Three-in-one Ceramic Rubber Liner丨Large Ceramic丨Seamed

tripleCeramic Rubber Liner("Large" usually refers to the large size of a single piece of ceramic, and "seamed" means that the piece is not a single piece.liner(There are gaps in the splices) are madeCeramic layer (high hardness and wear resistance), rubber layer (cushioning and impact resistance), metal substrate (fixed support) The core advantage of the composite wear protection material is the balance between abrasion resistance and impact resistance, which is widely used in strong abrasion conditions in many industries.

I. Multi-industry specific application scenarios

Based on the structural characteristics of "large ceramic + seamed" (large ceramic coverage area, high protection efficiency; seamed design to adapt to the complex equipment curvature), its applications are focused onMaterial Conveying, Crushing, GrindingTypical industries where there is "high wear + medium impact" are as follows:

1. minesWith the mineral processing industry

Mining is the core application area for this liner, mainly dealing with the scouring and impact of hard materials such as ore and slag:

• Location: Ball Mill / Rod Mill Liner (Replacement of traditional highmanganese steel(liners), mine silo/hopper walls, crusher discharge chute, conveyor belt drop point liners.
• application logicOre hardness (e.g. granite, iron ore) is extremely abrasive to the equipment. The large ceramic size reduces the number of splices and reduces the risk of material jamming; the rubber layer cushions the impact of falling ore (avoiding the ceramic from cracking), and the metal substrate ensures that the liner and the equipment shell are firmly affixed to each other, making the liner suitable for 24-hour continuous operation.

2. electrical powerIndustry (thermal power, new energy)

The "pulverized coal / ash conveying" in the power industry is typically a highly abrasive process and requires a high degree of sealing:

• LocationCoal conveyor pipes in thermal power plants (pulverized coal washout), ESP hopper/ash conveyor pipes (fly ash abrasion), fuel conveyor chutes in biomass power plants (straw/wood chip mix hard pellets).
• application logicAlthough the hardness of coal dust and fly ash is lower than that of ore, the long-term high-speed transportation (wind speed 15-25m/s) will cause the pipe to be "partially worn through", the high wear resistance of large ceramic liner (Moh's hardness 8-9, much higher than that of metal) can extend the service life of the pipe from 3-6 months to 2-3 years; the seamed design can be used to fill in the gaps by sealant to prevent dust leakage, which is in line with the environmental protection of the power plant. The slit design can fill the gaps with sealant to prevent dust leakage, which is in line with the environmental protection requirements of the power plant.

3. clinkerWith the building materials industry

The "Raw Material/Clinker Transportation, Crushing" segment of cement production is characterized by high wear and tear and high temperatures (150-200°C in some scenarios):

• Location: Cement rotary kiln downcomer liner, preheater cyclone inner wall, crusher feed hopper, cement silo inner wall.
• application logicThe raw material contains quartz sand (high hardness), clinker temperature is high, large ceramic liner's high temperature resistance (ceramic long-term temperature resistance of more than 200 ℃) and abrasion resistance can resist the material scouring; rubber layer can absorb the impact of clinker fall, to avoid the deformation of the equipment shell because of the long-term impact to reduce the number of downtime for maintenance (cement production line shutdown for a day loss of more than a million dollars).

4. steeltogether withmetallurgicalsector

The steel industry has to cope with the abrasion and minor corrosion of materials such as "ore powder, slag and coke":

• Location: Blast furnace coal injection pipes (pulverized coal + hot air flushing), chute liners for steel slag processing lines, coke silo walls.
• application logicThe ceramic layer is resistant to acid and alkali corrosion, avoiding double damage of the liner by "corrosion + abrasion" of the steel slag; the large-size ceramic covers a wide range and is suitable for long-distance conveying pipelines of blast furnace, converter and other large-scale equipments.

