★ Wear- and corrosion-resistant products and technologies for equipment in power plants, chemical plants, steel mills, and cement plants

Anti-corrosion and wear-resistant new technology

One, Wear-resistant and corrosion-resistant ceramic tiles

Wear- and corrosion-resistant ceramic tiles are manufactured by high-pressure molding and high-temperature sintering using a variety of hard materials. They exhibit excellent resistance to acid and alkali corrosion and possess exceptionally high hardness. Their Mohs hardness reaches as high as 8.5 to 9.0, and they offer wear resistance that is unmatched by other materials. Their service life can extend up to two major overhaul periods.

This ceramic sheet is bonded to areas requiring wear and corrosion resistance using a high-temperature-resistant organic composite adhesive, or securely fastened with bolts. It features a long service life, ease of installation, and suitability for various types of special-shaped equipment. Currently, it has been widely adopted and promoted in over a hundred power plants and steel mills across the country and has received high praise from users.

Fixed-occlusion ceramic veneers

Type Specification ：

                              Technical indicators:

Scope of application:

Widely used in coal-handling, material-conveying, ash-disposal, and dust-control systems at enterprises such as thermal power plants, metallurgy, petroleum, chemical industry, mining, and building materials industries—equipment that is wear-resistant, corrosion-resistant, and resistant to erosion.

Part used:

A. The coal pulverizer outlet ducts of power plant boilers, material bins, hoppers, coarse and fine powder separators, primary air-powder pipelines, induced draft fans, inner casings of pulverized coal discharge machines, fan blades, and other components.

B. On equipment such as dust removal systems in steel plants (smelting plants), duct bends, and the inner shells of dust collectors.

Impact-resistant stud rubber-composite ceramic

Construction method:

A. First, use a grinder to remove scale, oil, and rust from the surface of the equipment, then clean the surface thoroughly with a chemical cleaning agent.

B. Mix components A and B of the composite adhesive according to the specified ratio, then evenly apply the adhesive onto both the steel plate and the ceramic plate. Next, carefully affix the entire piece onto the treated surface in sequence, press firmly, and remove the protective release paper from the surface.

C. Allow to air-dry naturally for 24 hours, or use a sun lamp to accelerate curing by heating until fully cured.

D. The perforated ceramic sheet is installed using riveting or spot welding.

II. High-Temperature Corrosion-Resistant and Wear-Resistant Coating

The high-temperature corrosion-resistant and wear-resistant coating is meticulously formulated and processed using advanced technologies such as ultra-hard new materials, innovative synthesis processes, and nano-scale particle grading. At room temperature, this product cures rapidly; at high temperatures, it forms a hard metal-ceramic structure with excellent high-temperature wear resistance, high thermal conductivity, strong corrosion resistance, superior adhesion to metal surfaces, and excellent thermal shock stability. It is resistant to flaking and cracking, and its service life can last throughout an entire major overhaul period.

Product Model:

Technical indicators:

Scope of application:

The resistance of heating surface tubes—such as economizers, superheaters, reheaters, and air preheaters—in coal-fired boilers of thermal power plants or industrial boilers—to high-temperature gas erosion and abrasion.

Construction and Curing:

1. Thoroughly remove dust and rust from the surface of the heated pipe to be coated. Then, mix components A and B according to the specified ratio, stir thoroughly, and apply evenly using a paint brush (or spray gun). Apply 2–3 coats until the prescribed thickness is achieved. The prepared coating must be used within 8 hours.

2. Allow at least 24 hours for natural curing before use. For optimal results, it is recommended to first pass steam into the pipe to dry the coating, or to perform a low-temperature bake of the boiler for more than 8 hours prior to use.

3. Before the coating is dried and sintered, absolutely no water should be used to rinse it.

III. High-Temperature Wear-Resistant Lining Material (Slurry)

High-temperature wear-resistant lining materials are made by rationally combining various hard metals and non-metals, using a composite high-temperature binder as the bonding agent. The skeletal structure consists of tortoise-shell mesh or steel wire mesh. At room temperature, the material is chemically cured; when heated, it forms a rigid ceramic body. As a result, these materials exhibit excellent properties such as high-temperature resistance (up to 1790℃), resistance to intense erosion, difficulty in detachment, absence of cracking, and resistance to corrosion by various media, thereby significantly extending the service life of equipment.

