[Case Study] Ceramic Lining Project for Blast Furnace Hoppers and Bins at a Steel Plant: Expected Service Life Reaches 10 Years

The hoppers and bins at the top of a steel plant’s blast furnaces are highly susceptible to wear due to the continuous friction and impact caused by falling furnace materials. To ensure the longevity of the equipment, wear-resistant linings are essential.  

 

In 2021, we were honored to design custom wear-resistant ceramic linings for the hoppers and bins of the No. 7 and No. 8 blast furnaces at a renowned steel plant. The ceramic tiles were successfully installed, marking not just the completion of an engineering project but also our steadfast commitment to quality and durability.
 

Ceramic linings installed by Kingcera in 2021 for the hoppers and bins of blast furnaces

 

Fast forward to September 2024, during the plant’s routine equipment maintenance period. At the invitation of the plant, we dispatched a professional team to conduct a comprehensive wear assessment of the ceramic linings in the No. 7 and No. 8 blast furnace bins. The inspection results were remarkable: after several years of use, the degree of wear on the ceramic linings was less than one-fifth of the design thickness, with no instances of ceramic detachment or chipping. It is conservatively estimated that the linings can continue to serve for another 6-7 years, effectively extending the total service life to approximately 10 years. This achievement not only highlights the outstanding performance of Kingcera’s products but also saves the steel plant significant maintenance time and costs.

 

In stark contrast, the No. 6 blast furnace bin, which was lined with standard alumina ceramic around the same time, experienced severe wear on both the ceramic lining and the bin itself in less than a year. Some areas were even worn through, necessitating early repairs and replacements. This caused considerable disruptions and losses to the steel plant’s production.
 

 

Photos of the interior of the bins taken during the steel plant’s maintenance in September 2024

 

So, how did Kingcera’s linings achieve such an extended service life? This success is attributed to our multiple advantages:

 

1. Superior Ceramic Materials

The bins were lined with Kingcera’s proprietary K95 ceramic, a material developed through repeated testing and optimization. Compared to standard alumina ceramics, K95 offers significantly enhanced wear resistance and impact resistance.

 

2. Diverse and Precise Tile Design

Backed by a highly skilled technical design team, we tailor ceramic tile designs to match the internal shape of each piece of equipment. For the steel plant’s bins, over 100 distinct tile types were designed and produced, ensuring a perfect fit with the equipment and eliminating gaps or openings.

 

3. Rigorous Bonding and Installation Process

The ceramic tiles were bonded using Kingcera’s proprietary high-strength adhesive, which has 2-3 times the bonding strength of standard adhesives. Combined with the expertise of Kingcera’s professional installation team, every step of the process was executed with precision and meticulous attention to detail, ensuring that each ceramic tile was securely installed.

 

4. Thickened Designs at Special Impact and Discharge Points

This approach ensures synchronous wear, preventing localized excessive wear and thus safeguarding the overall service life of the equipment.

 

Thanks to our comprehensive expertise in ceramic material development, design, manufacturing, and installation, Kingcera has established itself as a leader in the steel industry. Our ceramic linings have earned widespread praise and trust from customers. We remain committed to our business philosophy of focusing on “brand, industry, customers, and team” and will continue to provide superior products and services to our valued clients.

(Original link: 【案例】钢铁厂高炉料斗料罐内衬陶瓷项目：预期使用寿命达10年 )