5. PortWith the logistics industry

When loading and unloading bulk cargoes such as "coal, ore, grain" in ports, the equipment is subjected to severe impacts and friction of materials:

• Location: Ship unloader hopper liners, belt conveyor drop hoppers, stacker reclaimer chutes.
• application logicBulk cargo loading and unloading volume is very large (single ship unloading capacity of more than 100,000 tons), the equipment needs to withstand high-frequency material impact, the elasticity of the rubber layer can buffer the impact (to reduce the deformation of the hopper), the abrasion resistance of the large ceramic liner can avoid hopper wear through (the traditional steel hopper needs to be replenished in 1-2 months, the traditional steel hopper needs to be replaced.Ceramic Liner(1-2 year service life); seamed design to accommodate shaped hopper configurations (e.g., tapered, curved walls).

II. Core strengths (key attributes that fit multiple industries)

1. Extremely abrasion-resistant, with a lifespan far exceeding that of traditional materials

• Ceramic layer (usuallyaluminum oxideCeramics, Purity 92%-99%)Mohs hardness up to 8-9(only lower than diamond), wear resistance is 10-20 times that of ordinary steel plate, 5-8 times that of high manganese steel; in the mining ball mill scenario, the service life can be up to 3-5 times that of the traditional high manganese steel liner, significantly reducing the frequency of replacement and downtime costs.
• Large ceramic sizes (e.g. common 200 x 300 mm, 300 x 400 mm) reduce the number of splicing seams and prevent material from seeping through the seams and wearing out the substrate, which further extends the overall service life.

2. Excellent impact resistance, avoiding the risk of "brittle cracking"

• Traditional pure ceramic liners are brittle and easy to break under impact; while in the three-in-one structure, theRubber layer (usuallynitrile rubber,neoprene rubber(70% or more) can absorb impact energy above 70%.(e.g. ore drop impact), play a "cushion protection" role, even in the mine under the strong impact conditions, the ceramic breakage rate is less than 5%.
• The metal substrate (typically Q235 steel) provides a solid support that can be welded and bolted to the equipment housing to prevent the liner from being dislodged by impact.

3. Adaptable to complex working conditions and environmentally tolerant

• temperature resistanceThe ceramic layer has a long-term temperature resistance of 200-300°C (special ceramics can withstand more than 500°C), and the rubber layer can withstand more than 150°C by optimizing the formula, which is suitable for the medium and high temperature scenarios in the cement and iron and steel industries.
• corrosion resistance: The ceramic layer is chemically stable and resistant to acid and alkali corrosion (e.g.metallurgy(corrosive materials in the industry, steel industry, steel slag corrosion), the rubber layer can also choose oil-resistant, acid and alkali models, suitable for multi-media environment.
• Seamless Design AdvantageThe spliced seams can be filled with high temperature / aging resistant sealant, which can be adapted to the curved and conical shape of the equipment (e.g. hopper, chute) and prevent material leakage, which is more flexible than the "Seamless Plate" (limited size and difficult to bend).

4. Reducing energy consumption and maintenance costs

• Ceramic surface smooth (friction coefficient 0.3-0.5, lower than 0.6-0.8 steel plate), can reduce the resistance of material transportation, reduce the energy consumption of conveying equipment (such as fans, motors), according to estimates in the power plant coal conveyor system can be energy-saving 5%-8%.
• Long service life, reducing the number of liner replacement (traditional steel liner replaced every 3-6 months, ceramic liner can be replaced once every 2-3 years), while avoiding the production losses caused by frequent downtime for maintenance.

III. Applicable Scenarios and Selection Recommendations

1. Prioritization of scenarios

• Sectors: Mining, Power, Cement, Steel (core production segments).
• Working conditions:High speed brush wear + medium impact(e.g., pipe conveyors, hopper discharges, ball mill liners), and the equipment needs to be in continuous operation for a long period of time (life expectancy of 1 year or more is required).

2. Careful selection of scenarios

• Low-temperature outdoor environments (below -20°C): Additional cost for low-temperature resistant rubber is required.
• High crushing stress conditions: easy to cause ceramic fracture, it is recommended to choose high manganese steel or wear-resistant alloy plate.
• Short-term temporary equipment: high initial cost, poor economy, can choose ordinary steel plate with rubber buffer layer.

3. Seam treatment recommendations

• Use of gaps created during installationSilicone sealant or polyurethane sealant with high temperature and aging resistanceFill seams and inspect regularly every 6-12 months to replenish glue in a timely manner to avoid material seepage into the wear substrate.