For over 30 years, CeraWear Systems has been successfully producing and distributing technical ceramics for the most varied applications.

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1 CERAWEAR Systems Your competent partner for industrial wear and corrosion protection solutions. Individual and competent development, production and installation of wear protection systems made of high-performance ceramics and metallic wear protection materials. CeraWear Systems GmbH. Ceramic & metallic wear protection materials. Schoellerstraße 2. D Eitorf Tel: +49 (0) / Fax: +49 (0) / Mobile: +49 (0) / info@cerawear.de

2 2 CeraWear Systems For over 30 years, CeraWear Systems has been successfully producing and distributing technical ceramics for the most varied applications. CERAWEAR alumina with an Al2O3 content of at least 92% is a modern high-performance material with outstanding wear protection characteristics. The primary material is an aluminium-based material that is pressed into shape using the dry pressing technique or processed with the slip casting technique. Then it is processed further as needed (cutting, drilling, milling and sintering). Quality management: The entire production process is certified in accordance with ISO 9001:2000. Individual engineered tiles or completely lined steel parts; we supply our customers with the following products depending on their requirements and wishes: Standard tiles or engineered linings Standard mats or mats cut according to customer specifications Grinding cylinders and balls Pipe segments and cylinders in different dimensions and wall thicknesses Tiles with holes, T-bar fixing or special grinding Tiles and mats vulcanised into rubber Complete solutions for the most varied components (including steel coating, lining and installation) CeraWear offers you: Short and flexible delivery times for standard goods and engineered linings Many standard products are available in stock Quality management in accordance with ISO 9001:2000 Delivery of complete systems from one source Tiles engineered according to drawing Range of products

3 CeraWear Individual Components 3 CeraWear standard tiles CeraWear standard tiles are mainly recommended for lining normal even surfaces. Special shapes that are adapted to requirements are used for complicated components. Tiles with holes for mechanical fixing, ferrules and plugs are used in cases of exposure to higher temperatures. CeraWear tiles with holes for mechanical fixing, ferrules and plugs are used in cases of exposure to higher temperatures. are available in many different dimensions and thicknesses by default, ranging from 6-50 mm, or up to 75 mm with larger formats. CeraWear mats CeraWear mats consist of rectangular or hexagonal mosaics that are glued onto acetate rayon, polyester foil or other suitable bases. Standard formats/mats: 500 x 500 mm, with mosaics 10 x 10 mm or 20 x 20 mm (rectangular mosaics) and SW20 mm and SW32 mm (hexagonal mosaics), thicknesses 2 12 mm. Special dimensions can be produced on request. Standard tiles Mats CeraWear ceramic/rubber composite solutions CeraWear ceramic and rubber composite in case of wear and impact stress: ceramic mats or smaller tiles are rubber-vulcanised with a hardness of approx. 50 Shore A. Boards are produced according to customer requirements (500 x 500 mm, 400 x 400 mm, 300 x 300 mm or special dimensions). Standard dimensions are: 500 x 500 mm with mosaics 10 x 10 mm, 20 x 20 mm or SW 20 mm and SW 32 mm, vulcanised into a 4 mm rubber base including bonding layer. CeraFix adhesives CeraWear supplies different adhesives for ceramic and steel coating, depending on the respective application: CeraFix-E: 2-component epoxy resin adhesive for temperatures up to 80 C CeraFix-EH: 2-component epoxy resin adhesive for temperatures up to 130 C CeraFix-S: Silicon adhesive for normal temperatures CeraFix-SH: Silicon adhesive for higher temperatures CeraFix adhesives

4 4 Engineered Linings Construction ceramics CeraWear Systems develops and manufactures system-integral components and complete systems for a great variety of applications. Assembly of ceramic linings can also be offered upon request. With modern CAD software, even the individual ceramic parts of complex components can be engineered with perfect fit. These can then be processed and adapted to precise dimensions prior to sintering. In this way, tedious and costly reworking of the individual ceramic parts on site can be avoided. Tiles engineered according to drawing Engineered linings for pipe sections CeraWear pipe segments and cylinders offer optimum protection against wear for steel pipelines. The cylinders and pipe segments are accurately adapted to the respective geometries and piping installations. Isostatic presses allow us to even realise very thin wall thicknesses. Inner diameters ranging from 25 mm to 250 mm can be realised in one single part. Pipe segments and cylinders A complete portfolio CeraWear not only produces ceramic linings for the most varied applications but also offers a complete service on request: engineering, production and installation of the ceramic lining into steel components. Chute linings

5 Application Fields 5 Wear protection solutions by CeraWear are used wherever highly abrasive materials are conveyed, transported and processed. Application fields: Cement industry Coal-fired power plants Iron and steel industry Mineral processing Machines and facilities in the basic materials and food industry Chemistry Paper Recycling and environmental protection technology Ball mill for pigments Separator linings for coal-fired power plants

