Greenbank Alumina

Greenbank Alumina
Extraordinary Abrasion Resistance

Abrasion Resistance in Materials Handling Systems

Protect equipment subject to rapid, abrasive wear, prolonging service life
Substantially reduce equipment maintenance expense
Improve production continuity by materially diminishing downtime

Alumina Internals

Unsurpassed Abrasion Resistance
Greenbank Alumina has remarkable resistance to both sliding and impact abrasion. It outlasts metal from three to fifteen times or more, and rubber and basalt ten to one. This exceptional toughness and durability have made it the recognized standard of the industry for long-term economy in lining industrial equipment subject to high wear. The life of material conveyors, cyclones, duct work, and other critical equipment is increased tremendously when protected by Greenbank Alumina’s superior resistance to abrasion and erosion. Moreover, where product contamination must be considered, Greenbank Alumina’s chemical inertness provides immunity to corrosive chemical attack.

Unique Composition
Impenetrable Greenbank Alumina is a high-alumina, extremely dense, ceramic material. Its high purity alumina crystals are bonded together with a crystalline aluminum silicate that insures the integrity of the ceramic shape after firing. Harder than tool steel and close to diamonds in hardness, it possesses extraordinary durability, as indicated on the accompanying Moh Scale of Hardness.

Moh Hardness Chart

Measurable, Documented Savings
Years of experience at Greenbank’s Porcelain Plant have proved conclusively that when the cost of lining material is weighed against the extended service life of equipment, Greenbank Alumina ceramic linings produce measurable savings. These are fully documented. Cost benefits include:

Elimination of metal parts replacement
Maintenance labour savings
Increased productivity through elimination of downtime for repairs
Total protection from material contamination

Infinite Applications
The applications for Greenbank Alumina linings are almost endless in material handling systems for dry materials, slurries, or dust-laden gases. Throughout the world, large and small companies alike have profited from Greenbank Alumina. Time and time again, it has been proven that once maintenance personnel recognize the benefits of an installation, the use of Greenbank Alumina expands rapidly into many other high wear areas. This is a lining that thrives under dry, moist, or wet conditions. Wherever granular materials are transported or where particulate laden gases are handled, Greenbank Alumina will protect those surfaces that deteriorate rapidly from abrasion.

Typical Equipment Utilizing Greenbank Alumina

Ballmills
Fan Housings
Centrifuges
Hoppers
Chutes
Hydrocyclones

Classifiers
Pneumatic
Coal Handling
Conveyors
Elbows
Skip Cars

Cyclones
Skirt Boards
Downcomers
Storage Bins
Duct Work
Vibratory Feeders

Mediums that are perfect for use with Alumina

Asbestos Rock
Minerals
Cement Clinker
Rice

Coal
Sand
Glass Cullet
Sinter

Gravel
Soybeans
Lime
Taconite

The versatility of Greenbank Alumina is one of its primary advantages.

Greenbank Alumina linings are available as:

TILE with tongue and grooved sides
TILE with straight sides
HEX-TILE (mat-mounted)
THIN TILE (lightweight)
PIPE LINERS and CAST SHAPES
SMALL BEADS

Greenbank Alumina beads provide a durable, abrasion-resistant coating when placed in an epoxy matrix in complex surfaces such as piping, pump housings, scraper blades, etc. The life of fibreglass or urethane pipe is extended appreciably when impregnated with Greenbank Alumina Beads.

Alumina Bead Sizes Chart

Pipeliners are available in pre-cast segments. They are either straight or curved, with matchmarks to
assure proper alignment in the curved line. In addition, completely fabricated lined pipe sections may be
ordered in the form of steel elbows and straights with integral liners.

Greenbank Alumina pipeliners can be manufactured in three to 12-inch inside diameters with a minimum
wall thickness of ¾ inch.

Custom-designed cast shapes are available in round, one-piece segments for lining elbows and curved pipe sections, and in special shapes for hydrocyclones, pulverizing machinery, valves, etc. Greenbank invites requests for quotation on specific high-wear parts.

Alumina Pipe Liners

Easily Installed. How to:
Depending on the application, Greenbank Alumina can be installed with epoxy, by welding with steel inserts, or with cement for higher temperature uses.

Using epoxy or cement:
Metal surfaces must be free of rust, scale, grease and other foreign substance to ensure optimum adherence. Sandblasting will provide a clean surface and create increased surface area to aid in a good ceramic-to-metal bond. Both the metal and ceramic should be coated with epoxy or cement to compensate for any minor irregularities between metal and block. Most epoxies are recommended for use where the temperature does not exceed 250 to 300°F. Manufacturers’ instructions should be followed carefully in selecting and curing the epoxy. Popular brands are available from Greenbank.