Product Model:

Technical indicators:

Applicable to:

Wear and corrosion resistance of system equipment used in industries such as power generation, metallurgy, and petrochemicals—including coal and material conveying systems, pulverizing systems, ash removal systems, and dust removal systems—for example: large flue ducts, windbox pipes, gas pipelines, pelletizing dust removal ducts, and cyclone dust collectors in steel plants (smelters); inlet and outlet pipelines of coal mills in power plant boilers, fine and ultrafine powder separators, primary and secondary air (and powder) ducts, rear flue ducts, and dust collectors; as well as cyclone separators, reactors (settlers), and regenerators in petrochemical refineries and catalytic cracking units.

Construction method:

1. First, clean the surface of the equipment thoroughly, then spot-weld the tortoise-shell mesh or steel wire mesh onto the equipment surface for secure attachment.

2. Mix components A and B in the specified ratio until thoroughly blended, then apply evenly to the equipment surface and firmly smooth it out. Each batch of mixed material must be used within 4 hours.

3. Allow to air-dry naturally for 24 hours or longer, then gradually increase the temperature before use.

4. Corrosion-Resistant and Wear-Resistant Nylon Plate

The wear-resistant and impact-resistant nylon lining is a newly researched and developed product with exceptional wear resistance and impact toughness. It is a rare-earth-modified, self-lubricating, oil-containing nylon sheet that can be applied as a lining in parts of equipment prone to wear. This significantly enhances the equipment’s wear resistance and impact resistance, thereby extending its service life. Currently, it has been widely adopted in various industries—including metallurgy, power generation, and petrochemicals—for applications such as material conveying systems, mixing units, storage bins, hoppers, and pipelines.

Product Performance:

This product is a polymer material with an average molecular weight exceeding 100,000—more than five times that of conventional nylon. Its mechanical properties significantly surpass those of ordinary nylon, and its overall performance is superior to other thermoplastic engineering plastics. Thanks to the addition of refined mineral oil additives to the polymer, this material exhibits enhanced self-lubricating and non-stick characteristics, reducing its coefficient of friction and improving its wear resistance. Meanwhile, the inclusion of a small amount of rare-earth materials in the polymer further enhances its comprehensive performance indicators, endowing it with exceptional resistance to oxidation, corrosion, and aging. Its heat distortion temperature exceeds 200°C, and it can withstand continuous temperatures up to 180°C.

Technical indicators:

Scope of application:

This product series can be widely used in cylindrical mixers, disc feeders, pelletizing discs, hoppers, discharge chutes, chutes, and other conveying and mixing equipment found in material handling and storage systems across industries such as metallurgy, power generation, and petrochemicals. It is also suitable for other low-temperature (up to 200℃) equipment that experiences severe corrosion, abrasion, and occasional impact. The products exhibit excellent impact resistance, outstanding wear resistance, and are non-corrosive, non-polluting, and effectively address the issue of material adhesion.

Construction method:

The lining board is pre-equipped with mounting holes; alternatively, holes can be drilled on-site according to specific conditions and then secured to the surface of the construction substrate using bolts.

Anti-Scorch and Energy-Saving New Product

I. High-Temperature Far-Infrared Coating

High-temperature far-infrared coatings are high-tech products manufactured using advanced equipment and specialized processes. They feature energy savings, increased furnace temperatures, improved combustion efficiency, prevention of coke formation, extended furnace service life, enhanced operational efficiency, reduced carbon content in furnace slag, and excellent high-temperature corrosion resistance. This product is an efficient, energy-saving solution that requires minimal investment, delivers rapid results, and is easy to use. To date, it has been applied to hundreds of thermal power boilers and thousands of other types of high-temperature kilns and furnaces across China, yielding remarkable results.

Product Model ：

Technical indicators ：

Applicable to:

It is applied by brushing onto the water-cooled wall tubes or refractory belts of power plant boilers, as well as onto the refractory walls or refractory belts inside high-temperature furnace chambers such as industrial boilers, steel rolling heating furnaces, heat treatment furnaces, forging furnaces, and petroleum heating furnaces.

Construction technology

1. Before applying the coating, first use a gas broom or brush to thoroughly remove dust, coke residue, oil stains, and loose materials from the furnace wall surface. When the furnace wall is dry, you may lightly apply some water to moisten the inner surface of the furnace.

2. Thoroughly stir the coating until no sediment or lumps remain. If the coating becomes too thick, you can add a small amount of water to dilute it.

3. Use a brush to apply (or spray) the material sequentially onto the furnace brickwork, water-cooled walls, or other lining materials.

