Adhesive modified special ceramic coating

Adhesive modified special ceramic coating is a two-component, room temperature cured polymer ceramic material. It is composed of high-performance wear-resistant aggregates (such as corundum and silicon carbide) and specially designed inorganic organic hybrid adhesives, in the form of adhesive paste, which can be applied to the surface of metal or concrete substrates by coating or scraping. It solves the pain points of traditional wear-resistant materials that require high-temperature baking or complex molds, and can form a dense, high-strength, and ceramicized protective layer at room temperature. It is an ideal “repairman” and “protector” for industries such as thermal power, cement, and steel to cope with gas-solid two-phase flow erosion and corrosion.

Q&A session: How can adhesive modified special ceramic coatings solve your equipment wear problem?
Q: The air ducts, elbows, and cyclone separators inside the equipment are frequently worn through by high-speed dust, and they need to be welded every three months. What should we do if it seriously affects production?
Answer: The adhesive modified special ceramic coating solidifies at room temperature after application, forming a ceramic coating with extremely high hardness (room temperature strength can reach over 150MPa). It is like putting a layer of “ceramic armor” on the metal inner wall, which can effectively resist the impact and shear stress of high-speed materials, extend the service life of the equipment to more than 5 years, and greatly reduce the number of shutdowns and maintenance.
Q: The operating temperature of the equipment is between 100 ℃ and 800 ℃, which requires both high temperature resistance and acid alkali corrosion resistance. Ordinary coatings are prone to powdering and peeling. Is there a long-term stable solution?
Answer: Our adhesive modified special ceramic coating adopts inorganic organic hybrid technology, with a temperature resistance range covering -60 ℃ to 1250 ℃. Its bonding system is chemical bonding, with excellent acid and alkali corrosion resistance and thermal shock resistance. It does not pulverize or crack at high temperatures, especially suitable for complex working conditions such as desulfurization flues and circulating fluidized bed boilers in thermal power plants.
Q: The equipment has irregular shapes, bends, variable diameters, and irregular parts, making it impossible to stick ceramic tiles. The pouring material is also difficult to construct. What should be done?
Answer: Adhesive based coatings are in the form of adhesive paste, with excellent thixotropy and plasticity, and can be applied to surfaces of any complex shape like putty. Whether it is a 90 degree elbow, a variable diameter pipe, or a conical part, seamless overall coverage can be achieved, completely solving the problem of gaps and easy detachment in ceramic tile construction.

Product core advantage: not only wear-resistant, but also the guarantee of equipment longevity

1. Excellent physical and mechanical properties
   Our adhesive modified special ceramic coating adopts the principle of tight packing, scientific aggregate grading, and a bulk density of over 2.65g/cm ³. The compressive strength at room temperature can reach 161MPa, and the flexural strength can reach 17.8MPa. This high-density and high-strength organizational structure makes its wear resistance much better than ordinary wear-resistant steel and weld overlay, with wear resistance more than 10 times that of 16Mn steel.
2. Excellent chemical stability and thermal shock resistance
   The main chain of the coating is composed of ionic and covalent bonds, which belong to strong binding bonds and have excellent acid and alkali resistance. It will not react with slag or sulfides in flue gas. At the same time, its thermal expansion coefficient matches well with the steel substrate, and with directional mesh reinforcement technology, it can withstand the drastic temperature changes caused by frequent driving and parking, without detachment or cracking.
3. Convenient construction and emergency repair capability
   -Room temperature curing: After adding specialized adhesive and stirring evenly on the construction site, it can be applied and reach theoretical strength in about 3 days without heating or baking.
   -Quick repair: For sudden wear and perforation, it can achieve fast repair without stopping the machine, fast curing, thermal shock resistance, and minimize production losses.
   -Seamless overall: The overall coating construction is seamless, without any joints, and there is no priority wear problem at the splicing joints.
4. Flexible customized services
   We are well aware of the significant differences in wear mechanisms under different working conditions. Therefore, we offer:
   -Formula customization: Adjust the aggregate and binder formula according to the operating temperature (medium/high temperature), corrosive medium (acid-base type), and impact angle (flushing/impact).
   -Customized construction plan: Provide full process technical support from turtle shell mesh welding, surface treatment to coating construction.
   -Color customization: Multiple color options such as gray, black, red, etc. can be provided according to on-site management needs.

Customer application case sharing
Case: Anti wear and anti-corrosion treatment of desulfurization flue in a large thermal power plant
-Requirement background: The original flue of the desulfurization system of the 2 × 300MW units in this power plant is in operation, and the high concentration dust after passing through the economizer causes severe erosion to the flue bends, variable diameters, and guide plates. The ordinary wear-resistant coating used originally had a large area of peeling off after half a year of operation, and the flue steel plate was worn through and leaked air multiple times. The induced draft fan vibration intensified, and the furnace needed to be shut down for welding repair every two months, seriously affecting the power generation efficiency and equipment safety.
-Solution: After on-site investigation by our technical team, we recommend using high-temperature resistant adhesive modified special ceramic coatings. The construction plan is as follows:

1. Sandblasting and rust removal should be carried out on the inner wall of the flue to expose the metallic luster and increase the roughness.
2. Weld turtle shell mesh at key locations such as bends and reducers to enhance the anchoring force of the coating.
3. Mix the specially formulated adhesive type ceramic coating with the dedicated adhesive in proportion, and manually apply and compact it to ensure no bubbles.
4. The thickness should be controlled at 20mm and cured at room temperature for 72 hours.
   -Final effect: After being put into use, the coating has been running continuously for more than 18 months without any damage. During the shutdown inspection, it was found that the coating surface was only slightly polished without any wear pits, and the guide plate and elbow were intact. The person in charge of power plant maintenance feedback: “With your ceramic coating, you no longer have to stare at the flue every day for welding repairs. The equipment operation rate has increased by at least 15%, and maintenance costs have been almost reduced to zero
   Case: Wear resistant treatment of vertical mill cyclone tube in a cement plant
   -Requirement background: The cyclone separator shell of the raw material vertical grinding system in the factory has been subjected to long-term erosion by dusty airflow, frequent wear through of the shell steel plate, severe dust leakage, harsh on-site environment, and environmental penalty risks.
   -Solution: Use our company’s high-strength wear-resistant ceramic coating to comprehensively apply protection to the cyclone cone and air inlet area.
   -Final effect: The equipment runs smoothly after construction, with an expected service life of more than 5 years, completely solving the problem of shell wear and dust leakage, and fundamentally improving the on-site environment.

Whether it’s flue elbows in thermal power plants, cyclone tubes in cement plants, or mining beneficiation equipment, adhesive modified special ceramic coatings provide the most reliable protective barrier for your equipment with their four characteristics of wear resistance, corrosion resistance, high temperature resistance, and convenient construction. We not only provide standard products, but also specialize in providing customized solutions from materials to construction based on your specific working conditions.
If you are troubled by frequent wear and corrosion of equipment, please feel free to contact us at any time and submit your operating parameters. We will provide you with the most professional wear-resistant protection solution!

Brudeze Ceramics supplies and sells a wide range of high-quality quartz glass, including alumina ceramics, zirconia ceramics, silicon nitride ceramics, aluminum nitride ceramics, silicon carbide ceramics, boron carbide ceramics, bioceramics, machinable ceramics, etc. We can meet the customization requirements of various ceramic products.