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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.

Ceramic lined pipe

Ceramic lined pipe is made through self-propagating high-temperature synthesis (SHS) technique.

Ceramic Tile Lined Pipes

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.

Ceramic sleeve lined Pipe

These Ceramic Pipe Sleeve or ceramic sleeve sintered as a whole part, and then fixed it into the steel pipe with our high-strength-temperature-resistant adhesive.

Bimetal Clad Pipe

Bimetal Clad Pipe is cast with mold vanishing vacuum suction casting cladding process.

Concrete Pump Pipe

The Concrete Pump Pipe is made of special quality steel which is quenched and carried out carburizing chemical treatment on the inner wall.

UHMWPE pipe

Ultra-high molecular weight polyethylene (UHMW-PE) is a new kind of engineering thermoplastics with more than 3 million viscosity-average molecular weight.

Rare earth metal wear resistant pipe

Rare earth metal wear resistant pipe and Bend are cast with mold vanishing vacuum suction casting cladding process.

Cast basalt lined steel pipe

Cast basalt lined steel pipe is made with lined cast basalt pipes, coat steel pipe and the cement mortar filling between the two layers, it sets the wear resistance and corrosion resistance of cast stone pipe, the toughness of the steel pipe and the consolidation of the cement mortar in one.

Silicon carbide alloy ceramic wear tube

The silicon reacts with the carbon forming more SiC which bonds the initial SiC particles.

Tubes Erosion Shields

Tubes Erosion Shields are used to reduce excess wear of boiler tubes within the extreme conditions prevalent inside a fossil fuel fired boile

In addition to straight tube shields, which go over straight sections of boiler tube, we also make shields to cover bends and special shields for finned tubes.

Snap rings are used in conjunction with Boiler Tubes Erosion Shields…


How to better packing the abrasion resistant pipe

There are probably hundreds of different methods for packing a abrasion resistant pipe and Elbows, and most of them have merit, but there are two principles that are vital for any method to work prevent rusting and Sea transportation security.

Ceramic lined elbows export to Tialand

Ceramic lined bends export to Vietnam

Ceramic Tile Lined Bend

Alumina ceramic sleeve lined pipe

Wear-resistant ceramic ring composite steel pipe

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.


The recommended Abrasion resistant pipe

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.

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


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.

Application of Abrasion resistant pipe in Dense Medium System

Serious wear and tear of the pipeline not only caused a lot of material waste and media running, running, dripping, leakage, and frequent pipeline maintenance replacement, increasing the labor intensity of workers, increased production costs.

As the medium pipeline is the transmission of high hardness, abrasive strong media suspension, the pressure of the feed cyclone into the tube, in addition to transport media suspension, but also includes coal and gangue. Therefore, compared with the slime mixed pipeline, the media pipe wear speed faster, especially the pressure pipe, such as the cyclone into the material tube, disengage sieve into the material and so on. According to the different materials and flow channels, the general life of the metal pipe material in about a few months to a year or so.

Coal preparation plant site

Many types of Abrasion resistant pipe, pipe diameter needs to be measured on-site

In recent years, wear-resistant technology and the rapid development of wear-resistant materials, Abrasion resistant pipe technology in addition to metal mines, construction, power plants and other areas of application, in the field of heavy media coal preparation has also been widely promoted, greatly improving the heavy pipe Of the service life, reducing the maintenance workload and material consumption, and promote the rapid development of heavy media coal preparation technology.

Commonly used wear-resistant media tube

Common wear-resistant pipe mainly stone pipe, ceramic wear-resistant pipe, alloy wear-resistant pipe. Cast stone is a natural rock as the main raw material, by ingredients, melting, burning, annealing made of an inorganic non-metallic materials. It has excellent wear resistance, corrosion resistance.

China’s metallurgical, thermal power, mining, chemical building materials and other departments are widely used cast stone materials. The main raw material for the production of cast stone is the broadly distributed basalt and diabase, which are basic magmatic rocks, and the chemical composition is relatively stable. Cast pipe than the alloy tube wear, tough, and has a high corrosion resistance, can be resistant to hydrofluoric acid and overheating of any acid and alkali corrosion. But the cast stone tube density is high, brittle, impatient impact, easy to break, the production process is complex, installation and maintenance is not convenient.