4. Application areas for boiler coatings in power plants: The coating can be applied to the combustion-supporting belts and, as needed, to portions of the membrane water-cooled walls, serving functions such as preventing coking, improving energy efficiency, and replacing the combustion-supporting belts to raise furnace temperatures. The construction method is the same as that used for conventional kilns and furnaces.

5. This coating should be applied by brushing (or spraying) 2 to 3 coats, with each subsequent coat applied only after the previous coat has dried. The recommended coating thickness is 1 to 2 mm, with a shrinkage rate of 80%. For special requirements, the coating thickness may exceed this range, up to a maximum of 10 mm.

Solidification Sintering:

After construction is completed, allow the coating to air-dry naturally for at least 10 hours. Then, gradually increase the temperature for curing and sintering as follows: from 0 to 200°C, at a rate of 50°C per hour; from 200 to 400°C, at a rate of 50 to 100°C per hour; and above 400°C, at a rate of 100°C per hour—continue heating until the maximum operating temperature is reached. In general, the slower the temperature rise, the better. Avoid rapid temperature increases at all costs, as excessively fast heating can easily cause cracking and peeling of the coating. For newly built furnaces, the curing and sintering of the coating must be even and slow; generally, follow the standard procedures for firing new furnaces.

New Thermal Insulation and Heat Preservation Technology

I. Refractory Fiber Spraying Technology

Fire-resistant fiber spraying is a new, energy-saving and heat-insulating mechanized construction technique adopted domestically in the 1990s. It is widely used in the lining construction of industrial kilns and furnaces, and is also suitable for internal and external thermal insulation of high-temperature pipelines, vessels, storage tanks, and tower structures.

I. Characteristics:

1. The product features a seamless, one-step formation of a three-dimensional network structure with an extended service life.

2. The irregular surface is easy to construct, provides excellent sealing, saves labor and materials, and boasts a smooth, aesthetically pleasing finish.

3. Low thermal conductivity, high thermal strength, and energy-saving rate of around 30%;

4. Implement composite material spraying based on the temperature gradient distribution according to the heat transfer mechanism.

5. Mechanical wet-process construction is fast, environmentally friendly, and does not require oven curing.

6. Convenient for retrofitting existing furnaces and constructing new ones.

II. Main Technical Specifications:

III. Construction Process:

1. The construction environment temperature for fiber spraying must be ≥5℃.

2. First, clean the surface of the construction substrate thoroughly, weld in the anchor nails, and apply an organic adhesive.

3. No formwork is required—shaping is done directly on the sprayed surface.

4. Spraying: The loose fiber cotton is fed into the spraying machine, where it is evenly broken down. The fiber cotton is then sprayed out at high pressure through the inner ring of the spray gun. At the same time, the high-temperature binder is atomized and ejected from the outer-ring nozzle of the spray gun. After the fiber cotton and binder are uniformly mixed outside the gun, they strike the surface being coated with a certain momentum.

5. Apply a layer 30–70 mm thick, continuously moving the spray gun nozzle in a spiral pattern, spraying in sections and applying multiple coats until the designed thickness is achieved.

6. Apply a surface hardening agent.

7. Rebound material from spraying must not be reused under any circumstances.

8. The sprayed fiber lining itself does not require oven curing before use.

II. High-Temperature Thermal Insulation Protective Coating

High-temperature thermal insulation protective coatings are a new type of high-tech product. They are carefully formulated and processed using hollow microspheres with high thermal resistance and excellent thermal insulation properties, as well as novel inorganic mineral fiber materials. These thermal insulation coatings exhibit outstanding high-temperature resistance and thermal insulation performance, demonstrating excellent high-temperature compatibility and adhesion to the substrate surface. They do not crack or peel off, effectively providing thermal insulation, protection, and preventing components from overheating—making them an ideal energy-saving material.

Product Performance:

⑴ Thermal Insulation Performance: The product utilizes high-thermal-resistance, high-temperature-resistant micro-powder hollow spheres and novel inorganic mineral fiber materials. Leveraging the unique physicochemical properties exhibited by the particle structure of these materials, as well as the high-temperature reflective characteristics of certain metal oxides and refractory compounds, the coating delivers outstanding thermal insulation performance.

⑵ High-Temperature Protective Performance: At high temperatures, the coating of high-temperature thermal insulation paint maintains an intact and rigid surface morphology, with a dense structure that does not shrink or oxidize. It exhibits excellent resistance to high-temperature thermal corrosion and erosion.

