Cast blast lined pipe and fittings

Cast blast lined pipe and fittings is composed by lined with cast basalt pipe, outside steel pipe and cement mortar filling between the two layers.

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Cast Basalt is a mineral of exceptionally high abrasion resistance, unlimited resistance to moisture, high compressive strength and resistance to virtually all acids and alkalis and is completely corrosion free. Cast blast is produced by melting selected natural basalt broken into sizes of 20-50 mm in shaft furnaces at temperatures around 1,300C, following by casting at which the melted basalt forms uniforms pherolithic crystals hence producing its typical physical properties, in particular its exceptional hardness and wear-resistance.

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

However, it is marked by ascertain sensitivity to impacts. Under Normal services conditions, cast basalt withstands temperatures up to approx. + 350C or-40C. However Cast basalt should not be subjected to temperature 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 length of 500mm.samller nominal bores of straight pipes, pipe segment for radial of 40 to 3,000mm of various angles, as well as special form piece linings are predominantly 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.

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.

Advantages
  1. Fused cast basalt surfaces remain smooth and low in friction when used over time, thereby offering the benefit of low caking.
  2. Fused cast basalt provides excellent protection against the following abrasive media: ore - sinter - ash - slag - sand - coal - clinker.
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:

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

Technical Details:

Specifications:


Why are cast basalt lined pipes so wear-resistant

The molding process of cast basalt lined pipe includes solution casting, sintering and thermal direct sintering. So, why the cast basalt lined pipe is very wear-resistant cast basalt lined pipe has been widely used in building materials, chemical industry, metallurgy, mining and other industries. Cast basalt lined pipe is an ideal substitute material for steel, iron, lead, rubber, wood, etc. In some parts of many equipment. Individual metals cannot achieve high wear resistance, acid and alkali corrosion resistance, and have the advantages of extending equipment service life, reducing maintenance man-hours, improving production efficiency, and reducing product costs.

The cast basalt lined pipe has the characteristics of thoughtful structure, low water absorption, high compressive strength and good wear resistance. Except hot phosphoric acid, hydrofluoric acid and dissolved alkali above 30℃, it has good corrosion resistance to almost all inorganic acids, organic acids, alkalis, salts, water and organic solvents. The brittle material of cast stone has high hardness, and the problem of cast stone is that it is brittle and is not easily impacted by heavy objects.

Under the microscope, the cast stone can be seen interlaced with individual pyroxene spheres or feather-like crystallites of 0.05-0.1 mm. The thoughtfulness of this internal structure greatly improves the hardness of the cast stone, and its mohs hardness reaches 7~8. The greater the hardness of the material, the better the wear resistance. From the point of view of atomic and molecular structure, the combination of silicon and oxygen atoms of this silicate mineral is connected with each other by a strong force.

Individual cast basalt lined pipes have good wear resistance in blast furnace tank utilization, and meet application requirements in terms of wear resistance, but there are also brittleness of ceramic materials, which are easily broken during the process of falling ore. The construction of single-piece pasting is incomplete, and signs of aging will appear after a long time of pasting. The wear-resistant material not only has good wear resistance in the use of blast furnace tanks, but also meets the application requirements in terms of wear resistance, and has a mortar material, which is tough and will not be smashed in the process of falling ore. Good performance, combined with cement, not limited by time and so on. The wear resistance of cast basalt lined pipes is also the reason for their widespread use.


Cast basalt lined pipes and fittings

Cast basalt pipe can be divided into straight pipe, elbow, three-way (four-way) pipe and variable diameter pipe, etc.

The excellent performance of Cast blast lined pipe and fittings is that it sets tenacity of steel pipe, abrasive resistance of cast basalt pipe, concreteness of cement mortar in one.

This greatly improves the products adaptive capacity in complicated operation conditions. At the same time. cement mortar is selected as the filling material and this can make the inside surface of steel pipe in alkali mediums. So the surface of steel pipe generates purifying films. These films can prevent being rusted.

Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings
Cast blast lined pipe and fittings

The Connection Of Cast Basalt Line Steel Pipe

Cast blast lined pipe and fittings Can Connect With Flange, Quick Assembly Joints And Welding.

Flange Connection

Flange Connection Is One Kind Of Common Pipeline Installation Connections. By Two Pieces Of Flanges, Pipeline, Valve, Equipments Are Connected And It Forms A Tight Piping System. When Pipeline Pressure Is Larger, Flange Connection Is Priority Selection. Flanges Have Lots Of Different Sizes. Flange Size Is Determined According To Pipeline Normal Diameter And Pipeline Operation Pressure.

The parameters of the outside steel pipe will be decided according to the working pressure of the system. The connection of the pipes and fitting will be of flange connections, easy—flexible joint connection or by welding.

By two pieces of flanges,pipeline,valve,equipments are connected and it forms a tight piping system. When pipeline pressure is larger, flange connection is priority secection. Flanges have lots of differents sizes.

Flange size is determined according to pipeline normal diameter and pipeline operation pressure.

Straight pipe draws with flange

Welding & Beveled End

It Suits Short Distance Pipeline System Without Maintenance. It Is One Kind Of Common Installation Connections. It Requires Installation Personnel Higher Welding Ability. It Also Restricts By Welding Site, Distance, Welding Positions. Welding Connections Is Inconvenient In Later Maintenance.

Easy-Flexible Joint Connection

It Is One Of High Efficient And Rapid Installation Connection. I T Has The Below Characteristic: Easily Install And Disassemble, Fast Installation, Temperature Adjustable Compensation Function, Saving The Necessary Expansion In Long Pipeline. Easy-Flexible Joint Also Has Angle Compensation Characteristic. At Smaller Angle Turning Points, Easy-Flexible Joint Can Be Instead Of Bends And Adjust Angle.

Cast blast lined pipe and fittings


Application area

  1. Thermal Power Stations: Raw Coal Chutes/ Hoppers, Feed Bunker/Coal Bunker, Ash Pits, Crushers, Bottom Ash, Disposal Slurry, Dust Lines/ Bends, Pipeline/Bends, Fly Ash. Trenches below Hopper and pipelines, Pulverized Coal Piping.
  2. Cement Plants: Dynamic Air Separators, Raw Mill Ducts/ Chutes, Drag Chain Conveyor, Grate Cooler Housing, Air Separator/ Cyclones, Coal Handling, Coal Hopper/ Chutes, Cement Conveying, Slurry Lines/ Bends Lines/ Bends, Discharge Boxes / Bankers, Lime/Silica Hoppers/Chutes, Chain Conveyor Housing, Mixers/Nozzles, Coal Venturi, etc.
  3. Steel plants: Coke sorting unit, Coal bunkers / sinter bunkers, Lime bunkers, Coke breeze, Sinter plant cyclones, Sinter plant flow conveyors, Iron slurry line, Thick slurry lines, Air lift pipes, Telescopic pipes, Granulated slag, Hot mill flume, etc.
  4. Coal Washer: Coal Washing Plants, Coal Transportation, Conveyor Chutes/Pipes, Floatation Cells, Media Sumps, Centrifuges, Cyclones, Sieves etc.

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.

Packed in steel cases

Pick in containers

Secure with wire ropes inside the container to prevent the package from moving during transport.

Cast blast lined pipe and fittings are packed in container



We supply Cast Basalt wear resistant linings; tiles, pipes and shapes that resist wear and provide protection to mining and industry equipment.

Abrasion Resistant Pipe Solutions

Conveying highly abrasive materials, steel piping systems are under constant attack often over long distances.

Q&A

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.

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.