Ceramic mosaic-lined pipe is a composite pipe with an outer steel layer, typically Q235, providing protection and support. Its thickness is generally 5-8mm. The inner layer consists of toughened, high-aluminum, wear-resistant ceramic sheets bonded to the metal substrate in a mosaic pattern. The spacing between the tiles meets technical standards, resulting in a smooth, flat, and non-flaking inner surface. Flange connections are specially treated to prevent wear.

Features:

Extremely wear-resistant. The ceramic sheets contain over 92% alumina, with a hardness of HRA ≥ 85, making them ten times more wear-resistant than hardened carbon steel. They also offer strong corrosion resistance, resisting various inorganic and organic acids, as well as organic solvents. Their smooth inner wall resists scaling and blockage, allowing for free flow of materials. Installation is easy, and the ceramic is lighter than conventional pipes, reducing the load on support equipment and saving material costs.

Applications:

Widely used in the power, metallurgy, mining, coal, and chemical industries, conveying abrasive granular materials and corrosive media such as sand, stone, pulverized coal, ash, and molten aluminum.

Installation Steps

Preliminary Preparation

Inspect the pipe's appearance: Confirm that the outer steel pipe is free of deformation and corrosion, the inner ceramic sheet is free of peeling and cracking, and the flange sealing surface is flat and undamaged. Verify that the pipe specifications (diameter, length, and wall thickness) are consistent with the design drawings.

Site and Tool Preparation: Clean the installation site and ensure adequate working space. Prepare a torque wrench, sealing gaskets (oil-resistant asbestos gaskets or flexible graphite gaskets are recommended), a level, and lifting equipment (such as a lifting strap; do not use wire rope to directly tie the Ceramic Lining).

Pipe Pretreatment: Blow the pipe's interior with compressed air to remove dust and impurities. If flange connections are used, evenly apply sealant (such as silicone sealant) to the flange sealing groove to enhance sealing.

Pipe Hoisting and Docking

Use the "two-point lifting method" for lifting. Wrap the lifting strap around the outer steel pipe (at 1/3 of the length from each end of the pipe) to avoid direct lifting force on the ceramic lining and prevent the ceramic sheet from falling off. Adjust the pipe axis: Use a spirit level to calibrate the pipe's horizontality (deviation ≤ 3mm/m). Ensure that adjacent pipe flange holes are aligned and flange surfaces are parallel (gap difference ≤ 0.5mm). Do not forcefully connect the pipes, which may damage the flanges or ceramic lining.

Connection and Sealing

Installation Bolts: Use a diagonal, step-by-step tightening method, using bolt specifications that match the flange (e.g., M20×80 high-strength bolts). Tighten each step to 1/3 of the design torque, completing the tightening in three steps to the design value (typically 300-500 N·m, depending on the pipe diameter) to avoid excessive local stress.

Seal Check: After connection, use a feeler gauge to check the flange gap to ensure there are no visible gaps. For welded connections (such as some large-diameter pipes), use a low-current, short-arc welding process. Keep the welding temperature below 200°C to prevent high temperatures from degrading the ceramic adhesive. Acceptance and Fixing

Appearance Inspection: Check that the ceramic lining is free of damage, flange connections are free of looseness, and the pipes have no obvious bends.

Pressure Test: Perform a hydrostatic test on the piping system (test pressure is 1.25 times the operating pressure) for 30 minutes. A pass mark is obtained if there is no leakage and the pressure drop is ≤ 0.05 MPa.

Support and Hanger Installation: Secure the supports and hangers at the designed spacing (usually 3-5m). Place rubber pads where the supports and hangers contact the outer steel pipe to prevent vibration and wear on the pipe.