother.

• Elevator/Stacker: As a guide slide in a guideway system.

2. Construction machinery and heavy equipment

• bulldozers: Widely used in buckets, buckets and other connection parts of thebushingcap (a poem)bushings, reducing pin wear.

• Bulldozers/loaders: Sliding support points for shovel blades, tracks, etc.

• crane: Acts as a liner in the sliding mechanism of the telescopic arm to ensure smooth telescoping.

3. Automated production lines and industrial robots

• Linear Modules: It can be used as a light-duty slide or limit block in applications where precision is not required to be extremely high.

• Flow line workbench: For sliding parts of fixtures and positioning mechanisms.

• Robot end-effector: Serves as a cushion or sliding part to avoid hard collisions with the workpiece.

4. Machining equipment

• CNC machine tools: Used for sliding guides for auxiliary mechanisms such as tool magazine doors and guards.

• Stamping equipment: As a bushing for a mold guide pillar, or as a sliding part of a feeding mechanism.

5. Rail transit and vehicles

• Train/subway doors: Widely used in door slides to ensure smooth and quiet door opening and closing.

• sunroof: Serves as a support block for the sliding sunroof glass.

• Seat adjustment mechanism: In slides used for forward and backward movement of the seat.

6. Warehousing and logistics equipment

• Shelving system: Used on the chassis rails of compact shelves and mobile shelves to make the shelves mobile and lightweight.

• sorter: As wear-resistant liners in chutes, manifolds, etc.

7. Other common equipment

• gym equipment: e.g. seat slides for fitness equipment, weight block guides.

• Door and window hardware: Pulleys and sliders for heavy-duty sliding doors and windows.

• agricultural machinery: Such as harvesters, planters and other parts that require sliding and friction reduction.