Recently, Kingcera conducted a follow-up visit to a steel port in Guangxi, where the customer gave high praise for Kingcera’s ZTA three-in-one belt head liner. This liner, used in the belt head position of the iron ore and bauxite conveying system, has been in continuous service for 46 months and is expected to complete a service cycle of 52 months. This duration is 10 times longer than that of traditional high-chromium overlay liners.
Usage of ZTA Ceramic Three-in-One Liner at the Steel Port (Installed in September 2021)
1. Operating Conditions Analysis
The port handles an annual throughput of 19 million tons, including 7 million tons of bauxite and 12 million tons of iron ore. The material characteristics pose multiple challenges to the equipment:
1. Physical Impact: Ore with a maximum particle size of 300mm continuously impacts the system at extremely high speeds.
2. Combined Wear: The high hardness of iron ore causes abrasive wear, while the cutting wear from bauxite adds complexity to the wear mechanism.
3. Environmental Corrosion: The salt spray environment of the port, combined with corrosive elements in the ores, leads to severe metal corrosion.
4. Large material flow, fast flow speeds, and coarse particles result in sustained high-intensity wear and impact.
2. Comparison of Liner Usage
Previously, the port used overlay liners made of "16mm normal carbon steel plate + 14mm high-chromium alloy," which required replacement every 4 to 6 months. Frequent downtime severely impacted operational efficiency and increased replacement costs. In September 2021, the port installed Kingcera’s ZTA three-in-one liner (6mm steel plate + 6mm rubber + 25mm ZTA ceramic). The current wear conditions are as follows:
1. Impact Areas: Although some surface cracking occurred at impact points, no ceramic pieces have dislodged, maintaining structural integrity and usability.
2. Non-Impact Areas: Only 10 to 15mm of wear has occurred, leaving a remaining thickness well within the design margin.
These results have garnered significant praise from the customer. Over four years of usage, the liner has not only reduced downtime and repair frequency, indirectly boosting production efficiency, but also saved substantial manpower and resources. The customer expressed strong interest in deepening collaboration with Kingcera and expanding the use of ZTA ceramic liners to other ports within their group. A preliminary cooperation agreement has already been reached.
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