Wear Resistant Ceramics Using Fly Ash
Details of present/Existing Technology. Shortfall / Technological gaps in the existing technology
The existing technology uses costly raw materials such as alumina, kaolin, etc. causing the higher cost of production. Also the sintering temperature in existing technologies is quite high (1700-18000°C), thus more energy consumption.
Approach adopted in new technology to evade technological gap in the exiting one
Fly Ash has been used as one of the major raw material to partially substitute the alumina. The Fly Ash consists mainly of silica and alumina, the alumina present in Fly Ash was used as source and Silica as bonding materials.
Advantages
The present technology uses fly ash as one of the major raw materials which is a waste of thermal power plants and causing serious environmental problem. So the major advantage is mitigation of pollution. Gainful utilisation of fly ash, cost and energy savings are the added advantages.
Constraints in technology
The free carbon content should be <5% and iron content should be <2% in fly ash otherwise it will adversely affect the product quality.
Brief description
The type of wear resistant ceramic products can be produced using 10,25 and 40wt% fly ash for high, moderate and low wear resistant applications. The products are harder than tool steel and next to dimond on Moh's scale of hardness. These extremely hard, dense and impenetrable ceramics, which finds a number of industrial applications, substantially decrease the maintenance cost of equipment and increase the life of components 8-10 times to that of metal. There can be many successful application of the presently developed wear resistant ceramics in place of alloy sttel, basalt and high alumina liners.
Major raw material
Fly Ash, Technical Alumina, Alumino-silicate minerals, additives
Major Plant Equipment
Weighing machine, Ball Mill, Filter press, Granulator, Mixture, Hydraulic Press, Kiln
Applications
Areas which are prone to wear such as material handling equipment, pipe lines, chutes, bunkers, hoppers, ball mills, etc.
Status of Development
Pilot plan scale
Ecological/Environmental Impact
The present technology will help in reducing pollution control as it uses fly ash, which is waste material
Technology Transfer Assistance Offered
- Process know-how
- Details of the equipment
- Plant lay-out
- Quality assurance methods. Assistance in setting up the plant and separate terms
For further information please contact :
Director
National Metallurgical Laboratory
Jamshedpur-831 007, India