Ceramic wear tube is made of self-propagating high temperature synthesis centrifuge. The seamless steel pipe on the centrifuge tube mold, in the steel pipe by adding iron and aluminum powder mixture. This mixture is called aluminum heat in chemistry. Centrifuge tube mold rotation to a certain speed, the Mars ignited aluminum heat agent, aluminum heat agent immediately burn their own, burning quickly spread, and in the spread of a violent chemical reaction, aluminum heat agent after the reaction of corundum and iron, At the same time release a lot of heat, is the original material in the steel pipe and the reaction after the product, even if the melting point of 2045 ° corundum will all melt, because the reaction is very fast, only a few seconds, the molten reactant in the centrifugal force, Size to be separated. Iron is centrifugal force thrown to the inner wall of steel, Al2O3 is distributed in the inner layer of iron. As the steel pipe quickly heat and heat transfer, Al2O3 and Fe quickly reached the freezing point, and soon stratified solidification. The final formation of ceramic wear-resistant tube from the inside out, respectively, corundum ceramic layer, iron-based transition layer, and the external steel pipe layer. High temperature molten iron liquid.

And the Al2O3 liquid, contact with the inner wall of the steel pipe, so that the inner wall of the steel pipe in the semi-molten state, so that the formation of iron and steel pipe metallurgical structure, iron layer and corundum ceramic layer between the liquid formation of a strong combination of its combined strength (that is, Laminated strength)> 15MPa; ceramic wear-resistant tube crushing strength (that is, from the tube outside the tube when the strength of ceramic crushing)> 350MPa.

Ceramic tile lined pipe & fittings

Ceramic tile lined pipe and the traditional steel pipe, wear-resistant alloy cast steel pipe, cast stone pipe and steel pipe and other essential differences. Ceramic tile lined pipe is a seamless steel pipe, the inner layer is corundum, this corundum is molten state under the action of centrifugal casting. Corundum layer hardness up to HV1200 ~ 1400, it is better than the ordinary combination of corundum grinding wheel performance is much better, can be corundum grinding wheel wear off.

Ceramic tube wear resistance is mainly by the inner layer of a few millimeters thick corundum layer, which wear-resistant alloy cast steel pipe, cast stone pipe both by the composition and organization, but also by the thickness of the anti-wear has been a qualitative leap. The same specifications and unit length of the quality of Ceramic tile lined pipe only wear-resistant alloy steel pipe 1/2, cast pipe 1/3; the cost per meter project reduced by 30% to 40%; so ceramic wear pipe in addition to performance Superior, the project cost also has obvious advantages.

Ceramic tile lined pipe with good thermal shock resistance, this performance in the construction of useful. As the outer layer of steel, coupled with the inner temperature does not crack, in the construction, the flange, purge mouth

And so can be welded, can also be used direct welding method for pipe connection, which wear-resistant alloy cast stone pipe and cast stone pipe in the construction is not easy welding and welding can not be better. In case the production site due to special reasons, ceramic wear tube rupture situation, can be immediately emergency welding to ensure safe production and prevent environmental pollution. It should be noted that the thickness of the ceramic layer in the Ceramic tile lined pipe is not uniform, and it is possible to break out during the transportation, installation, tapping and bending deformation between the two stands, resulting in uneven wear during operation and affecting the use Life, and even cause short-term local steel pipe damage.


What Steel pipe is suitable for pulverized coal conveying?

There are two ways to choose pulverized coal conveying, that is, the use of pulverized coal cans dedicated trucks or the use of pipe pneumatic conveying, and pneumatic conveying a good continuity, capacity and good sealing, is the most commonly used in blast furnace pulverized coal conveying mode.

According to the difference of powder gas ratio μ, pipeline pneumatic conveying is divided into dense phase conveying (μ>40 kg/kg) and dilute phase conveying (μ=10-30 kg/kg). Dilute phase conveying is widely used in China.