Typical HD Properties

Greenbank Alumina tile being applied with epoxy
on a coal classifier

How to Select the Right Form
Tongue and grooved tile has proven to be the industry leader and most popular configuration for many years. The prime advantages of the interlocking tile joints are possible elimination of weld-attachment expense for many applications and reduced probability of the tile becoming detached from the steel surface. Notable is the fact that Alumina tongue and grooved tile costs no more than Alumina straight-sided tile. Weldable tongue and grooved tile is recommended for the ultimate in security.

Alumina Tile Sizes

Straight-sided Tile is particularly well suited
to pipe lining and areas where it is difficult to
install tongue and grooved style.

Pipe Lining

Tongue & Groove Cyclone Lining

Tongue & Grooved
tile-lined coal chute

Hex-tile is used for lining both concave and convex curved sections where other types of tile will not readily fit. This unique, flexible, pre-mat-mounted tile permits easy, rapid, low cost, do-it-yourself surfacing of curved sections.

Standard Sizes: Hex-Tile
Individual Hex-Tiles are 51/64 inches across flats and available in four thicknesses (1/8, ¼, 3/8, ½ inches) mounted on 6 x 6 inch mats.

Thin Tile is recommended for lining light duct work that will not support heavier tile and for areas of
relatively light abrasion.

Weldable System
Where high heat, impact, or corrosion are considerations, attachment by welding is advisable. The weldable system permits use of ceramic liners to temperatures in excess of 1000 to 1500°F. Both the tongue and grooved and straight-sided tile are supplied with a tapered hole, metal insert, and an Alumina cap. Installation is as follows:

Prepare metal surface
Coat tile on the bottom and sides with about 1/16” of adhesive away from the weld hole
Put Alumina tile in place and seat metal insert.
Lay a weld covering the entire bottom of insert, avoiding touching of the insert with the weld rod. Weld should be built to no more than 3/16” and should not fill the cone.
Coat outer circumference of cap with adhesive and insert.

Examples Of Arlcite’s Superior Performance
The following are but a few examples of the multitude of industries that have turned to Alumina to fight their high-wear problems. From agricultural grain terminals, to steel plants, to cement manufacturers, Alumina provides lasting protection where rubber and plastics wear, trowelable materials break up, and steel liners just won’t stand up.

plug weld

plug welding mig

Alumina Plugs

Grain Elevator
As elevator operators testify, grain passing over or through handling equipment has a surprisingly severe erosive action on steel parts. Expensive production delays and frequent repair can be avoided by lining high wear areas such as chutes, hoppers, ducting and cyclones with durable Alumina ceramics.

Coal Preparation
Frequent interruptions of production at coal preparation plants, caused by the abrasive properties of coal, have been minimized wherever Alumina linings have been installed. This protection against rapid wear from the movement of dry coal, as well as slurries, has proved to contribute substantially to the economical operation of the modern coal washing and grading facility. As a result, the coal industry in the United States and abroad is adopting on a large scale the lining of equipment with ceramic facings, confident that the initial cost will soon be more than offset by the resulting economies. There is documented proof that the service life of equipment is extended as much as 15 times, and even more in some instances, by high alumina Alumina linings.

Coal Burning Power Stations
Electric utilities are increasingly reaping the benefits from Alumina lining of coal handling components. Whether Alumina is incorporated in the original plant design or retrofitted, rapid wear problems are readily overcome. The versatility of Alumina shapes and sizes facilitates the design of protective applications of pulverizers, chutes, classifier cones, and burner lines. Freedom from boiler shutdowns, for frequent and excessive maintenance of high-wear areas, represents substantial savings in operating costs at modern power generating plants.

Alumina Lining in Coal Burning Power Stations

Mineral Producer
This cyclone (see photos bottom of page 7) has been lined with Alumina weldable tiles on top and tongue and grooved tiles on the sides. The industrial sand producer will realize many years of wear from Alumina. In another sand application, an elbow lined with Alumina lasted for three years, an improvement of 250 to one over the previous method.

Blast Furnaces And Coke Ovens
Life span of a blast furnace sinter chute was tripled when lined with Alumina over SAE 1038 steel plates. A coke oven chute lined with Alumina showed a wear index 14 times better than high tensile, rolled steel plate (SAE 1038), and two to five times better than two types of armor plate.