6 6 Cast Basalt Cast basalt is a mineral wear protection material characterised by high abrasion resistance, resistance to chemicals and high pressure resistance. Natural basalt is melted at approx. 1,250 C and cast into moulds. The maximum application temperature is approx. 350 C. Cast basalt is suited for conveyor components with mainly friction wear, e.g. funnels, channels, hoppers, chutes, chain trough conveyors, mixers, pipes, bends, cyclones, etc. Straight pipes with basalt lining Funnel lining Basalt cylinders Physical characteristics Bulk density g/cm Water absorption weight % 0 Mohs hardness 8 Compression strength N/mm 2 > 450 Bending strength N/mm 2 30 Linear expansion coefficient 6 8* 10 6 Disk lining with special mortar Thermal conductivity W/mK 2

7 Fused Corundum 7 Fused corundum is a mineral wear protection material consisting of alumina and zirconia. Special properties: high abrasion resistance, resistance to chemicals and high temperature stability. Raw materials made of alumina and zirconia are cast into tiles, shaped components and pipes. Application temperature up to max. 1,000 C. Suited for conveyor components exposed to extreme wear and/or high temperatures, e.g. channels, chutes, cyclones, separators, bends, etc. Straight fused corundum cylinders Tiles with stepped bore Tiles with special backside Shaped bricks engineered acc. to drawing Top cyclone part lining Physical characteristics Bulk density g/cm Porosity % 0 Mohs hardness 9 Compression strength N/mm 2 > 400 Bending strength N/mm 2 70 Linear expansion coefficient 6 7* 10 6 Lining of a sugar beet flume Thermal conductivity W/mK 4.2

8 8 Hard Overlay Welding Hard overlay welded metal sheets are universally applicable. They are produced with special welding methods. They consist of a weldable base material as well as of an adapted hard overlay. The hard overlay welded plates can be cut with the latest cutting technology and cut into drawing-conform components through plasma, laser or water jet cutting. Cold or hot shaping is possible afterwards for production of cyclones, separators etc. Screw conveyor flight Standard dimensions 2,900 x 1,400 mm 2,400 x 1,150 mm 1,900 x 1,150 mm Base plate Overlay 2 mm 2 4 mm 3 mm 3 6 mm 4 mm 4 8 mm 5 mm 3 8 mm Total thickness Cone 6 mm 4/ mm/14 mm 8 mm 5/ mm/16 mm 10 mm 5/ mm/20 mm 15 mm 5/ mm/25 mm 20 mm 5/ mm/30 mm Wheel loader paddles 25 mm 5/ mm/35 mm

9 Fixing Options 9 Attachment options: Plug welding Rear welding onto the base Special suspension systems Screw attachment with counter-bore rings Screw attachment with welded-on bolts Application options: Chute linings Hopper linings Concrete mixer linings Screens Separator linings Ventilators Pipelines (ash transport or dust transport) Cyclone inlet with overlay welding Standard plates with hole Separator housing lining Top part of cyclone for ash transport Hard overlay welding/rubber composite plate The base material is a standard steel. Special steels are also used for special applications. The wear layer consists of a C-Cr-Fe system with primary chrome carbides to achieve a high degree of hardness. Combinations with rubber (to reduce the noise level) are also possible.

10 10 Lined Pipes and Bends Conveyor pipes are used to transport bulk materials. Due to the required transport speeds and the strong particle flow, substantial wear problems occur in pneumatic systems, especially in bends, cones, branch-pieces and deflectors. The lining material is selected according to speed, conveyed medium, particle size and volume. Cast basalt, fused alumina, pipes overlay-welded on the inside and alumina are used here. Alumina guarantees the longest service life. The wear rate of hydraulic systems is lower. Here, the advantage of ceramic is its corrosion resistance to the conveyed medium. Fixing options The interconnection of lined pipes or their connection to unlined pipe segments is usually made with fixed and/or loose flanges. Transition flanges or adapter flanges are further connection options. When using Al2O3 pipes and pipes overlay-welded on the inside, the flange dimensions of the existing pipes can be maintained. Pipeline for ore transport Al2O3 is fitted into the pipes as cylinders or tiles with different layer thicknesses. Cylinders as from an inner diameter of 25 mm up to 250 mm with wall thicknesses ranging from 5 to 25 mm are available. Larger pipes are lined with mats or pre-engineered tiles. Advantages of Al2O3: Extremely wear-resistant Variable layer thickness Low inherent weight Thin mortar bed Pipe coating with ceramic mat lining Pipe segments Straight pipes for ash transport

11 Overlay welding 11 Pipelines are frequently equipped with electronic wear control systems for environmental protection reasons. Overlay-welded pipes and systems are universally applicable, also in case of extreme requirements. In the past, pipes had to be crafted from sheet metal and welded together in segments, which was quite tedious work. Thanks to the most modern robot technology CeraWear is today able to supply pipes and bends with overlay-welding both on the inside and also on the outside of the pipe. Pipe segments as from an inner diameter of 40 mm can be engineered. Coal dust transport pipeline in a cement factory Pipe segment with electric wear monitoring Flexible hoses with ceramic inlay Flexible hoses with ceramic inlay Pipes overlay-welded on the inside Flexible hoses with wear-resistant inner lining made of Al2O3 or casting are applied wherever flexibility is required. The connection is established with fixed or loose flanges. Couplings are also used in rare cases.

