Feature Highlights

 Solid Zirconia Ceramic Components

The disc, liner, stub shaft and stem shroud are all manufactured of solid zirconia ceramic; the flow-path is therefore fully enclosed by ceramic components ensuring exceptional erosion-resistance.

 Blowout-Proof Stem

An internal stem retention ring ensures the stem cannot blow out if the actuator is removed or if the gland is serviced when the pipeline is under pressure.

 Downstream Pipe Protection

The valve center line is offset toward the valve inlet; the extended-body therefore absorbs the erosive effects of slurries and prevents downstream pipe erosion.

Zirconia Stem Shroud

The valve stem is completely encased by the unique Z-Max™ zirconia ceramic protective sleeve system to eliminate wear.

 Hardened Stainless Steel Stem

Equal-strength stem and disc connection is designed to reduce stress propagation in the disc. The top of the stem extends into the actuator on most valve sizes to offer precise positioning and control.

 PTFE-Encapsulted O-Rings

…are durable, resist abrasion, and offer excellent chemical compatibility.

 ISO Mounting Pad

…is offered as standard, and allows for automation flexibility and compatibility with popular actuators.

 Stainless Steel Hardware

…resists corrosion and allows for easy maintenance.

 Durable, Cast Steel Housing

…securely protects the ceramic components and offers increased rigidity and strength. White epoxy coated as standard for corrosion-resistance and for ease of identification.

 Position Indication

The top of the stem features an indicator for quick and easy identification of disc position when installed in the pipeline.

 Matching Pipe and Valve Bores

The Z-Max™ bore is manufactured to match standard pipe I.D.’s to avoid disjointed alignment. Matching bores increases valve life and reduces maintenance.

 Retention Ring Back-Sealing

Limited leakage is observed if the stem packing is removed while the pipeline is under pressure.

 Serialized Valves

Each valve is individually-serialized and supplied with a riveted nameplate.

Bypass and Original Lines

Gerdau Ameristeel, NJ was having long standing problem of maintenance in their carbon transfer lines. They were replacing 2” sch 80 carbon steel nozzles & inserts every 12 hour shifts. Ceresist evaluated the process and provided the same design with sintered silicon carbide nozzles and extended the life of the nozzles to 4 months.

Our long term solutions to the steel industry provide huge cost savings. We not only provide lining but a complete fabricated product which the customer can easily install without having to adapt to the new system.

Jacketed Reducer w/Monolithic Alumina Liner

 Slurry Erosion-Wear Solutions   

The use of ceramics in wear resistant components has been considered over the past two decades to exploit the properties of these materials. Wear resistant  components using engineering ceramics like silicon carbide, zirconia toughened alumina  now provide a huge advantage in aggressive slurry applications especially in industries like polysilicon manufacturing & FGD scrubbers. 

The angle of incidence of the particles is extremely important to determine the main wear mechanism acting on the surface of the components submitted to erosion. It is well known that micro-cutting prevails for low impact angles whereas for angles close to 90° the dominant effects are low-cycle fatigue. In addition, corrosive attack occurs when the particles are carried by a liquid, which can directly cause pitting or pin holes will eventually fail in service. 

A cost-effective way to improve the slurry erosion & corrosion resistance is to install Ceresist designed slurry piping where in minimal joints are present and the ceramics are backed with highly corrosion resistant epoxy adhesives. 

Ceresist Inc. is fully capable of designing ASME B 31.3 code piping lined with ceramics and providing minimal joints. Our elbows/Tees are in most cases monolithic seamless liners which will ensure the high velocity slurries will not leak through the seams. 

Application history: 

High velocity slurries 

Coke powder 

Silica 

Recycle slurries 

catalyst lines 

Our manufacturing facilities are fully equipped with the latest equipment for quick turnaround of products without sacrificing high quality workmanship. Please send in your enquiries for this product line to sales@ceresist.com

Corrosion Wear-Chlorine gas

   The growing demand for hydrocarbon resources has resulted in accelerated increase of oil production. Oil sands conveying requires erosion & corrosion resistant piping. This can be achieved by providing an extremely wear resistant material which can operate even at elevated temperatures. The presence of carbon dioxide (CO²), hydrogensulphide (H²S) and free water can cause severe corrosion problems in oil and gas pipelines. Internal corrosion in wells and pipelines is influenced by temperature, CO² and H²S content, water chemistry, flow velocity, oil or water wetting and composition and surface condition of the steel. A small change in one of these parameters can change the corrosion rate drastically due to changes in the properties of the thin layer of corrosion products that accumulates on the steel surface.