Because of its extremely high hardness and scaling resistance, its resistance to wear the first pipe, than bimetal, shell nets, surfacing 6 times times, nylon, PTFE 10 times times, 15 times times as carbon steel. It is an ideal wear-resistant conveying pipe, which can save energy and prolong the service life of pipelines.

Coal industry conveying pulverized coal, mineral powder, tailings, pulp pipe for many pipes, as these media contain about 30% of iron ore, the wear of steel pipe is very strong, the General Service life of the steel pipe for six months to year. Conveying washing solid liquid mixture: coal mining and mineral processing slurry conveying pipeline has tailings pipe, concentrate pipe and so on. Coal preparation plant to transport the mixture of flotation, flotation concentrates and heavy medium suspensions, such as solid-liquid mixtures, steel pipe use 16 months wear, and the annual cost of costly maintenance.

Self-propagating technology makes the ceramic liner composite Steel pipe has a unique structure, which determines the excellent physical and mechanical properties of ceramic steel pipe, it not only abrasion resistance, corrosion resistance, high temperature, but also has high hardness, strength and good resistance to mechanical impact and thermal shock of the comprehensive performance.


Classification and designation of wear-resistant pipes for power industry

The abrasion pipe of thermal power plant is mainly conveying raw coal powder, ash slag, flue gas desulfurization (FGD) limestone powder and slurry, due to the transmission of medium velocity fast, poor operating conditions, resulting in pipelines, especially elbow, variable diameter pipe serious wear and corrosion, not only consumes a lot of metal materials, but also to the thermal power plant security, economic operation has brought hidden dangers. The abrasion mechanism of pipeline is mainly based on erosion wear.

Wear-resistant pipe can be divided into two categories: single metal pipe and composite pipe.

Power industry wear-resistant pipe variety, pipe code, use characteristics, application range and nominal diameter see the following table:

Types Wear-resistant pipe code Usage characteristics and application range DN/mm
Low alloy wear-resisting cast steel pipe
(Single metal pipe)
ZG40GrNiMoG Good abrasion resistance, high strength, poor weldability, suitable for pulverized coal and ash pipe DN100-1000
ZG45Cr2MoG Good abrasion resistance, high strength, poor weldability, suitable for pulverized coal and ash pipe
Medium Alloy wear-resisting cast steel pipe
BTMCr30G Good abrasion resistance, high strength, poor weldability, suitable for pulverized coal and ash pipe DN100-1000
ZG42Cr2Si2MnMoG Good abrasion resistance, high strength, poor weldability, suitable for pulverized coal and ash pipe

(Single metal pipe)





BTMCr30G Good abrasion resistance, corrosion resistance, high strength, can not be welded, suitable for corrosion-resistant wear pipeline DN30-1200
BTMCr26G Good abrasion resistance, low strength, no soldering, suitable for pulverized coal piping DN40-1200
BTMCr20G Good abrasion resistance, low strength, no soldering, suitable for pulverized coal piping DN100-1000
BTMCr15G Good abrasion resistance, low strength, no soldering, suitable for pulverized coal piping
BTMCr12G Good abrasion resistance, low strength, no soldering, suitable for pulverized coal piping
BTMCr8G Good abrasion resistance, low strength, no soldering, suitable for pulverized coal piping
BTMCr2G Good abrasion resistance, low strength, no soldering, suitable for pulverized coal piping
Anti-abrasion white cast iron
(Bimetal Composite Pipe)





