Composite ceramic elbow with replaceable wear part

Abstract

The utility model relates to the technical field of bent pipe, specifically is a kind of composite ceramic bent pipe of replaceable wear part.In the back camber wear area of metal shell layer is equipped with maintenance opening, and base flange is fixed in the edge of the maintenance opening, further including detachable wear block unit, wear block unit is from inside to outside in turn for partial ceramic block, partial resin layer and partial metal arc plate, its layered structure corresponds with main body, wear block unit is provided with the compression flange connected with base flange and is fixed at maintenance opening, and the working inner surface of partial ceramic block and the inner surface of ceramic lining are smoothly transitioned.Wear can be replaced in the back camber wear area when the local area is individually replaced, without replacing the whole bent pipe, it helps to reduce maintenance workload and material consumption.

Description

Technical Field

[0001] This utility model relates to the field of pipe bending technology, specifically a composite ceramic pipe with replaceable wear-resistant components. Background Technology

[0002] In pneumatic conveying systems in industries such as power, metallurgy, and chemicals, bends are key components for changing the conveying direction of powdery and granular materials. During operation, high-speed flowing solid particles (such as coal powder and mineral powder) continuously impact the back arc side of the bend, making this area the weakest link in the entire conveying pipeline, most susceptible to wear. The wear resistance and service life of the bend directly affect the operational stability and maintenance costs of the production system.

[0003] Currently, common methods to improve the wear resistance of bends include using integrally cast wear-resistant alloy bends or lining the inner wall of steel pipes with wear-resistant ceramic sheets. While integrally cast bends possess a certain degree of toughness, their hardness and wear resistance remain insufficient under certain high-wear conditions. Ceramic-lined bends, although having high surface hardness, may suffer from ceramic sheet breakage and adhesive failure leading to detachment under long-term strong impacts. Furthermore, composite structures composed of different materials may face challenges to interfacial bonding stability under temperature changes and mechanical vibration conditions due to differences in physical properties such as the coefficient of thermal expansion between the materials.

[0004] When severe wear occurs in localized areas of a bend, particularly in the back arc wear zone, traditional solutions often require replacing the entire bend or performing large-area repairs, which can lead to lengthy downtime and high maintenance costs. Therefore, exploring solutions that facilitate maintenance and replacement for easily worn areas of bends, based on existing technologies, to address the challenges posed by localized wear remains a worthy area of ​​research in this field. Utility Model Content

[0005] The present invention aims to solve the above problems, thereby providing a composite ceramic bend with replaceable wear-resistant parts that are easy to maintain.

[0006] The technical solution adopted by this utility model to solve the aforementioned problem is: A composite ceramic bend with replaceable wear-resistant components comprises a ceramic liner, a resin adhesive layer, and a metal outer shell layer, which are sequentially composited from the inside out. A maintenance port is provided in the back arc wear area of ​​the metal outer shell layer, and a base flange is fixed at the edge of the maintenance port. The bend also includes a detachable wear-resistant block unit, which consists of a partial ceramic block, a partial resin layer, and a partial metal arc plate, from the inside out. Its layered structure corresponds to the main body. A clamping flange connected to the base flange is provided on the wear-resistant block unit and fixed at the maintenance port. The working inner surface of the partial ceramic block and the inner surface of the ceramic liner transition smoothly.

[0007] Compared with the prior art, the outstanding features of this utility model, which adopts the above technical solution, are: By incorporating detachable wear-resistant block units, individual areas can be replaced when wear occurs in the back arc wear zone, eliminating the need to replace the entire bend and reducing maintenance workload and material consumption. The layered structure of the wear-resistant block units corresponds to the main body and has a smooth inner surface transition, which helps maintain the integrity of the flow channel and the smoothness of material transport. This structural design provides an alternative maintenance method for dealing with localized wear, helping to improve the targeted nature of bend maintenance operations.

[0008] As a preferred embodiment, a further technical solution of this utility model is: Furthermore, the outer edge of the local ceramic block is embedded in the inner wall of the center hole of the clamping flange, and the local resin layer and the local metal arc plate are stacked and fixed on the outer end face of the clamping flange in sequence. This structure enables the components of the wear-resistant block unit to form a relatively tight bond with the clamping flange, which helps to improve the integrity of the wear-resistant block unit and the stability of its connection with the flange, providing a feasible implementation method for the detachable structure.

