Ceramic Ring Lined Pipe for a Fly Ash Conveying Project in Kazakhstan

A customer in Kazakhstan was looking for a more durable replacement for steel pipe sections used in a dry abrasive powder conveying system.

The existing pipeline was exposed to continuous particle erosion, and several sections had already shown obvious internal wear. The customer wanted a solution that could improve wear resistance without creating installation problems when replacing the original pipes.

For this project, we proposed steel pipes lined with segmented alumina ceramic rings.

Unlike conventional ceramic tile lining, each ceramic ring covers the full internal circumference of the pipe. For straight pipe sections, this creates a relatively continuous wear-resistant surface and eliminates longitudinal tile joints around the pipe wall.

The steel outer pipe provides structural strength and supports the flange connections, while the alumina ceramic lining protects the internal surface from abrasive particle contact.

One Detail We Focused on: The Finished Internal Diameter

For replacement pipes, ceramic thickness cannot be considered separately from the finished bore.

Once ceramic rings are installed inside the steel pipe, the available flow diameter becomes smaller. If the original pipeline dimensions are copied without allowing for the ceramic lining, the replacement pipe may have a smaller internal passage than expected.

In pneumatic conveying systems, this can influence local gas velocity and pressure loss.

For the Kazakhstan project, the pipe dimensions and ceramic lining were therefore reviewed together so that the required finished internal diameter could be maintained as closely as possible.

This is especially important at flange connections.

A noticeable difference between the ceramic-lined bore and the adjoining pipeline can create an internal shoulder. Such areas may disturb particle flow and become new localized wear points.

Flange and Lining Details Were Reviewed Together

The replacement pipe had to fit the existing pipeline, so the external dimensions alone were not enough.

During the design review, attention was given to the flange arrangement, overall pipe length, internal ceramic bore and the position where the ceramic lining terminated at each end.

The objective was to avoid leaving unnecessary exposed steel at the connection while keeping the pipe suitable for installation with the existing system.

For customized ceramic-lined pipe sections, these small dimensional details often determine whether the replacement works smoothly on site.

Why Ceramic Rings Were Selected

The project mainly involved straight pipe sections carrying abrasive dry material.

For this type of application, ceramic rings offer several practical advantages.

The ceramic surrounds the full pipe circumference, providing wear protection in every direction. The ring structure also reduces the number of longitudinal joints compared with individually installed ceramic tiles.

At the same time, the ceramic grade and thickness can be selected according to the actual operating conditions rather than using one standard configuration for every pipeline.

For elbows, reducers, or more complicated fittings, a different lining arrangement may still be required because the wear pattern and geometry are different.

High Temperature Needs a Separate Review

Another point discussed during the project was operating temperature.

Alumina ceramic itself has excellent high-temperature resistance, but the complete pipe cannot be evaluated only according to the ceramic material.

The fixing method, thermal expansion between the steel shell and ceramic lining, temperature cycling and mechanical conditions must also be considered.

For this reason, higher-temperature ceramic-lined pipelines are reviewed as a complete system before the final lining structure is confirmed.

Production and Inspection

Before shipment, the ceramic-lined pipe sections were checked for the main dimensions and lining condition.

Particular attention was given to:

• Flange dimensions and alignment
• Overall pipe length
• Finished ceramic-lined bore
• Ceramic ring positioning
• Condition of the lining at both pipe ends
• External coating and packing protection

The finished pipes were prepared for transport with additional protection around the flange and ceramic-lined ends to reduce the risk of impact damage during handling.

A Practical Wear Protection Solution for Kazakhstan Industry

Kazakhstan has extensive mining, power generation, and mineral-processing industries, many of which use pneumatic or mechanical systems to transport abrasive bulk materials.

For straight pipe sections in these systems, ceramic ring-lined steel pipe can provide a practical combination of structural strength and internal wear protection.

The final design, however, should always be based on more than ceramic hardness alone.

Pipe dimensions, finished bore, flange connections, operating temperature, and the actual wear position all need to be considered together.

ELACERA provides customized ceramic-lined pipe sections according to project drawings and operating requirements.