⑶ Adhesion: This product uses a compounded adhesive that has been introduced, enabling the coating to exhibit excellent compatibility with the substrate surface. As a result, it can maintain dimensional stability over the long term even at high temperatures and demonstrates superior adhesion and thermal shock resistance on the surface.

Scope of application:

Areas prone to overheating, such as superheaters in power systems, firewalls in metallurgical systems, and exterior walls of kilns in building materials systems.

Technical indicators:

Construction method:

1. First, thoroughly remove any surface dust, plaster, rust, and scale from the construction surface. Then, mix components A and B according to the specified ratio, stir thoroughly, and apply evenly to the substrate surface using a brush or spray method, applying 2 to 3 coats to achieve the required thickness.

2. The furnace can be baked only after the coating has naturally cured for at least 24 hours. First, dry the coating at a low temperature for 12 hours, then gradually increase the temperature at a uniform rate.

Fire-resistant and wear-resistant materials specially designed for furnaces and kilns

The refractory and wear-resistant material specially designed for boilers is developed by our company based on a synthesis of advanced technologies both domestically and internationally. Through the introduction of new materials or independent R&D efforts, this material is specifically tailored for highly worn areas in circulating fluidized bed boilers, pulverized coal furnaces, and other industrial kilns. It features thick material application and cutting-edge technology.

1. Blue Clay

"SIRPLAST PH 70 MU," manufactured by Italy’s Sermat Company, is a high-grade, fire-resistant, and wear-resistant composite material. It boasts exceptional abrasion resistance, superior bonding performance, and easy application and construction characteristics. Moreover, it can withstand high temperatures up to 1600℃. Industry insiders commonly refer to it as "multi-alumina mud" or "blue mud." "Blue mud" finds wide-ranging applications in industries such as power generation, metallurgy, steelmaking, and ceramics.

Blue Mud (SIRPLAST PH 70 MU) Properties and Specifications

Physical properties

Application characteristics of blue clay:

1. Simple, safe, and quick construction—particularly suitable for captive power plants of enterprises that find it difficult to shut down their boilers for extended periods;

2. Construction is not affected by weather, air humidity, or other factors, making it relatively convenient.

3. Utilizing blue mud for wear resistance, no surface treatment of the wall pipes is required. The construction process does not damage the substrate, does not alter the substrate’s material composition, and will not cause thermal deformation of the substrate.

4. The blue mud anti-abrasion construction method allows for application at any height on water-cooled wall tubes, with a thickness of no more than 0.5 cm on the front side of the tubes—something that conventional non-metallic anti-abrasion materials cannot achieve.

5. The platform where the refractory material at the burner belt meets the wall pipe can be made exceptionally smooth, thereby virtually eliminating vortex formation and significantly reducing wear.

6. If welding repairs are carried out on water-cooled wall tubes that have undergone metal spraying for wear protection, the coating is prone to cracking. However, this phenomenon does not occur when using a wear-resistant surface treated with blue clay.

7. The wear-resistant cycle is generally longer compared to conventional wear-resistant technologies; if our company’s unique combined construction method is adopted, even more ideal results can be achieved.

8. The construction cost is generally no higher than that of conventional wear-resistant construction.

9. Blue clay can also be used to repair areas where castables have fallen off (such as in the return chute, central tube, water-cooled screen, and other similar parts). It requires no formwork or molds, is simple and easy to apply, and does not need oven-drying after repair—instead, you can directly fire up the furnace. Thanks to its excellent bonding performance, the results far surpass those achieved using other materials.

10. By using blue clay for construction, after the warranty period has expired, if necessary, appropriate repairs can be made annually during routine furnace shutdowns and maintenance, thereby significantly extending the wear-resistant service life and keeping repair costs highly economical.

Scope of application:

Blue mud is primarily used for wear protection of water-cooled wall tubes in the refractory belt area of circulating fluidized bed boilers. It is also an excellent repair material used for wear resistance or repair of other high-temperature metal containers.

II. Wear- and Fire-Resistant Castables

This product uses corundum, silicon carbide, and ultrafine calcined high-alumina bauxite as its primary raw materials. By adding ultrafine powders and other composite additives, the product exhibits characteristics such as high early- and mid-temperature strength, excellent resistance to erosion, good thermal shock stability, minimal wear, and ease of construction.

