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Application of wear-resistant ceramic plates in mining chutes
Product Description
The working environment of mining chutes is extremely challenging, and their wear mechanisms are complex and diverse, mainly manifesting as three core problems: firstly, erosive wear, where high-hardness ore particles fall from a height, impacting the inner wall of the chute at speeds of tens of meters per second, causing strong cutting and chipping effects, especially in areas such as chute corners and material drop points, where wear is more concentrated; secondly, impact wear, where the periodic impact of large ore blocks easily leads to deformation and cracking of the lining plates, and even causes damage to the chute base; and thirdly, corrosive wear, where the humid environment in underground mines and the acidic and alkaline media in the ore slurry accelerate the corrosion of metal lining plates, further reducing their wear resistance.
For a long time, mines have mostly used metal lining plates such as manganese steel and high-chromium cast iron as protective materials for chutes, but the Rockwell hardness of these materials is only HRC50-60, and their wear resistance is limited. Data shows that the service life of traditional metal lining plates is usually only 3-6 months, and in some high-wear areas, it is even less than 1 month. Frequent replacement of lining plates not only requires a large amount of manpower and resources but also causes production line downtime, with a single downtime loss often reaching hundreds of thousands of yuan, placing a heavy operational burden on mining companies. Therefore, the development of protective materials that combine high wear resistance, impact resistance, and corrosion resistance has become an urgent need for the mining industry.
Product parameters
| Items |
Specifications |
| Content of alumina |
≥95% |
| Density |
≥3.8 g/cm3 |
| Rockwell A hardness |
≥85HRA |
| Impact strength |
≥1500 MPA |
| Fracture toughness |
≥4.0MPa·m1/2 |
| Bending Strength |
≥330MPa |
| Thermal conductivity |
20W/m.K |
| Thermal expansion coefficient |
7.2×10 6m/m.K |
| Volume wear |
≤0.02cm3 |
The core advantages of wear-resistant ceramic plates:
Wear-resistant ceramic plates are made from high-purity alumina (Al₂O₃), silicon carbide (SiC), and other core raw materials through high-temperature sintering and precision machining. Their physical and chemical properties comprehensively surpass traditional metal materials, providing comprehensive wear protection for mining chutes. Their core advantages are mainly reflected in the following aspects:
Extreme Wear Resistance
The Mohs hardness of alumina ceramic plates can reach 9 (second only to diamond), and the Rockwell hardness is as high as HRA85 or above. Its wear resistance is 266 times that of manganese steel and 171.5 times that of high-chromium cast iron, effectively resisting the erosion and abrasion of various ore particles. Enhanced ceramic plates with added silicon carbide particles can further increase the hardness to HV1800, improving wear resistance by 25% compared to ordinary ceramic plates, making them suitable for highly abrasive conditions such as ore slurry chutes and slurry pumps.
Balanced Impact Resistance
To address the brittleness of ceramic materials, the industry employs a composite structure design featuring a "ceramic + tough substrate." Through a rubber buffer layer or a special adhesive, the ceramic plate is tightly bonded to a tough substrate, such as a Q235B steel plate. The hard ceramic layer handles wear resistance, while the elastic layer below effectively absorbs the impact energy of the ore, preventing the ceramic plate from cracking and falling off, thus achieving both "high wear resistance" and "impact resistance." Practical tests have shown that this composite structure can withstand an impact strength of 10-15 J/cm², perfectly suited for the high-impact conditions of mining chutes.
Stable Corrosion and High-Temperature Resistance
Alumina ceramics have extremely stable chemical properties, resisting acid and alkali media and ore slurry corrosion without rusting. This makes them suitable for the humid and corrosive complex environments found in underground mines. At the same time, their excellent thermal stability allows them to maintain stable performance in high-temperature environments above 800°C, making them suitable for special conditions such as high-temperature powder conveying, extending the service life by 4-6 times compared to traditional polyurethane rubber liners.
Significant Overall Economic Benefits
Although the initial investment in wear-resistant ceramic plates is higher than that of metal liners, the life-cycle cost advantage is significant. On the one hand, their service life can be extended to 2-5 years, greatly reducing the frequency of liner replacement and downtime; on the other hand, the density of ceramic plates is only 1/3 of that of metal materials, which reduces the overall weight of the chute and lowers driving energy consumption. In addition, the smooth ceramic surface and low friction coefficient reduce material adhesion and clogging risks, improving conveying efficiency. Case studies show that after upgrading a coal mine's chute with ceramic plates, the annual maintenance costs were reduced by over 800,000 yuan, resulting in a return on investment of over 300%.