Ceramic liners provide the cost effective solution to achieve the production rate desired without loss in downtime or sudden maintenance.
Our products are lined with silicon carbide liners which has the highest wear resistant compared to any other metal. SiC is also universally corrosion resistant even at elevated temperatures. Corrosion-resistant alloys such as 13% Cr steel and duplex stainless steel are often used downhole and, recently, also for short flowlines. For long-distance, large-diameter pipelines, carbon steel is the only economically feasible alternative and corrosion has to be controlled by chemical additives to the transported fluids.
Using ceramics inside the pipe as the wetted components will provide considerably high cost savings over an extended period of time.

Well head piping-Erosion & Corrosion

    Ceramics have now taken the lead role in the oil & gas industry in solving erosion & corrosion problems. Ceramics like sintered silicon carbide offer the highest wear resistance as compared to any other liner or alloy in the materials family.

Ceresist designs piping as per ASME codes and ensures that the wetted parts are always ceramic to ensure continuous operation and minimal downtime. Our piping is designed to last  36x times longer than carbon steel piping. Sand erosion is a major concern in the industry especially when conveyed at high velocities will wear out steel or alloy piping. 

Sand particles from oil and gas production may cause considerable erosion damage in critical parts of transport and processing equipment such as valves and chokes. Increased longevity of such components will lead to significant savings as offshore oil and gas production move subsea, and it can be achieved in two ways; through selection of erosion-resistant materials or through design optimization.

A total of 28 different materials including standard steel grades, solid tungsten carbide materials, coatings and ceramics have been tested under various impact angles and velocities of sand particles, and examined for erosion characteristics. Alpha sintered Silicon carbide & Reaction Bonded Silicon Carbide have shown the least wear resistance. This proves that with proper design these are the long term solutions for the oil & gas industry.

Applications:

Catalyst & coke transfer lines

Cyclone piping

Flow nozzles

Choke beans

Wear liners

Valve components

Our manufacturing facilities are fully equipped with the latest equipment for quick turnaround of products without sacrificing high quality workmanship. Please send in your enquiries for this product line to sales@ceresist.com

Zirconia ceramics can be used as liners where impact is a concern due to the high fracture toughness of the ceramic. 

Features:   

• Excellent thermal shock characteristics
• Reduced spalling and erosion
• Complex shape capabilities
• Custom-designs to suit your specific needs
• custom joints designs available for mating surfaces
• Repeatable dimensions

 Our monolithic & pre-engineered tiled piping are the best in the industry. We hydro-test all our tiled piping to ensure integrity of the liners. The pre-engineering ensures the tiles are mechanically locked in as well along with chemical bonding. This ensures that you will get continous wear protection.

Benefits:  

•  Simpler design
•  Wear resistance x 15-32 times over steel
•  Ease of installation, custom I.D, flange types
• Lower overall operating cost

 Applications include:  

• Nozzles
• Cyclones
• Spigots
• Impeller Rings
• Apexes
• Valves
• Suction Pumps
• Dust collectors
• Cones
• Chutes
• Autoclave parts
• Vessel and Pipe Linings

Our manufacturing facilities are fully equipped with the latest equipment for quick turnaround of products without sacrificing high quality workmanship. Please send in your enquiries for this product line to sales@ceresist.com

Pulverized Fuel Piping

Ceresist provides wear resistant products to the power generation industry. As pulverized coal is propelled through pipe systems to power plant burners, high velocity movement of fuel causes continuous wear problems particularly in elbows, where directional flow changes and abrasive particles impinge against the interior of the pipe.

Elbows with steel interiors have a relatively short life in this environment lasting only few years. Installing Ceresist, Inc. elbows can significantly increase the estimated life of your system to between 10 to 40 times depending on the diameter of the pipe, angle of the bend, solids loading and specifications of the fuel.

Ceresist, Inc. specializes in ceramics technology in designing and installing complex wear protection systems. The standard 90% alumina ceramic we offer for such an application is pre-engineered and custom-made to be one of the best wear materials for fine particle abrasion, whilst still maintaining attractive investment expenditure.

