Cast Basalt Half Pipe

Cast basalt half pipes have an excellent performance of high abrasive and high corrosion resistance.

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Cast Basalt Half Pipe

The walls are lined with hexagonal or rectangular tiles. Circular bunker and silos are lined with radial rectangular or hexagonal form pieces, exactly fitting the respective circumference.

Basalt casts are considered the best lining materials for industries dealing with abrasion resistance. The other application areas of basalt casts are bends, lining pipers and trenches.

Cast basalt is a mineral material produced by melting natural basalt at a temperature of approximately 1300°C, followed by casting into moulds. This contributes to its superb physical and chemical properties.

Cast basalt half pipe is a common component of the heating part of tubes. It is usually used in power station boilers.The useful life of tube shield is 3-5years. The tube shield has a variety of material and the selection of the material shall be subject to the original design of the boiler.The tube shield is divided into straight pipe and bend pipe. The main effect of tube shield is to protect the pipe and increase the service life of the pipe.

Cast basalt pipe shields are designed to eliminate major maintenance and downtime costs from boiler and condenser tube failure.

We offer cast basalt tiles for coal bunkers and chutes. These cast basalt tiles are bedded as well as jointed in cement/special bonding agents like resins depending upon application. These tiles mostly find application in automotive industry and are designed to provide long-lasting lining and enhancement to involved operational life cycle for both plant as well as equipment.

Cast basalt tile fitting
Cast basalt tile compounds

Application

It is usually used in power station boilers. The useful life of tube shield is 3-5years. The tube shield has a variety of material and the selection of the material shall be subject to the original design of the boiler. The tube shield is divided into straight pipe and bend pipe. The main effect of tube shield is to protect the pipe and increase the service life of the pipe.

Cast bastle tiles construction site Cast bastle tiles construction site
Cast bastle tiles construction site Cast bastle tiles construction site

Main Specification Of Cast blast lined pipe and fittings

Cast Basalt Pipe DN
(mm)
Standard Steel Pipe OD
(mm)
Cast Basalt Thickness
(mm)

Length
(mm)

80 159 25 4000
100 168 17.5

20
4000
6000
8000
125 195
150 219
175 245 6000
8000
10000
12000
200 273
225 300
250 325
275 345
300 377
350 426
400 478 20
25
450 529
500 600 25
550 650
600 720 30 6000
650 770
700 820
750 870
800 920

Other specifications of cast steel pipe lined with basalt can be manufactured according to customer technical requirements. Suitable for large-diameter basalt lining steel pipes with a nominal diameter greater than 800mm. Generally, according to the running status of the pipeline, different cement is used to fix the basalt brick inside the finished steel pipe to complete the basalt lining steel pipe. Its advantages are good wear resistance, wide range of use, basically not limited by the size of the pipeline and low cost of pipeline installation.

Comparision Chart

Comparison of Ceramic lines with few other materials under standard conditions :

Material Thickness(mm) Approx life ( Months )
Mild Steel 10 3-5
Cast Iron 20 6-8
Ni-Hard 20 12-14
Cast Basalt 30 20-25
Ceramic 10 35-40

Ceramic lined equipment and bends

Hard & Compact Smooth & Inner Withstands High-Abrasion & Corrosion In any of the process industries especially Sled and Cement corrosion and abrasion lead to significant downtime of the plant. Further, the useful life or the equipment itself may get impaired because of the high abrasive nature of the materials being used. Thus, ‘wear mechanism’ results in hut down, replacement, etc., which is costly, resulting in loss to tilt: tunic of millions of dollars.

Characteristics

Technical details:


Packaging and delivery of cast basalt products

Cast basalt pipe adopt foam packaging, then in accordance with the specifications to put them into wooden cases, sometimes them can be directly loaded into the compartment or container.

Pack cast basalt pipes Pack cast basalt pipes Shipping packing cast basalt pipes Shipping packing cast basalt pipes

Shipping packing

Wear-resistant cast basalt slabs

Wear-resistant cast basalt slabs

Wear-resistant cast basalt slabs Cast basalt composite pipeline for ash discharge port of power plant

Cast basalt composite pipeline for ash discharge port of power plant

Packing customize bend Packing customize bend Packing customize bend Packing customize bend Packing customize bend Shipping packing cast basalt pipes Cast basalt tiles are packed in wooden cases

Cast basalt tiles are packed in wooden cases

Cast basalt tiles are delivered to sea port

Cast basalt tiles are delivered to sea port


What is Cast basalt

Cast basalt is a mineral of exceptionally high abrasion resistance, unlimted resistance to moisture, high compressive strength and resistance to virtually all acids and alkalis and is completely corrosion free.

Cast basalt

Cast basalt is produced by melting selected natural basalt broken into sizes of 20-50 mm in shaft furnaces at tempreatures around 1,300C, following by casting at which the metled basalt forms uniforms pherolithic crystals hence producing its typical physical propertics, in particular its exceptional hardness and wear-resitance.

Cast basalt reaches a value of hardness of 8( min ) on the Moh's hardness scale. for comparision : the highest value10is only attained by dimonds. by virtue of these properties,the silicate cast basalt provides outstanding protection against abrasion and scrubbing.

however, it is marked by asertain sensitivity ti impacts.Under Normal services conditions, cast basalt withstands tempratures up to approx.+ 350C or-40C. However Cast basalt sholud not be subjected ti temprature shocks.

