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How are advanced ceramics used in mineral-processing equipment?

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Steps in doctor blading, a tape-casting process employed in the production of ceramic films. Ceramic powder and solvent are mixed to form a slurry, which is treated with various additives and binders, homogenized, and then pumped directly to a tape-casting machine. There the slurry is continuously cast onto the surface of a moving carrier film. The edge of a smooth knife, generally called a doctor blade, spreads the slurry onto the carrier film at a specified thickness, thereby generating a flexible tape. Heat lamps gently evaporate the solvent, and the dry tape is peeled away from the carrier film and rolled onto a take-up reel for additional processing.
advanced ceramics Steps in doctor blading, a tape-casting process employed in the production of ceramic films. Ceramic powder and solvent are mixed to form a slurry, which is treated with various additives and binders, homogenized, and then pumped directly to a tape-casting machine. There the slurry is continuously cast onto the surface of a moving carrier film. The edge of a smooth knife, generally called a doctor blade, spreads the slurry onto the carrier film at a specified thickness, thereby generating a flexible tape. Heat lamps gently evaporate the solvent, and the dry tape is peeled away from the carrier film and rolled onto a take-up reel for additional processing.

Advanced ceramics are essential in mineral-processing equipment because they are exceptionally robust, providing superior resistance to the corrosive and erosive environments typical of handling liquids, particulates, and suspensions.12

In these industrial settings, advanced tribological ceramics are utilized for a variety of critical components, including:

  • Linings: Used as chute and pipe linings to protect against wear from material transport.1
  • Cyclone Components: Employed as walls and internal parts for cyclones.1
  • Pump Parts: Utilized for liners, seals, plungers, and shaft sleeves.1
  • Valves: Used in various valve configurations, such as balls, rings, and seats for ball valves, as well as rotary and gate valves. When slurries or fluids require precise metering, ceramic metering valves are frequently employed.1

These materials are chosen for their extreme hardness and strength, which allow them to withstand impingement wear—the primary wear mechanism in mineral handling where particles impact and erode surfaces. By incorporating advanced microstructures, such as ceramic-matrix composites or transformation-toughened zirconia, engineers can significantly enhance the service life of equipment exposed to these harsh conditions.1