Burner Nozzle

 Beyond development of superior ceramic products, our expertise in computer design, pre-engineering, fabrication & installation gives us a technical knowledge that few manufacturers have. We offer full line manufacturing control by providing premier quality raw material, designing and fabricating the steel and installing the ceramic lining in the elbow.

We Sell Solutions

Analyzing a wear problem is a complex process. Our design engineers understand wear problems and specify solutions to suit environment. Material properties, engineering tolerances, attachment methods & material costs are all considered in a Ceresist wear solution.

Applications:

Chutes/Hoppers

Classifier Cones

Cyclone Separators

Fan housing & Blades Lined Piping

Slurry Piping

Nozzles

Wear Panels

Our manufacturing facilities are fully equipped with the latest equipment for quick turnaround of products without sacrificing high quality workmanship. Please send in your enquiries for this product line to sales@ceresist.com

Designed to Endure

High-Purity Alumina

Alumina ceramic is by far the most commonly used ceramic, and is commercially

available in many different purities — from a porous 76% refractory material to a

high-purity, inert 99.9%. However, important properties such as hardness and

corrosion resistance are drastically reduced when installing low-purity alumina in

harsh environments.

Ceresist fittings are available with high-purity 99.5% and 99.8% alumina ceramic.

These grades are 42% harder than chrome carbide hardfacing, three times harder

than glass, and nine times harder than carbon or stainless steel. Alumina also

exhibits an extremely high level of corrosion resistance — even at high temperatures

— and is the ideal material for high wear applications where corrosive and abrasive

fluids are present. It is a very cost-effective material, and deliveries are quite rapid.

Nitride-Bonded Silicon Carbide (NB SiC)

The nitride bonded silicon carbide ceramic consists of sintered silicon carbide

particles fired in a silicon nitride ceramic matrix. It is nine times harder than carbon

or stainless steel, exhibits superior chemical resistance to acids and alkalies, and

furthermore possesses excellent high temperature and thermal shock resistance.

NB SiC is cast into custom shapes, and may be fabricated in lengths up to 60” and

diameters up to 46” — allowing for extremely cost-effective long runs of piping

whilst minimizing the number of individual segments. It is slightly porous, which

limits its use in cavitating environments, but is an excellent material for basic wear

applications.

Sintered Silicon Carbide

Whether submerged in corrosive environments, subjected to extreme wear and

abrasive conditions, or exposed to temperatures in excess of 1,400°C (2,552°F),

sintered silicon carbide will outperform other commercially available ceramics or

metal alloys, including high-alumina, RB SiC, and superalloys.

Sintered silicon carbide is one of the hardest high-performance materials available,

second only to diamond. Additionally, it weighs less than half as much as most

metal alloys, 40 percent as much as steel and about the same as aluminum. The

high density, low porosity and chemical inertness of sintered silicon carbide permit

it to function in environments of hot gases and liquids, in oxidizing and corrosive

atmospheres, and in strong acids and bases, even at extremely high temperatures.

The high thermal conductivity of sintered silicon carbide, combined with its low

thermal expansion, produces excellent thermal-shock resistance far better than

tungsten carbide, aluminum oxide and reaction-bonded silicon nitride.

These properties make sintered silicon carbide the most wear– and corrosion–

resistant ceramic we offer for use in the most agressive services.

Designed to Endure

Ceresist ceramic lined fittings are designed to outlast linings such as glass, rubber, basalt, hardfacings, coatings, trowelable linings, cure-in-place linings, and plastics that are commonly used to extend the life of piping systems. These materials are only a fraction of the hardness and wear resistance of our ceramics, and with the introduction of a corrosive into the process or high temperatures, most linings become severely incompatible and their use is extremely limited. Ceresist fittings feature ceramics that approach diamond in hardness, are chemically inert to almost all corrosives, and may be installed in services where temperatures exceed 1,100°F.

Applications

Ceresist ceramic lined pipe spools are our best-selling product. With numerous installations spanninga vast variety of industries, we are able to provide our customers with a pipe spool that will be cost-effective, and provide years of trouble-free service.

Where to Use
Ceramic pipe spools are most commonly used downstream of control valves, pumps, bends, or after any flow element that creates diverted or turbulent flow.

Ceramic Materials
Reaction-bonded silicon carbide, alumina, and sintered silicon carbide are all available in straight pipe spools. The selection of each particular ceramic depends upon the corrosiveness and wear factor of each process. Both reaction-bonded silicon carbide and alumina are approximately 8.5x harder than carbon steel, with sintered silicon carbide being about 16.5x harder.

