2026-03-19
A large coal-fired power plant was experiencing 4-5 unplanned shutdowns per year due to failures in their coal conveying pipelines. The cause was straightforward: high-velocity pulverized coal acted like a sandblaster, continuously eroding the inner wall of carbon steel pipes. Even with 16mm thick wear-resistant steel pipe, the average service life did not exceed 8 months.
The repair cost itself was not high. The real cost was downtime – every shutdown meant lost power generation and scheduling pressure on the entire grid.
The plant replaced the most severely eroded sections – elbows, tees, and reducers – with alumina ceramic-lined composite steel pipes. The ceramic layer, 8-10mm thick, achieves a hardness of HRA 85 or above and is bonded to the steel outer pipe using high-temperature adhesive combined with a mechanical interlocking structure.
| Parameter | Wear-Resistant Steel Pipe | Ceramic-Lined Pipe | Improvement |
|---|---|---|---|
| Average Service Life | 7 months | 42 months | 500% longer |
| Annual Shutdowns | 4-5 times | 0-1 times | 80% reduction |
| Cost per Repair | ¥8,000 | — | Eliminated |
| Cumulative Maintenance Cost (3 years) | ≈¥120,000 | ≈¥45,000 | 62% lower |
"We used to inspect the pipeline for wear every month. Now we check once a year. More importantly, we no longer have to reduce load due to coal dust leakage from worn pipes."
Ceramic-lined pipes are particularly well-suited for:
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Elbows and reducers in pneumatic conveying systems
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High-velocity fluid streams containing hard particulates
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Abrasive environments at moderate temperatures (≤300°C)
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Critical points where frequent shutdowns are unacceptable
