Ceramic Wear Panel

A ceramic wear plate is a high density alumina panel bonded to chutes, hoppers, transfer points, and cyclones. It protects steel equipment from abrasive materials like ore, coal, cement, and ash. The core advantage: steel or rubber liners wear through in months; a ceramic wear plate lasts years. For plant operators, that means fewer shutdowns, predictable maintenance, and lower operating costs. In a large open pit mine, metal chutes needed replacement every three months; after switching to high purity alumina tiles, service life extended beyond one year.

Two purity grades are common. 92% alumina has Mohs hardness 9 and bulk density of 3.60–3.63 g/cm³. 95% alumina has higher density (3.68–3.70 g/cm³) and better wear resistance for more demanding applications. Both have water absorption below 0.01%. That means no liquid gets in – no freeze thaw cracking, no chemical attack from acidic slurries.

High purity calcined alumina powder is formed by dry pressing or cold isostatic pressing, which ensures uniform density throughout. Isostatic pressing produces green body density and is easier to sinter. Slow drying prevents micro cracks. Sintering at 1700°C creates a dense structure with Mohs hardness 9 and density ≥3.65 g/cm³. Quality control includes chemical analysis, hardness testing, and dimensional inspection. Outofspec plates are rejected.

In a copper and gold mine in Western Australia, a high-velocity underflow transfer chute was processing multimineral ore at 2,200 tonnes per hour. Existing studded white iron wear liners showed heavy wear during a 13-week shutdown, requiring ceramic filler as a temporary fix. After switching to zirconia-toughened alumina ceramic wear plates, the trial passed a six-month service check with projected 12-month service life – a 500% increase. Shutdown time dropped 80%, labour requirements fell 80%, and wear in high-impact zones was only 5-10 mm over six months.

Power plants: coal conveying lines suffered wear leakage requiring shutdown 2-3 times monthly. After installing alumina liners, maintenance dropped to once per quarter, and operating costs fell 40%. Cement plants: clinker cooler discharge chutes, cyclone pipes, and pneumatic conveying systems all benefit from ceramic protection. Steel mills: blast furnace hoppers, sinter plant chutes, and material handling systems are protected from iron ore, coke, and sintered materials. Multi-mineral mine in South Australia: white iron liners wore heavily within 13 weeks; ceramic plates delivered 500% longer service life and cut shutdown time by 80%.

Tecera supplies 92% and 95% alumina wear plates in thicknesses 6-50 mm, in plain, trapezoid, hexagon, and custom shapes. Free samples for destructive testing. Lead time 2-3 weeks standard, 4-6 weeks custom. Global shipping. Respond within two business days.

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