Housing Materials
In addition to our standard carbon steel housing, stainless steel 316 or 304, FRP, and vinyl ester wrapping, other custom housing materials may be supplied. For added protection, a corrosion and abrasion–resistant epoxy coating is applied to carbon steel housings to offer longevity in harsh environments as well.

Control Valve at 20% Open Most wear caused by a control valve occurs when the valve is controlling at a low percent open position, and usually within 1 1/2 diameters downstream.

Variations

In addition to being equipped to custom-manufacture straight pipe spools to our customer’s exact specifications, the following are just some of the common straight-pipe spool variations:

Different Flanges Each End – For connecting piping systems to machinery or systems that have larger flanges. It is preferred that fluid flows to the larger flange to avoid piping restrictions caused by the ceramic lined pipe spool.

One Flange Offset From End - Commonly used to terminate piping into a tank or similar equipment that is flanged, whilst having the pipe spool act as a nozzle.

Nozzle-Type – Used when terminating flow into an open tank.

Pressure and Velocity Reducing Orifice Plates for Severe Service

Abrasion and Wear Resistant: 99.5% alumina ceramic is more than 7 times harder than stainless steel, and 2½ times harder than Stellite®. This allows the use of the ceramic orifice plate in erosive services that would otherwise diminish the useful service life of conventional pressure-reducing devices. The thick, solid-ceramic insert assures dependable, long-term service without frequent replacement and the need to inspect the bore integrity.

Corrosion Resistant: 99.5% alumina is inert to, and does not interact with, almost all organic and inorganic chemicals used in manufacturing processes. It is fully compatible with a wide range of chemicals, and can even withstand highly corrosive fluids at elevated temperatures with no damaging effects.

Unaffected by Cavitation: Ceramic orifice plates may also be used in high differential pressure and high velocity services without suffering the damaging effects of cavitation.  Additionally, they are ideal for reducing the pressure, velocity and cavitation that would otherwise damage more expensive, harder to replace valves and critical flow elements.  Ceramic orifice plates offer tremendous savings when considering less component replacement due to wear and abrasion.

Replaceable Ceramic Inserts

The unique and innovative design of the OP Series ceramic orifice plates allows the end-user to quickly dismantle and replace the ceramic inserts. This cost-effective and intuitive design eliminates the need to purchase new assemblies, does not require special tools, does not demand cumbersome assembly or alignment methods, and may be completely refurbished and reinstalled into the process line in min­utes, saving costly labor and down-time.

Multiple bore-size inserts may be purchased to fine-tune flow conditions, compensate for adjustments or changes in the control loop, or can simply be discarded and replaced with a new insert when the original has performed its usable service life.

Inexpensive ceramic inserts are readily available in a variety of sizes, bores, or ceramic materials to suit each process or fluid. Typically in stock, delivery for either spare replacement ceramic inserts or whole assemblies is rapid, eliminating the need to stock locally.

Technical Data

Model Number Designation

3-Way Multi-Port Ceramic Lined Ball Valves

Ceresist’s line of 3-way multi-port ceramic-lined ball valves have been developed to offer end-users a dependable and robust valve with an extremely long-term maintenance-free service life.  Out alumina lining is 8x more wear-resistant than carbon and stainless steel, whereas our high-purity sintered silicon carbide is 16 times more wear resistant.

Features

• Solid ceramic protects the valve from erosive wear throughout all flow paths
• Available in high-purity alumina or high-purity sintered silicon carbide ceramics
• Optional chrome carbide hard facing on the ball exterior surface resists wear and assures leak-proof performance
• Standard seats are RPTFE; UHMWPE, tunsten carbide coated SS316, and high-purity sintered silicon carbide are also available
• Stainless steel housing is standard; carbon steel available as an option
• Trunnion ball design
• Automation mounting in compliance with ISO 5211
• Optional cavity fillers prevent media build-up and solids entrapment within body cavity.  Available in solid ceramic, refractory, or epoxy.

Sizes and Standards

• 1 1/2″ to 12″ sizes
• ANSI 150 lb & ANSI 300 lb
• Round-ported ball configuration
• L or T flow path options
• Material and test certificates available upon request

High Purity Alumina Lining

High Purity Sintered Silicon Carbide Lining

Flow Patterns

Technical Data