[0009] Furthermore, in the longitudinal section passing through the axis of the elbow, the profile of the local ceramic block is composed of straight line segments inclined relative to the direction of the fluid inlet. This profile design can guide the impacting material, so that the impact direction of the material forms a certain angle with the surface of the ceramic block, which helps to disperse part of the impact force, thereby potentially improving the impact resistance of the ceramic block.

[0010] Furthermore, the angle formed by the straight section and the central axis of the fluid inlet of the elbow is 30° to 60°. This angle range can achieve a relative balance between guiding the material and effectively bearing the impact force. If the angle is too small, the guiding effect will not be obvious, and if the angle is too large, it may weaken the support of the thickened block itself.

[0011] Furthermore, an included angle of 45° is a preferred option, providing a practical implementation in achieving effective material guidance and maintaining structural strength.

[0012] Furthermore, a sealing element is provided between the base flange and the clamping flange. The sealing element is designed to improve the sealing performance of the flange connection interface, which helps to reduce the possibility of material leakage from the interface and may have a positive effect on maintaining the stability of system operation. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the main cross-sectional structure of an embodiment of the present utility model; The following are labeled in the diagram: 1. Ceramic lining layer; 2. Resin adhesive layer; 3. Metal outer shell layer; 4. Base flange; 5. Compression flange; 6. Local ceramic block; 7. Local resin layer; 8. Local metal arc plate. Detailed Implementation

[0014] The present invention will be further described below with reference to embodiments, the purpose of which is only to better understand the content of the present invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0015] A composite ceramic bend with replaceable wear-resistant components comprises, from the inside out, a ceramic liner 1, a resin adhesive layer 2, and a metal outer shell layer 3, which together form the main structure of the bend. The metal outer shell layer 3 can be made of carbon steel or low alloy steel. The ceramic liner 1 is bonded and fixed to the inner wall of the metal outer shell layer 3 by the resin adhesive layer 2, which is epoxy resin or polyurethane resin. A maintenance port is provided in the back arc wear area of ​​the metal outer shell layer 3, and a base flange 4 is fixed at the edge of the maintenance port. The bend also includes a detachable wear-resistant block unit, which consists of, from the inside out, a partial ceramic block 6, a partial resin layer 7, and a partial metal arc plate 8. Its layered structure corresponds to the main body. A clamping flange 5 connected to the base flange 4 is provided on the wear-resistant block unit and fixed at the maintenance port. The working inner surface of the partial ceramic block 6 smoothly transitions with the inner surface of the ceramic liner 1.

[0016] Furthermore, the outer edge of the local ceramic block 6 is embedded in the inner wall of the center hole of the clamping flange 5. The center hole of the clamping flange 5 and the local ceramic block 6 are fixed by interference fit or by filling with high-temperature resistant adhesive. The local resin layer 7 and the local metal arc plate 8 are stacked and fixed on the outer end face of the clamping flange 5 in sequence. The local ceramic block 6, the local resin layer 7 and the local metal arc plate 8 are pre-composite into an integral component by bonding and mechanical means, and then assembled with the clamping flange 5. This structure enables the components of the wear-resistant block unit to form a relatively tight bond with the clamping flange 5, which helps to improve the integrity of the wear-resistant block unit and the stability of its connection with the flange, and provides a feasible implementation method for the detachable structure.

[0017] Furthermore, in the longitudinal section passing through the elbow axis, the profile of the local ceramic block 6 is composed of straight line segments inclined relative to the fluid inlet direction. The local ceramic block 6 is preferably made of alumina, silicon carbide, or zirconium oxide ceramic. Based on this, the three-dimensional shape of the local ceramic block 6 has the expected mainstream impact center as the thickest point. The thickness of the thickest point of the local ceramic block 6 is 1.5-3 times the reference thickness of the ceramic liner 1. Its thickness decreases smoothly along the axial direction and circumferential direction of the bend, forming a reinforcement that matches the back arc wear zone. The local ceramic block 6 covers 60%-80% of the bending angle of the bend. This profile design can guide the impacting material, so that the impact direction of the material forms a certain angle with the surface of the ceramic block, which helps to disperse part of the impact force, thereby potentially improving the impact resistance of the ceramic block 6.