12 12 Conveyor systems Safe protection of your system guarantees a long service life and fault-free permanent operation from A to Z. We take care of planning, production and the entire installation. Planning: The specialists at CeraWear develop individual and economic solutions for any application case maximum profitability for the highest demands. All that rendered by one source. Production: The wear protection products are produced on the basis of state-of-the-art technology. The individual components are pre-assembled prior to shipping in order to ensure dimensional accuracy. Installation: Depending on the size and type of the respective system part, the linings are installed in the factory or directly on the customer's premises anywhere in the world. Installation plan top part of a cyclone Press for ceramic tiles Pre-assembly to ensure dimensional accuracy Installation of ceramic tiles Assembly of ceramic tiles Assembly of complete components

13 Material Combinations and Engineered Linings 13 Material combinations Prefabricated elements: assembly in the factory or on site. A two-component epoxy resin adhesive is used for gluing. Pre-engineered linings Linings made of composite materials provide efficient and economic solutions for the most varied application cases: Many times, the wear stress varies. The combination of different materials is expedient in these cases. Composite linings made of rubber/ceramic, basalt/alumina, ceramic/hard overlay welding are applied. Lining of a separator feed Ceramic tiles glued onto sheet steel Lining of a drum Exchangeable panels ceramic/rubber/steel Combination lining ceramic/hard overlay welding cone

14 14 Hard Cast Chrome Hard cast chrome parts are produced with different alloys for applications requiring a high degree of hardness or impact resistance. Either high wear resistance or high resistance to impacts is achieved. Typical application fields: Chutes, pipes, hoppers, grinding systems, pump housings, shaft conveyors, parts of crushers, striker plates in grinders, clinker cooler plates, chain links. Boards have standard dimensions of 300 x 300 mm. Wall thicknesses between 20 and 50 mm are available. The advantages of cast wear resistance metal in different strengths: optimum adaptation to the most varied geometries at economic prices with serial parts production. The components are made to measure in large and small quantities. Depending on the application conditions, the maximum application temperature is 350 C. Grinding roller mill segments made of hard cast chrome Pump housing Grinding roller made of hard cast chrome Hard cast chrome sheets after mechanical processing Screen linings Clinker cooler plates

15 Silicon Carbide CeraWear and Hard Individual Material Components Compound 15 Silicon carbide The following silicon carbide grades are being applied at present: SSIC, SISIC, NSIC, RSIC. Application for: pumps, pump impellers, nozzles, shaft protection sleeves, and pipe linings. Depending on the production method, plates or pipes can be manufactured. Simple as well as complicated geometrical shapes are possible. Silicon carbide ceramic distinguishes itself from the other wear protection materials with its very high thermal shock resistance. Hard material compound Hard material compound is a material combination of high-strength binder and extremely wear-resistant ceramic additives. It can be applied as normal temperature material up to 400 C, and as high temperature material up to max. 1,200 C. Hard material compound is applied as mortar onto an expanded metal construction. Overhead installation is no problem if required. For larger surfaces, the material can be applied by spraying. Pipeline with hard material compound Discharge segments made of silicone carbide Installation of hard material compound

16 16 CeraWear Technical Ceramics The company s headquarters are located in Veszprém (Western Hungary). The production halls and office buildings cover a total space of 4,700 m2. Around 140 persons are employed here. 96% of our products are exported. The key customers are located in the USA and in Western Europe. Additional sales regions are Southern Europe, the Far East, Mexico and Canada. Suppliers are located in Germany, Italy and England. The annual production quantity of approx. 50 million products in the field of technical ceramics is achieved with the following technologies: Isostatic pressing and grinding, dry pressing, extrusion and high-pressure injection moulding. The products have an Al2O3 content between 90% and 99.7% and also contain zirconia. The Al2O3 powder is prepared in an internal spray tower, which guarantees a uniform product quality. Of course, our company is certified in acc. with ISO 9001:2008 and has been producing its products since 1995 in accordance with this globally accepted quality standard. Our portfolio: Production of low-pressure injection mouldings Components for the paper industry Ceramic inserts for surgical instruments and devices Processing of ceramic parts CeraWear Systems GmbH Ceramic & Metallic Wear Protection Materials Schoellerstraße 2. D Eitorf Tel: +49 (0) / Fax: +49 (0) / Mobile: +49 (0) / info@cerawear.de

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