Sizes : Cast basalt produces are manufactured as tiles, from pieces and segments. straight pipes are spun-cast, available for nominal bores of 32 to 600 mm with the wall thickness ranging from 20 to 30mm and a standard lenght of 500mm.samller nominal bores of straight pipes, pipe segment for radill of 40 to 3,000mm of vatrious angles, as well as special formpiece linings are pre dominately sand-cast. The standard wall-thickness is 20mm. depending on the respective quantity, steel moulds can also be used, the wall thickness in those cases usually being 30 to 40mm.

Cast basalt lined pipe can be mainly used as abrasive material and ash handling system like chute slip trough, funnel, silos, a variety dust catcher, revolving-flow machine, various scraper transport planes, all the feeder liner. Laying the ground all types of chemical plants, it can be for lining picking tank or storage of corrosive substance of the storage room.

According to customer requirements along with cast basalt production technology and we can offer various specifications and various shape to meet client's need.

Friction Resistance : As more material is passed over Cast Basalt it gets polished up thereby reducing friction further. Cast Basalt improves in service after getting polished. Wetting also improves its performance in practical applications.

Impact Resistance : Direct Impact Resistance at 90 degree is low like all other ceramics, but it can be increased with proper installation by reducing the angle of impact. Cast Basalt is the best wherever sliding abrasion exists. Moreover, external impact strength of composite basalt pipe (enclosed in M.S. Shell) is always more than that of bare Ni-hard Pipe.

Chemical Resistance : Cast Basalt is almost absolutely acid/alkali resistant (except Hydrofluoric Acid) and hence corrosion resistant.

Weight and Sizes : Basalt Tiles are available in regular shape square of 200 x 200 x 30 mm thick, weighing approx. 90 kg/sq m; whereas bends and pipes are lined using Basalt Cylinders of various standard sizes from 50NB upto 500NB.

Temperature : Cast Basalt withstands temperature up to 4500 oC.

Design Aspects


Cast basalt produce process

Cast basalt process

Processing technology and application of cast basalt lined pipe

Cast basalt pipe is a kind of silicate crystalline material that has been produced and processed. It uses natural rock (basalt, diabase and other basic rocks) or some industrial waste slag as the main raw material. After melting, pouring, crystallization and annealing and other processes. Cast stone has excellent wear resistance and corrosion resistance. Cast stone products mainly include cast stone slabs, cast stone pipes, cast basalt lined pipes, jacketed cast stone pipes, cast stone wear-resistant expansion joints, cast stone wear-resistant valves, cast stone powder and various wear-resistant and resistant cast stone powders as raw materials. Putty slime, etc. Has been widely used in electric power, mining, coal, metallurgy, chemical, construction and other industrial sectors severely worn and corroded parts and equipment.​​

the cast basalt lined pipe is composed of the inner lined cast stone pipe, the outer steel pipe and the cement mortar filling layer between the two. It integrates the wear resistance and corrosion resistance of the cast stone pipe, the toughness of the steel pipe and the consolidation of the cement mortar. In one. It improves the adaptability of the Product to various complex working conditions. At the same time, the use of cement mortar as a filler can make the inner surface of the steel pipe in an alkaline medium, and the surface of the steel pipe will produce a purification film, which can prevent corrosion. It is resistant to wear, corrosion, and high pressure, and is safe and convenient to transport.

​​

Cast basalt lined pipes are divided into straight pipes, curved pipes, tee (cross) pipes, reducing pipes, etc.​​

The diameter series of the cast stone composite elbow is the same as that of the cast stone composite straight tube, and its turning radius and center angle are made according to user requirements.​​

Non-standard specifications of cast basalt lined pipes can be made according to customer’s technical requirements. For large-diameter cast basalt lined pipes with a nominal diameter of more than 800mm, different cements are usually used to paste the cast stone plates on the inner wall of the well-processed steel pipes according to the operating conditions of the pipe fittings to form an integrated cast basalt lined pipe. Its advantages are good wear resistance, wide application range, small size limitation of pipe fittings, and low cost of pipe fittings.


Cast basalt Process

Natural gas is used for melting basalt stone in melting furnace. Natural gas is currently very clean and environmentally friendly fuel. No any pollution. To the customer requirements choose environmental protection material that is a good choice.

The product processed from cast basalt is a new type of silicate crystalline material. Using natural rock (basic database, shale, etc.) or industrial waste as the main raw material components, smelting, casting, heat treatment and other processes are regularly arranged, crystalline, hard, and fine-textured metal industrial materials. Casting basalt has an excellent high abrasion and high resistance. Abrasiveness. Corrosion resistance.

Wear-Resistant Material Preparation

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Friction Resistance – As more material is passed over Cast Basalt it gets polished up thereby reducing friction further. Cast Basalt improves in service after getting polished. Wetting also improves its performance in practical applications.

Impact Resistance – Direct Impact Resistance at 90 degree is low like all other ceramics, but it can be increased with proper installation by reducing the angle of impact. Cast Basalt is the best wherever sliding abrasion exists. Moreover, external impact strength of composite basalt pipe (enclosed in M.S. Shell) is always more than that of bare Ni-hard Pipe.

Cast basalt pipe
Cast basalt cylinders

Chemical Resistance Cast Basalt is almost absolutely acid/alkali resistant (except Hydrofluoric Acid) and hence corrosion resistant.
Weight and Sizes - Basalt Tiles are available in regular shape square of 200 x 200 x 30 mm thick, weighing approx. 90 kg/sq m; whereas bends and pipes are lined using Basalt

  • Cylinders of various standard sizes from 50NB upto 500NB.
  • Temperature - Cast Basalt withstands temperature up to 450 o C
  • Life - Life of basalt-lined pipe is estimated to be 7 to 10 times that of Cast Iron, and 3 to 4 times that of Ni-hard Steel.

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