[0018] Furthermore, the angle formed by the straight section and the central axis of the fluid inlet of the elbow is 30° to 60°. This angle range can achieve a relative balance between guiding the material and effectively bearing the impact force. If the angle is too small, the guiding effect will not be obvious, and if the angle is too large, it may weaken the support of the thickened block itself.

[0019] Furthermore, an included angle of 45° is a preferred option, providing a practical implementation in achieving effective material guidance and maintaining structural strength.

[0020] Furthermore, a sealing element is provided between the base flange 4 and the clamping flange 5. A sealing groove is provided on the mating surface of the base flange 4 and the clamping flange 5, and the sealing element is embedded in the sealing groove. The sealing element is a rubber O-ring or a polytetrafluoroethylene gasket. The purpose of the sealing element is to improve the sealing performance of the flange connection interface, which helps to reduce the possibility of material leakage from the interface and may have a positive effect on maintaining the stability of system operation.

[0021] During assembly, first weld and fix the base flange 4 to the edge of the maintenance port of the metal outer shell layer 3, ensuring that the flange plane fits well with the outer wall of the pipe. Then, place the assembled wear-resistant block unit and the clamping flange 5 into the maintenance port, adjust the position so that the inner surface of the local ceramic block 6 is flush with the inner surface of the ceramic lining 1, and connect the base flange 4 and the clamping flange 5 with bolts, achieving the specified sealing preload. This completes the installation. When replacement is needed, loosen the bolts to remove the entire wear-resistant block unit for maintenance or replacement. By incorporating detachable wear-resistant block units, individual areas can be replaced when wear occurs in the back arc wear zone, eliminating the need to replace the entire bend and reducing maintenance workload and material consumption. The layered structure of the wear-resistant block units corresponds to the main body and has a smooth inner surface transition, which helps maintain the integrity of the flow channel and the smoothness of material transport. This structural design provides an alternative maintenance method for dealing with localized wear, helping to improve the targeted nature of bend maintenance operations.

[0022] The above description is only a preferred embodiment of the present utility model and does not limit the scope of the present utility model. All equivalent changes made based on the content of the present utility model specification and its drawings are included within the scope of the present utility model.

Claims

1. A composite ceramic bend with replaceable wear-resistant components, the main body comprising, from the inside out, a ceramic liner, a resin adhesive layer, and a metal outer shell layer, characterized in that: A maintenance port is provided in the back arc wear area of ​​the metal outer shell layer, and a base flange is fixed at the edge of the maintenance port. It also includes a detachable wear-resistant block unit. The wear-resistant block unit consists of a partial ceramic block, a partial resin layer and a partial metal arc plate from the inside to the outside. Its layered structure corresponds to the main body. The wear-resistant block unit is provided with a clamping flange connected to the base flange and fixed at the maintenance port. The working inner surface of the partial ceramic block and the inner surface of the ceramic liner transition smoothly.

2. The composite ceramic bend with replaceable wear-resistant components according to claim 1, characterized in that: The outer edge of the local ceramic block is embedded in the inner wall of the center hole of the clamping flange, while the local resin layer and the local metal arc plate are stacked and fixed on the outer end face of the clamping flange in sequence.

3. The composite ceramic bend with replaceable wear-resistant components according to claim 1, characterized in that: The outline of the local ceramic block is composed of straight line segments that are inclined relative to the direction of the fluid inlet.

4. The composite ceramic bend with replaceable wear-resistant components according to claim 3, characterized in that: The angle between the straight section and the central axis of the fluid inlet of the elbow is 30° to 60°.

5. The composite ceramic bend with replaceable wear-resistant components according to claim 4, characterized in that: The included angle is 45°.

6. The composite ceramic bend with replaceable wear-resistant components according to claim 1, characterized in that: A sealing element is provided between the base flange and the clamping flange.

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