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Abrasion resistant pipe

Abrasion Resistant Pipe Solutions

Conveying highly abrasive materials, steel piping systems are under constant attack often over long distances. To combat abrasion and keep piping systems in service as long as possible, the industry solution has been to install abrasion resistant (AR) pipe much harder on the Brinnell Scale than standard steel pipe. The harder the inner wall, studies have shown, the better it resists gouging or plowing action of abrasive sliding particle flow.

There are several different material of abrasion resistant pipe

Each grade is typically made to a specific Brinell hardness value, as opposed to other steels that are made with tensile strength and toughness in mind.

SHS ceramic lined
SHS are currently being developed the world over for the production of powders and near-net shape components of advanced materials.
Ceramic tile lined pipe
has very uniform coating of specially formulated ceramic material that is affixed to the inner of the pipe and gives a very smooth surface.
Ceramic ring composite steel pipe
The wear resistant ceramic ring is a special kind of ceramic with Al2O3 as the main raw material and the rare metal oxide as the flux.

Abrasion occurs when materials are rubbed across one another over a period of time.

Bi Metal Clad pipe
Bi Metal Clad
Bimetal Clad Pipe and Bend are cast with mold vanishing vacuum suction casting cladding process.
Rare earth metal wear resistant pipe
Rare earth alloy wear-resistant high chromium cast iron pipe under compared with the high manganese steel materials

Unfortunately, this type of abrasion is only one type of wear experienced within the piping system. Impact abrasion, where a slurry meets the inner pipe wall at closer to 90° such as at the bends, elbows, laterals or tees in the system, has a decidedly unwelcome effect on the inner wall of the pipe.

At sharper angles, abrasive material actively “chips” away at a more brittle inner wall, eroding the surface from the inside out. So predominant is the problem that frequent replacement, repair, and the associated maintenance expenses at the bends, elbows, laterals and tees in the system are accepted as the norm.

“When you have a sharp impingement angle, the abrasive material in the slurry can chip away at a brittle inner pipe wall,” said SumXu, chief engineer, Ultra Tech Pipe. “On the other hand, a more ductile inner wall deforms on impact and is better suited to withstand impact abrasion over time.”

So, the solution would appear straightforward. For sliding abrasion, an extremely hard interior pipe wall for the straight lengths of pipe and a more ductile inner wall at the directional transitions? Not so fast. Turns out size transitions and directional changes can experience both abrasive and impact wear.

According to SumXu, the variety of considerations that need to be addressed when it comes to abrasive wear illustrates the difference between simply ordering a piece of pipe and the broader field of piping system design.

“Designing a piping system is really a balancing act and each system is different,” SumXu said. “In some cases, if the abrasive material is softer than the steel used for the bends and it’s not moving very quickly, even an impact situation will not wear away the pipe. If the abrasive material is very hard or being conveyed at a higher velocity, alternative solutions at the directional transitions are required.”

According to SumXu, solutions include induction hardened pipe bends, installing wear tiles and inserts, lining the bend with various abrasion resistant materials and designing in longer radius bends when possible.

Induction Hardening of the Bends

Strength and wear resistance can be improved by the addition of alloying elements to the steel during the pipe manufacturing process. This material is commonly referred to as AR200 (abrasion resistant) piping.

Strength and wear resistance can also be increased with secondary processing of the steel, including heat treating by induction hardening. Induction hardened pipe can last up to three to eight times longer than mild steel, with only a moderate price increase.

Several years ago, SumXu’s company released its Ultra 600 series induction hardened pipe, a unique single wall pipe with a 250 Brinnell hardness number (BHN) ductile outer surface that tapers to a 600 BHN inner wall surface.

The process begins with a steel pipe manufactured to a proprietary chemistry developed by Ultra Tech, followed by induction heating, and finally water quenching of the inner surface to create the single wall pipe.

At 600 BHN the inner wall of the pipe can withstand the sliding abrasion of most common mining slurries, while its more ductile outer surface behaves like mild steel and can be cut and welded with proper procedure in the field, configured into a variety of fittings, and can accept the standard end options of flanges, weld rings and couplings.

Using this proprietary process, Ultra Tech can create pipe in various diameters up to 40 inches in varying lengths and wall thickness. The same technology is used to create the bends, elbows, laterals and tees with the same hardness profile.

Based on the premise that when two objects meet the harder object wins out, induction hardened pipe for both straight lengths and directional transitions is often sufficient for slurries of “softer” material such as coal and limestone. In some cases, mild steel pipe with induction hardened bends may work as well.

Increasing the Radius of the Bends

Another legitimate technique to mitigate the effects of impact abrasion is using induction hardened pipe in long radius bends. “If there is enough room, you can design the bend with an impingement angle of less than 15°, which is a small enough angle that you no longer have impact abrasion but essentially sliding abrasion,” SumXu said. “With a large enough bend, for all intents and purposes you have made it a straight pipe.”

Because Ultra Tech is able to induction harden the pipe during the bending process, they can vary the arc rad

Abrasion resistant pipe specification, Standard and identification


Straight pipes be
Long-term use in power plants


Pipe elbows be Long-term
use in power plants

Because the outer surface behaves like mild steel, the product can be cut and welded with proper procedure in the field, configured into a variety of fittings, and can accept the standard end options of flanges, weld rings and couplings.

Abrasive Applications

One-hundred-twenty-nine-million tons of coal ash—a byproduct of the coal burning process—is produced every year. Most power plants transport the coal ash in liquid form to large surface impoundments or in solid form at landfills near the facility through long lengths of steel piping, which can range in length from several thousand feet to miles.

Properties of the Ceramic-lined Steel Composite Pipes >>
Ceramic (Corundum: a-Al2O3) lined abrasion resistant straight pipe and fittings are lined with highly abrasion resistant ceramic by SHS ----Characteristics of SHS self-burning ceramic composite pipe
Application of Abrasion resistant pipe

Abrasion resistant pipe applied in coal-fired power plant ash and slag discharge tube, powder, powder tube, desulfurization pipeline,in addition also widely used in the following industries:

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