NEW CAPITAL EQUIPMENT / PLANT EXPANSION
Ceramic Technology Inc. In 1985 CTI Business Plan stipulated ceramics as a primary liner in the redesign of mineral process equipment. The plan was a bold approach to improve performance competing with traditional process equipment lined with abrasion resistant plate; rubber, chrome carbides, ceramic liners and a new generation of fabrication were controversial it was met with a large degree of skepticism in all the mining sectors.
Forward to the present day 2018. In the 34-years we have labored to improve the performance of mining process equipment progressively defining Alumina Oxide Ceramics as a high-performance liner replacement for process equipment.
CTI’s focus on improved design targeted replacement cycle of mining process equipment, from 1-year performance to extended range 5x-20x. It is also worth to note that our warranty claim is .043% to date for 2018 is typical for the last 34 years as a Contract Manufacturer of the exclusive CTI-X7® Ceramic Process Equipment.
Before 1985 the standard liner for mining operational equipment repair was AR 400, UHMW, rubber, and chrome carbide, etc. Maintenance and replacement of process equipment are costly. Plant maintenance requires many hours of overtime labor to maintain plant process equipment for 24X7 continuous productions.
The production maintenance cycle of coal mining and coal-fired power industries is brutal, especially given the 24 -7 process production that most operations are presently operating. Maintaining, repairing and replacement of the equipment due to the impact wear and reactive erosion of material flows.
The production replacement cycles on pipes, chutes, hoppers, distributors, pulverizer fans, conveyors, head-chutes, etc. For the last thirty-four years, the need for improvement has been relentless, being production driven our X-7® standards developed improving operational cost across the North American Continent.
CTI -X7® Ceramic Lined Process Equipment as recognized throughout the United States and Canada as a preferred innovative performance solution.
Our team of engineers has developed designs which have been awarded multiple patents in the United States, Canada, and Australia.
CTI-X7® Ceramic Process Equipment has proven over the last 34-year of 24-X7 continuous operation of coal and mineral mining. CTI makes it their mission to help you achieve the same levels of operational efficiency that many of our customers are presently tracking.
Engineering and Contract Manufacturing
Many reliability engineers recognize CTI-X7® Ceramic Performance Process Equipment as the best standard of performance in the replacement cycle of capital plant and expansion equipment. As well as meeting the needs for a redesign and improved maintenance fabrication that will help improve your operational performance.
New Capital Equipment/Plant Expansion
The CTI-X7® SAM-1 Screen redefines screen feed point technology, counter to the radius sieve bend and dropbox standard of the last 50 years. The angle of discharge promotes magnetite, fines classification, water retention, and serves to balance coal circuits. The screen static velocity allows for as much as 80% recovery, classification of fines before spray washing and final screening on a banana and flat screens increasing screen life, efficiency, and promoting cleaner, safer operation.
Most operations are staffed leanly to keep labor costs at a minimum; this requires a repair service to replace parts. Most mineral process plants keep a couple of good welders on staff to form the nucleus of an operation maintenance crew; however, this doesn't allow for any significant events such as major repairs or rebuilds.
Due to plant maintenance crews short staffed nature, CTI-X7® offers an in-depth Plant Maintenance Service geared to support operations on a large or small scale.
Our sales and service engineers are on call to gather baseline information on maintenance throughout CTI's Catalog of Products. Our engineering department focus to help customers define the best path to maximize maintenance priorities to improve and extend life over present performance.
With specific field details and after extensive discussion with the customer, CTI's engineering staff does a preliminary drawing, take-off for a quote, and defines material design for customer's review and approval.
This process generates a quick response quote for the desired maintenance product. On receipt of PO, CTI's dedicated sales and engineering staff confer to detail drawing for customer approval to verify the design. In most cases, a finished product will be delivered to the customer's plant within 3-4 weeks after receipt of final approval drawing.