Main technical specifications:

Instructions for use:

1. First, clean the surface of the construction substrate thoroughly. For metal surfaces, weld studs or steel mesh.

2. This material is a pre-mixed, uniformly blended dry ingredient. Before use, first mechanically dry-mix it for 2 minutes, then add tap water and continue mixing for about 3 more minutes before proceeding with pouring. The mixed material must be applied immediately, vibrated into shape, and continuously poured into place.

3. After molding at temperatures above 10℃, the formwork can be removed after 24 hours; in a humid environment, curing should last for more than 3 days.

4. After maintenance, proceed according to the prescribed furnace baking procedure.

5. During handling and storage, this material must be strictly protected from moisture and bag damage.

Scope of application:

The easily eroded and worn areas of a circulating fluidized bed boiler include: the air distribution plate, the dense-phase zone in the furnace, the furnace outlet, the superheater guard plates, the bends in the flue gas duct at the furnace top, the cyclone separator, the air-dust pipe of the return material feeder, and the economizer plates.

III. Wear- and Fire-Resistant Tamping Materials

This product is primarily made from high-quality silicon carbide, brown (white) corundum, and other premium additives carefully selected and appropriately incorporated. It uses a composite binder as the bonding agent, and features high refractoriness, excellent bonding strength, outstanding resistance to erosion and wear, and ease of construction.

Main technical specifications:

Scope of application:

Refractory linings for circulating fluidized bed boilers, inner walls of pulverized coal furnaces, combustion zones, and areas subjected to severe flue gas erosion in bubbling fluidized beds, cyclone furnaces, and other thermal process kilns.

IV. Wear-Resistant and Fire-Resistant Plastic Refractory

This product is made from primary raw materials such as electrofused corundum, silicon carbide, and ultra-grade bauxite, combined with a carefully formulated blend of composite additives and binders. It features excellent plasticity, high temperature resistance, long shelf life, exceptional wear resistance, and increased strength as the temperature rises.

Main technical specifications:

Scope of application:

The air distribution plate, furnace outlet, and pin-fixed areas of the water-cooled walls in circulating fluidized bed boilers—high-temperature zones subject to severe wear and difficult to access for construction—can also be used for local repairs and lining repairs on other thermal equipment.

Other new technologies and new materials

1 Micro-expanding wear-resistant plastic material

It can be used for furnace roof penetration pipes in circulating fluidized bed boilers, pulverized coal furnaces, and fluidized bed furnaces; refractory layers in furnace internal flame deflection corners and complex sections of furnace walls; all sealing devices on the furnace roof, including those at the outlet of cyclone separators, as well as other thermal equipment components of the furnace body.

2 Thermal shock-resistant castables and coatings

It can be used for surface repair and temperature stabilization in areas with significant temperature fluctuations, such as the ignition air ducts and water-cooled wind boxes of circulating fluidized bed boilers, as well as the ash hoppers of pulverized coal furnaces.

3、PA-801 Refractory castables

It can be used for constructing furnace walls, furnace roofs, furnace chambers, and cold ash hoppers in carbon rotary kilns, pulverized coal furnaces, and circulating fluidized bed boilers. It is also suitable for on-site casting and the fabrication of prefabricated components for industrial kilns such as cement kiln kiln mouths, grate coolers, feeding chutes, preheating cylinders, and chain belts.

4 Special high-strength and wear-resistant bricks

This product is made primarily from corundum silicon carbide and high-quality, high-alumina clinker. It is produced through a rational particle-size distribution combined with a composite binder and then subjected to high-temperature sintering. It represents an application in which unshaped refractory materials are transformed into shaped forms. The product boasts high compressive strength, excellent wear resistance, outstanding thermal stability at high temperatures, and good thermal shock resistance. Moreover, it does not require furnace drying, making it ideally suited for use as a wear-resistant lining in thermal process kilns such as circulating fluidized-bed boilers.

5 Acid-resistant bricks, acid-resistant mortar, acid-resistant castables

This product is a preformed item meticulously crafted from high-quality acid-resistant materials, binders, and additives. It effectively resists erosion caused by acidic flue gases containing high levels of sulfur and is primarily used for lining chimneys, flues, and other acid-resistant kiln interiors in power plant boilers.

6 High-temperature porcelain powder

This product is made by crushing, grinding, and grading porcelain fired at high temperatures. It is available in several mesh sizes, including 320 mesh, 200 mesh, 160 mesh, and coarser grades down to 100 mesh. It is primarily used as a filler for alkali-resistant, wear-resistant, and refractory materials, as well as a filler for industrial anti-corrosion coatings. It finds applications in industries such as power generation, petrochemicals, metallurgy, and building materials.