Ceramic Linings

Key Applications:

1. Mining & Mineral Processing:

• Slurry Pipelines & Elbows: Ceramics withstand continuous high-velocity slurry, reducing erosion and flow resistance.
• Separators & Cyclones: Ideal for handling abrasive ore particles and high-pressure slurry flows.
• Screw Conveyors & Troughs: Provide longevity in material movement zones prone to gouging and scouring.

2. Power & Cement Plants:

• Ash Handling Systems: Ceramics resist hot, abrasive fly ash and bottom ash.
• Coal and Clinker Chutes: Withstand high temperature and continuous material impact.

3. Steel, Fertilizer & Chemical Industries:

• Acidic or Alkaline Slurry Pipes: Ceramics remain stable in strong chemical environments.
• Material Separation & Classification Units: Used where both abrasion and corrosion are at play.

Common Forms of Ceramic Linings:

1. Ceramic Tiles or Bricks:
   • Square, rectangular, or hexagonal shapes.
   • Installed via adhesive bonding or mechanical fastening.
2. Ceramic Pipe Liners:
   • Cylindrical ceramic tubes or segmented tile linings inside carbon steel pipes.
3. Pre-Engineered Ceramic Panels:
   • Custom-shaped plates for equipment interiors like elbows, launders, or hoppers.
4. Monolithic Ceramic Linings:
   • Seamless linings applied via slip casting or gunning for larger surface areas.

Manufacturing Process:

1. Raw Material Preparation:

• High-purity alumina (typically 92%–99.5%) is mixed with binders and forming agents.
• Optional additives like zirconia may be used for enhanced toughness.

2. Shaping:

• Dry Pressing: Powder is compacted in molds under high pressure to form dense tiles.
• Slip Casting: Liquid slurry is poured into molds to form complex shapes.
• Isostatic Pressing: Used for forming uniform pipes and elbows with consistent density.

3. Sintering:

• Shaped ceramic pieces are fired in kilns at temperatures above 1,500°C to achieve final hardness.

4. Finishing:

• Tiles are cut, ground, or machined to precise tolerances.
• Surfaces may be roughened to improve bonding if used with adhesives.

Installation Methods:

• Epoxy Bonding: Industrial-grade adhesives are used to bond ceramic tiles to metal or concrete substrates.
• Welding with Steel Backing: Steel-backed ceramic tiles or panels are bolted or welded onto structures.
• Mortar or Mechanical Fixing: For brick-style linings in large vessels or reactors.

Benefits of Ceramic Linings:

Unmatched Hardness – Rated 9+ on Mohs scale; resists the harshest abrasion.
Excellent Corrosion Resistance – Ideal for acidic and alkaline environments.
High Temperature Tolerance – Can operate above 1,000°C depending on the ceramic grade.
Smooth Surface Finish – Reduces material buildup and improves flow.
Extended Equipment Life – Minimizes downtime and long-term maintenance costs.
Custom Fitment – Available in custom shapes for pipes, elbows, chutes, and vessels.

Ceramic linings are the industry standard for protecting equipment in the most demanding material handling environments. Whether handling slurry, ash, ore, or corrosive chemicals, ceramic liners provide unmatched performance where other materials fail. Their exceptional hardness, durability, and chemical resistance make them indispensable for long-term operational reliability and cost savings.