To improve on this delivery schedule, CTI-X7® maintains an extensive drawing library to reissue maintenance items as needed. We feel this approach supports your operations and augments a complete integrated service. For many years we have enjoyed working with our operational customers to advise and install the CTI-X7® Ceramic Process Equipment. The impact and high wear replacement contingents to supporting safe and efficient operations.
We are proud to offer Made in Virginia Custom Fabrications and strive to utilize materials made in U.S.A in every fabrication.
Large Diameter Carbon and Stainless Piping
Due to converging cost factors of urethane and rubber liners, we can now offer ceramic flue liners - 24", 30", 36", 40" pipes that reflect a much-improved cost-effective performance with extended life 5X plus.
We see rapid wear in elbows and fittings. By detailing elbow impact points (sharp angular areas and areas with high velocity flows) to be lined with 1" and ½" ceramic tile configurations in high wear areas, we significantly increase the life of piping.
We usually incorporate carbon steel piping (¼"-3/8" wall), or tubing to match existing IDs or make interphase to straight section runs; however, we can also utilize 304 and stainless alloys. Piping options include straight spools, elbows, and special headers. All fittings meet code and flange specification. All fabricated equipment inspected with each piece marked for installation before leaving the warehouse.
We offer supplemental bolt and gasket packs for ease of installation (see Maintenance Support Kits).
Our engineering department incorporates the latest CAD and plasma procedures, as well as, 3D modeling to work out segment replacements. All surfaces can be blasted to 6 mil specifications to ensure correct profile before painting and lining. We can use epoxy primer and finish coat: 6-8 mil DFT of Devote 261 Epoxy Primer Coating and QC349 Urethane Finish Coat.
We look forward to supplying your piping needs.
Maintenance Support Kits
For years Ceramic Technology, Inc. was involved in the onsite installation. Many times our onsite technicians have come up short on miscellaneous materials. Failing to anticipate documents required on an install, is always frustrating and costly! The same problem arises when primary fabrications are delivered to site. Even good receiving manager sometimes fail to have adequate bolts, gaskets, etc. on hand at the time of install. To combat this frustration, we offer complete CTI-X7® Ceramic and Maintenance Support Kits for installation and repair.
Our dedicated engineering and materials team work hard to make installation and repair of all our customers' equipment as fast and easy as possible.
Our shipping support team offers a palletized or boxed set of all bolts, gaskets, tile, and adhesive needed to complete every job. For quick installation reference, all support kits also include two (2) copies of Erection Drawings.
We highly recommend the CTI-X7® all-inclusive Maintenance Support Kit. Customers can be specified when ordering; allowing our Materials Managers to gather materials, verify contents, and deliver with custom CTI-X7® Fabrication. This step ensures the job to be complete onsite without having to shut down installation to run for parts to complete repairs. Customers can also coordinate this additional service through our Materials Manager, Sales Engineer, or Engineering staff to order these items.
We look forward to working with your managers to improve your maintenance efficiency by installing The CTI-X7R Ceramic Pipe and Fittings you can take comfort in knowing you have selected the best to improve plant performance and improve your focus on maintenance efficiency. www.ceramictech.com
CTI Sump Assemblies
We continue to be the benchmark supplier of CTI-X7® new capital plant and expansion equipment, as well as meeting the need of redesign and improved maintenance fabrications. Our engineering team focuses on delivering cost-effective, ceramic-lined fabrications in a responsive manner that will help improve your operational performance. CTI’s technicians utilize the latest AutoCAD and plasma technology to provide accurate fabrications to specifications on time and site-specific.
Customers realize a better ROI when this CTI-X7® sump design is selected. The complete fabrication procedure is better controlled with the life of sump at 20+ years with little to no maintenance. Tech teams complete fit-ups and liner phase to CTI-X7® standardized specification in a controlled environment.
