Wear- and Corrosion-Resistant Ceramics for Protection of Pipelines and Rotating Equipment

Engineering ceramics have a growing application potential for the wear- and corrosion protection of piping systems and for manufacturing of working parts of rotating equipment in mining and -mineral industries, including oil, gas, coal, ores, and others. The alumina, zirconia, alumina-zirconia, and silicon carbide-based engineering ceramics developed and manufactured by Ceramic Protection Corporation used for extraction, processing, conveying, and dust collection equipment are reviewed. These ceramics have high hardness (greater than the majority of processed materials) and mechanical strength, moderate fracture toughness (fracture toughness of zirconia ceramics is close to metal fracture toughness), excellent wear- and corrosion resistance, ability to withstand high temperatures (greater than 1000°C) and thermal shocks. These ceramics successfully withstand various solid and liquid abrasive media transported at high velocity and turbulence, under high pressure and cavitation. In terms of wear- and corrosion resistance ceramics are significantly stronger than hard steels widely used in the piping systems, and may successfully replace hard metals such as tungsten carbide. The features of the compositions, microstructure, and properties of these ceramics are considered. The wear test results are discussed; the factors effected wear resistance are emphasized. In dependence on the working conditions and the product design, a ceramic material may be chosen or developed in each particular case. The manufacturing processes of the considered ceramics and the installation technique are described. These ceramics are produced on the large-scale basis, and the parts may be manufactured in accordance with the customer design and requirements. The ceramic components may be manufactured as monolithic bodies, including bodies with the complicated shapes, or as tiles; in both cases they are easily installed into equipment. The main features of the ceramic product design are discussed. Pipe lining, including elbows, T- and Y-sections, cyclones and reducers, nozzles, pump parts, seals, valves, and others made from these ceramics are successfully used in the most important sections of piping systems and rotating equipment. The use of the ceramics reduces the wear- and corrosion problems, increases the life cycle of equipment without damage and shutdowns.