Application Process and Matching Solutions for Wear-Resistant Ceramic Tiles
The application of wear-resistant ceramic tiles in mining chutes must follow the principles of "condition adaptation and process standardization." The appropriate ceramic type and installation process should be selected based on the chute structure and material characteristics (particle size, hardness, and drop height) to ensure maximum protection.
Ceramic Tile Selection Strategy
Based on the differences in wear intensity, targeted selection is possible: for areas with normal wear (such as the side walls of the chute), 92% or 95% purity alumina ceramic tiles with a thickness of 3-8mm should be used; for areas with high impact and high wear (such as the material drop point and corners), ZTA toughened zirconia ceramic tiles or silicon carbide reinforced ceramic tiles with a thickness of 8-15mm should be used. Additionally, for irregularly shaped chute structures, curved and rounded ceramic tiles can be customized using processes such as laser cutting and waterjet cutting to ensure a perfect fit with the inner wall of the chute.
Comparison of Mainstream Installation Processes
Currently, there are three main installation processes for ceramic liners in mining chutes, each suited to different working conditions:
Adhesive Bonding Method: Ceramic liners are bonded to the inner wall of the chute using high-strength epoxy structural adhesive. This method offers high construction efficiency and a smooth surface, and is suitable for large flat or gently curved chutes and working conditions with material impact strength ≤ 5 J/cm². During construction, the substrate surface must be clean and dry, with a roughness of Ra3.2-Ra6.3 μm. The adhesive layer must be full and free of voids, and the curing time should be at least 24 hours.
Stud Welding Method: Ceramic liners are fixed to the chute base using stud welding. Each stud has a tensile strength of ≥ 15 kN, and the method offers excellent impact resistance, making it suitable for high-drop (≥ 5m) and high-impact working conditions. This process requires proper welding sealing and anti-loosening treatment to prevent slurry penetration and subsequent corrosion of the base material.
Dovetail Groove Composite Process: This method uses a combination of mechanical fasteners and structural adhesive for double fixation. The interface bonding strength is ≥ 8 MPa, and it offers outstanding vibration resistance, making it suitable for chutes, vibrating screens, and other equipment that are subjected to long-term high-frequency vibrations. Its disadvantages include high processing precision requirements and a longer installation period.
Key Technical Points for Construction
The installation quality directly determines the service life of the ceramic tiles, and three key points need to be carefully controlled: firstly, substrate preparation, which involves removing oil and rust through mechanical grinding to ensure a surface flatness error of ≤2mm/m; secondly, layout design, using CAD drawing to plan the layout, controlling the joint gaps to 0.5-1mm to avoid localized stress concentration; and thirdly, curing and maintenance, controlling the ambient temperature to 15-30℃ and relative humidity to ≤70% during adhesive application, and preventing any load on the equipment during the curing period to ensure the adhesive layer reaches the designed strength.
Company Profile
Yibeinuo New Material is a national high-tech manufacturing enterprise integrating R&D, design, manufacturing, and technical services in domestic wear-resistant ceramics. It has a certain influence on the domestic wear-resistant industry. Its products are widely used in steel, cement, coal, and ports. , Chemical, lithium battery, mineral processing, construction machinery, and other industries are exported to Southeast Asia, South Korea, Japan, Australia, Europe, the United States, and other countries, and are well received by users at home and abroad!
Factory workshop introduction
The company has advanced abrasion-resistant ceramic production lines, isostatic pressing, automatic presses, vulcanizing machines, spray drying towers, etc., as well as steel structure production lines.
Selection method of abrasion-resistant ceramics
| Product model |
Operating temperature (℃) |
Applicable media |
Material particles(mm) |
Scope of application |
| Paste type |
300 |
Powder/Slurry |
≤3 |
Pneumatic conveying of powder or slurry below 300°C |
| Welded |
300-800 |
Powder/Slurry |
≤10 |
Pneumatic conveying of larger particle powder or slurry below 800℃ |
| Dovetail |
≤800 |
Powder/Slurry |
≤200 |
Conveying larger particle powder or high-speed rotating equipment below 800°C |
| Impact resistant |
≤800 |
Granules/Slurry |
≤200 |
Bulk material conveying system below 800℃, especially suitable for a mixture of hard bulk material and powdery material |
| Ceramic rubber composite type |
-50~150 |
Granules/Slurry |
≤10 |
A bulk material conveying system below 150℃, especially suitable for pure soft bulk material conveying, can resist large impact |
Twoja wiadomość musi mieć od 20 do 3000 znaków!
