Large-diameter wear-resistant ceramic elbows (typically those with a diameter ≥300mm) are primarily used to transport high-hardness, highly abrasive media (such as slurry, coal dust, sand, and gravel). Their performance and lifespan are closely related to operating specifications, operating condition control, and maintenance measures.
Installation Precautions
Alignment and Fixing: During installation, ensure the piping system is concentrically aligned to avoid misalignment that could cause localized stress cracking in the ceramic layer. Use flexible supports or compensators to reduce stress caused by thermal expansion and contraction or vibration.
Welding and Connecting: Avoid direct welding on the ceramic part (ceramic is not resistant to high-temperature shock). When welding steel pipe sections, keep a clear distance from the ceramic layer to prevent ceramic dislodging due to high temperatures. When connecting flanges, tighten bolts evenly to avoid unilateral stress.
Flow Direction Markings: Pay attention to the flow direction markings (such as arrows) on the ceramic lining of the elbow to ensure the media flow direction is consistent with the design to avoid reverse erosion and wear.
Regular Inspection and Maintenance
Inspect quarterly: Focus on checking the outer wall of the elbow for bulges, cracks, or dust/powder leakage. These are often early signs of ceramic layer delamination or cracking.
Clean up accumulated material: To prevent localized buildup and erosion caused by biased flow, it is recommended to use compressed air or soft tools; do not use metal hammers.
Avoid cutting and secondary processing
Chip-type ceramic elbows must not be cut or welded. Once the integrity of the ceramic layer is damaged, it is very likely to start delamination at the cut. If on-site adjustments are necessary, it is recommended to use self-propagating high-temperature synthesis (SHS) integral ceramic elbows, plasma cutting, and polishing.
System Design and Layout Optimization
The elbow curvature radius should be ≥ 1.5 times the pipe diameter. A smaller radius will increase erosion wear.
The distance between two elbows should be ≥ 6 times the pipe diameter to avoid localized over-wear caused by eddy current accumulation.
Emergency Measures for Abnormal Operating Conditions
If localized ceramic delamination is detected, high-temperature wear-resistant repair adhesive and ceramic chips can be used for temporary repair. However, the entire section must be replaced as soon as possible to prevent wear through the metal substrate and leakage.
The service life of large-diameter, wear-resistant ceramic elbows (typically 3-8 years) depends on operational control and maintenance. The key is to avoid excessive erosion, extreme temperature fluctuations, mechanical shock, and media corrosion. Regular inspections and timely addressing of minor hazards can effectively reduce maintenance costs and ensure stable conveying system operation.
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