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Abrasion resistant pipe

Abrasion resistant pipe

Abrasion resistant piping systems are widely used at coal-fired power plants for a variety of purposes, including the conveyance of coal ash slurry to nearby settling ponds, the transfer of limestone slurry to absorber spray towers for removal of sulfur dioxide (SO2) and hydrogen chloride (HCl) from flue gases and for transporting away the calcium sulfate by-product of the flue gas desulfurization process.

After Analyses and research, it was thought that the main facts which affect drilling pipe abrasion resistant ring failure were abrasive property of formations, selection of high-abrasive material, and wielding technique.

Sunny Steel provides its customers with the full range of abrasion resistant lined pipework including Straight Pipe, Bends and Elbows, Reducers, Tees and Y-pieces (See diagrams as below).

Straight pipe in Bottom Ash
Straight pipe
ceramic-tile-lined-pipe_process-Ceramic-patch
Bends & elbows
Tee
Ceramic lined reducer pipe
Reducer
Ceramic lined
Ceramic lined pipe expansion joints
Abrasion resistant Tees in ore power
Lateral wye

Types of Abrasion resistant pipes Are Available?

There are several different abrasion resistant steel grades. 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.

Ceramic-Lined Pipe and elbows

The ceramic-lined pipe and fittings are designed to outlast linings such as glass, rubber, basalt, hardfacing, and coatings that are commonly used to extend the life of piping systems.

Ceramic Tile Lined Pipes and fittings

Ceramic Tile Lined pipes have very uniform coating of specially formulated ceramic material that is affixed to the inner of the pipe and gives a very smooth surface.

Bi Metal Clad pipe
Bi Metal Clad Pipe, Bend

Bimetal Clad Pipe and Bend are cast with mold vanishing vacuum suction casting cladding process.

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:

耐磨陶瓷复合管的种类有哪些?
耐磨陶瓷复合管的种类有离心浇铸复合陶瓷管道、贴片耐磨陶瓷管道、一体成型耐磨陶瓷管道、全称陶瓷内衬复合钢管,这几种耐磨陶瓷复合管的具体介绍如下:
离心浇铸复合陶瓷管道

离心浇铸复合陶瓷管道是采用“自蔓燃高温合成-高速离心技术”制造的复合管材,在高温高速下形成均匀、致密且表面光滑的陶瓷层及过渡层。因为制作工艺简单,成本较低,适合长距离输送粉体采用,但是其耐磨性比耐磨陶瓷管道稍差,一般用作直管。 

贴片耐磨陶瓷管道

贴片耐磨陶瓷管道是用耐高温强力粘胶将氧化铝陶瓷片粘贴在管道内壁,经加温固化后形成牢固防磨层。该种产品制作工艺相对简单,制作周期短,成本相对较低。 

一体成型耐磨陶瓷管道

一体成型是将陶瓷管件整体烧制后,用特制填充料将其浇筑在钢管内部组装而成。该管道内壁光滑、密封性密封性好,具有良好的耐磨、耐腐蚀性能。但是该种产品制作周期长、成本高。

Q&A

What is SHS?

Self-propagating high temperature synthesis (SHS) is used to describe a process in which the initial reagents (usually powders), when ignited, spontaneously transform into products due to the exothermitic heat of reaction.

A well-known example of SHS reaction is the thermite reaction given below:

Fe2O3 + Al → 2Fe + Al2O3

This reaction generates temperatures above the melting point of alumina and is used in the thermit welding process for joining railway lines.

Several other terminologies - such as combustion synthesis, gasless combustion or self-propagating exothermic reaction - are used to describe the process.

The types of material that can be formed using this process include metal borides, silicides, carbides, nitrides, sulphides, aluminides and oxides.

Alumina Ceramic – Abrasion Resistant Linings

Alumina is a cost effective and widely used material in the family of engineered ceramics. Alumina ceramics have been developed and optimized for maximum wear resistance and corrosion resistance. A high density, diamond like hardness, fine grain structured and superior mechanical strength are the unique properties that make it the material of choice for a wide range of demanding applications.

Alumina Ceramic has uses similar to cast basalt but it has greater resistance to wear in high velocity applications and impact resistance in extreme dynamic systems.

Sunny Steel provides its customers with the full range of abrasion resistant lined pipe work including straight pipe, bends and elbows, reducers, tees and y-pieces. Sunny Steel offers a comprehensive range of lining materials designed to combat erosion.

Basalt and alumina ceramic are the two generally accepted lining materials. Other linings which complement the basalt and ceramic include Eucor, AZS, silicon nitride bonded silicon carbide, and ceramic filled epoxy coatings.

Ceramic lined pipe struct section

Designed to match standard pipe flanges for easy installation in high-wear areas of the pipeline only. Maximum long-term cost-savings in replacement parts and downtime.

Ceramic lined extension pipe draws

Abrasive Applications

Coal preparation plant siteOne-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.

Limestone slurry is also commonly used by coal-fired plants for the effective removal of sulfur dioxide and hydrogen chloride from flue gases. These wet scrubber flue gas desulfurization (FGD) systems utilizes a pumped in limestone slurry through which flue gas containing SO2 is passed in absorber spray towers. The limestone slurry reacts with the flue gas, removing the SO2. The limestone in slurry is then converted into calcium sulfate. This waste material produced by the process is then pumped out from the bottom of the spray towers through steel pipe for further treatment for use in commercially viable by-products such as gypsum board and cement.

To deal with the extremely abrasive and caustic nature of these various slurries, plant maintenance managers are looking to a variety of “abrasion resistant” steel pipe products and accessories to replace standard mild steel pipe in these high wear areas.

Pipe Options

Most abrasion resistant pipe options operate on the premise that when two objects meet, the harder object wins. As such, products are available in a variety of increasing hardness, measured on the Brinell Scale from A-R steel (200 BHN) through iron cast pipe (up to 800 BHN).

Unfortunately, any product that is very hard throughout the wall thickness is also brittle. This brittleness is unacceptable as piping systems are constantly flexing and moving as a result of pressure surges and spikes and due to mechanical and physical contact at the facility.
However, one type of pipe delivers the best of both worlds: an induction hardened pipe with an abrasion resistant inner surface that tapers to a strong, yet ductile outer surface.

At 600 BHN, the inner surface of this induction hardened pipe can withstand most common abrasives and tapers to a 250 BHN outer surface that is ductile enough to accommodate normal handling during shipment, installation and maintenance. With this process, pipe can be created in various diameters up to 40”, in varying lengths and wall thickness.

Warranty

We are Quality Department tests and ensures all of our products are 100% inspected unreported. To an offer we customers additional corps of mind, all our products carry a 24-month warranty against defects or faulty workmanship.We fluid-flow products such as pipe and fittings, chokes, orifice plates, etc, carry a warranty against, erosion, defects, and/or faulty workmanship.

The warranty is determined to each creator and the maximum duration maximally in service. Should any of the RS fail within the warranty period, We'll replace or repair the defective product (s) at No. end user. Please contact the Sunny steel for details on the How to obtain a warranty for our products.

Inspections

As part of our quality regimen, 100% of incoming raw materials, semi-finished products, as well as finished products are thoroughly inspected prior to being entered into our inventory. We have established multiple hold points throughout fabrication as well as a comprehensive final inspection for all products.

Abrasion resistant pipe specification, Standard and identification

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.

The recommended Abrasion resistant pipe

This is because hardness is one of the most important factors when trying to increase abrasion resistance.

Please view the recommended Abrasion resistant pipe, bend, elbow, tee, reducers as below:



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