CTI SAM-1 Static Pre-Screens
The CTI-X7® SAM-1 Screen redefines screen feed point technology, counter to the radius sieve bend and drop box standard of the last 50 years. The angle of discharge promotes magnetite, fines classification, water retention, and serves to balance coal circuits. The screen static velocity allows for as much as 80% recovery, classification of fines prior to spray washing and final screening on banana and horizontal screens increasing screen life, efficiency, and promoting cleaner, safer operation.
CTI Protection Screens
The CTI-X7® Protection Screen provides single visual rapid classification inspection resource to control particles while constantly ensuring accuracy per flow sheet design. Screen feed normally ranges from 0.35mm to 3mm screens. Minus size report to design flow sheet specification. Oversize plus range reports to coarse process or reject.
CTI Cyclone Tub Assemblies
From our plant location in Cedar Bluff, VA we are able to deliver complete CTI-X7® Cyclone Tub Assemblies to meet specifications. We can supply pre-fitted units detailed to facilitate schedule and plant configurations. Tubs ship as modular units to defray shipping and installation costs 6 through 24 way banks available with top or bottom distributor feed configuration. Our units are lined with ceramic and can include optional splash guards and cover plates; includes 10-12 mil Devoe Epoxy Coating.
Shipping FOB Cedar Bluff, VA 24609
CTI SAM-1 Heavy Media Systems
The CTI-X7® SAM-1 Heavy Media Circuit brings all the latest ceramic elements together to present a much-improved redesign that combines the best wear and separation technology to date. The recovery of magnetite and better classification on pre-feed to process screens represents a new benchmark in 24 x 7 process performance.
CTI Chute Systems
Many years of coal operation experience provide an underlying base of expertise that allows us to evaluate and improve your operations by applying the latest technology. We look forward to supporting your team by improving performance through your materials handling systems.
We continue to be a benchmark supplier of new capital plant and expansion equipment as well as meeting the needs of redesign and improved maintenance fabrications. Our engineering team focuses on delivering cost-effective, ceramic lined fabrications in a responsive manner that will help improve operational performance.
CTI Pump Adapters
For many years, standard piping connecting procedure for pump discharge to process piping required a Concentric Bell Reducer to flange to pump volute discharge. This transition had always been a high wear point, calling for maintenance on HM Lines in less than a year.
In 1999, CTI-X7® received US Patent 5875814 for our Pump Adapter. By utilizing two ceramic sleeves, we are able to provide ceramic adapters to complete the interphase from pump to pipe with a versatile design that replaces concentric reducers and now this has become the preferred pump to discharge standard utilized throughout the coal industry!
CTI Cyclones Overflow & Underflow Boxes
Heavy Media Cyclones are positioned at a 12 degree centerline axis arrangement; we can provide these arrangements with overflow and underflow boxes matched with ceramic liners to meet impact conditions. We are also able to recommend CTI-X7® Shroud Overflow and Underflow arrangements to meet the 24x7 process schedules of today's operational plans.
CTI Rotating Distributors
The CTI-X7® Self Propelled Distributor tracks a progressive history benchmarking the first ceramic lined distributor at 400-450 TPH. The ability to evenly split feeds to 4-8 vibrators 3/8" x 0" - 24x7 required a bearing shaft assembly that would operate in a strict condition. Also by sizing GPM flow through ceramic nozzles from a gravity drop, we were able to establish consistent 40-45 RPMs of the rotating tub. The bearing shaft pedestal assembly is isolated, and many of our units are still operating today. Also on large units (2000/2250 TPH), we detailed and built sealed shaft assemblies that are to the best of our knowledge are still in operation.
Our CTI-X7® in-house designs range from 48" design at 350-400 TPH to 10' diameter at 1500-2000 TPH. All exposed wear parts are lined with ceramic. Ceramic distributors can be set up for 3" to 1/4" x 0", 1/8" to 300 mesh size material splitting consistent flow to 2 to 8 points of discharge to screens or other processes.