Time-saving: significantly extend lifespan and reduce downtime
The most core advantage of wear-resistant ceramic linings is their exceptional wear resistance, which can significantly extend the service life of equipment, thereby "saving time.".
Extended service life: Practical case data shows that on dock conveyor chute linings, traditional alloy plates typically require replacement after handling only 100,000 tons of cargo per plate, whereas the new wear-resistant ceramic linings can extend service life to 700,000 tons. This means replacement frequency drops sharply from nearly 300 plates per year to just 42 plates.
Extended maintenance intervals: Under operating conditions such as medium-speed coal millers in power plants, the service life of composite ceramic liners can reach 16,000 to 20,000 hours, exceeding that of high-chromium alloy clad liners (6,000 to 7,500 hours) by more than 2.7 times. This directly reduces the frequency and total duration of shutdown maintenance.
Effort saving: reduces labor intensity and facilitates installation
Effort saving "is not only reflected in the reduction of labor intensity for workers, but also in the convenience of installation and maintenance.
Reduce labor intensity: Due to the greatly extended service life, the frequency of frequent replacement of lining plates by workers is significantly reduced. For example, in the above dock case, the annual replacement time decreased from 2336 hours to 336 hours, reducing nearly 2000 hours of installation and maintenance time.
Flexible installation method: There are various installation methods for wear-resistant ceramic lining plates, which can adapt to different working conditions. There are "adhesive types" that are bonded with high-strength adhesives, suitable for rapid on-site construction; There are also "welding type" or "bolt fixed type" that are fixed by welding screws or bolts for a more secure connection. There is also a "three in one" lining plate (ceramic+rubber+steel plate) that can be directly installed with bolts or welding, which is very convenient.
High cost-effectiveness: significantly reduced overall costs
Although the unit price of wear-resistant ceramic lining plate may be higher than that of ordinary steel plate, its comprehensive use cost is more advantageous.
The total cost has significantly decreased: Taking the dock hopper as an example, although the unit price of old-fashioned alloy lining plates is higher, due to their extremely short lifespan, the total annual cost after considering materials and labor is as high as 531440 yuan. After replacing with ceramic lining plates, even considering the replacement quantity of 42 pieces, the total annual cost is only 33600 yuan, with a cost reduction of up to 93.7%.
The economic benefits are obvious: another data from the power plant shows that although the price of a set of composite ceramic grinding rollers (430000 yuan) is higher than that of overlay welding grinding rollers (200000 yuan), their long service life reduces the annual comprehensive maintenance cost from 270000 yuan to 152000 yuan. Based on comprehensive calculations, the direct economic benefits of using ceramic lining plates can be increased by more than 20%, and 8 coal mills can save nearly one million yuan in spare parts costs per year.
Additionally, it should be noted that different product types need to be matched for different operating conditions. For example, for small-diameter, high flow rate straight pipes, ceramic rings sintered as a whole may have a longer lifespan; For irregular parts with large material impact, ceramic patches (small piece inlay) are more flexible and economical. Only by selecting based on specific application scenarios can the advantage of high cost-effectiveness be maximized.
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