BTMCr30-G Good erosion resistance, high strength, can be welded, suitable for limestone, gypsum, pulverized coal and ash pipe DN30-1200
BTMCr26-G Good abrasion resistance, high strength, can be welded, applicable to pulverized coal and ash pipe, used for slurry, coal slurry conveying DN40-1200
BTMCr20-G Good abrasion resistance, high strength, can be welded, applicable to pulverized coal and ash pipe, used for slurry, coal slurry conveying DN40-1000
BTMCr15-G Good abrasion resistance, high strength, can be welded, suitable for pulverized coal and ash pipe
BTMCr12-G Good abrasion resistance, high strength, can be welded, suitable for pulverized coal and ash pipe
BTMCr8-G Good abrasion resistance, high strength, can be welded, suitable for pulverized coal and ash pipe
BTMCr2-G Good abrasion resistance, high strength, can be welded, suitable for pulverized coal and ash pipe
Inner wall surfacing composite pipe
DNM-IV-G Excellent abrasion resistance, can be welded, suitable for pulverized coal and ash pipe ≥DN200
DNM-V-G Excellent abrasion resistance, can be welded, suitable for pulverized coal and ash pipe
Alumina ceramic composite lined pipe
Aluminum Thermal MethodTR-G
Ceramic Lined composite steel pipe
Wear resistance is very good, high strength, can be welded, easy installation, applicable to pulverized coal and ash pipe, hot air pipe and economizer, hot air pipe, powder conveying, the product cost-effective. DN32-1200
Paste methodTC-G Good abrasion resistance, high strength, can not be welded, suitable for pulverized coal and ash pipe, desulfurization slurry pipe and variable diameter pipe ≥DN200
Rubber composite lined Pipe XS-G Good abrasion resistance, high strength, no welding, suitable for operating temperature -40~100℃ slag pipe DN50-1200
High temperature wear-resisting liner compound pipe WM-G Good wear resistance, high strength, can be welded, suitable for working temperature less than 1800 ℃ dry powder pipe, hot air pipe ≥DN100
Cast stone composite lined pipe ZS-G Good abrasion resistance, low casting strength, high brittleness, can not be welded, applicable to pulverized coal and ash pipe, desulfurization slurry pipe ≥DN40
SIC lined composite pipe SiC-G Good abrasion resistance, can not be welded, suitable for pulverized coal and ash pipe, desulfurization slurry pipe ≤1200

Anti-abrasion effect of 8 kinds of chemical compositions in wear-resistant materials

Carbon:

High manganese steel castings wear resistance is not the higher the carbon content, the more wear-resistant, but there is a limit, when the carbon content of >1.4% after the casting of carbide, water toughness can not completely dissolve into the austenite, the gap-soluble carbide also reached saturation, so not only for the wear resistance, but also to reduce the strength and toughness of materials, It is easy to break in service.

Silicon:

High silicon content reduces the solubility of carbon in austenite, carbide precipitates on the grain boundary increase and hypertrophy, after water toughening, leaves the large microscopic loose in the grain boundary, but in order to completely eliminate, the silicon content in the steel, the control in the 0.4-0.6% best, the silicon content >0.8% has no obvious influence to the high manganese steel performance

Vanadium (Titanium):

These two elements are the natural in pig iron, in the trace alloy elements, they can form a very high hardness of carbon nitride, dispersed in the matrix, is conducive to improving the microhardness and wear resistance of the substrate, while the refinement of the grain is also beneficial. Molybdenum: The main role of molybdenum is to refine the matrix, refining carbide, improve the electrode potential of the substrate, improve corrosion resistance. Because the price is high, it is not economical. Under the condition of metal casting, a small amount can play a significant role in the wear-resisting steel balls with special requirements.

Chromium:

Chromium is a carbide forming element. Chromium in addition to the carbon combined with carbide, the rest are dissolved in the base body, so as to improve the electrode potential of the substrate, to resist corrosion is advantageous. If its content is more than an hour, may appear m3c type carbide, causes the hardness and the toughness to reduce. If its content is large, the number of carbides in crystallization increases significantly, and the toughness decreases, and the hardness of the matrix decreases, which leads to the decrease of wear resistance. But now some manufacturers have adopted special production and treatment technology to solve this problem, so that the content of chromium can reach 30%.

Manganse:

Manganese is the formation of austenite elements, the formation of carbide also works, too high manganese will make the organization appear austenite, austenitic tissue is not suitable for grinding ball, because the austenite grinding ball in both dry and wet grinding, will cause a large number of crushing and peeling, but because deoxidation and sulfur are manganese, so the content of manganese in the wear-resistant ball can not be too high.

Phosphorus:

Phosphorus dissolved in steel rarely, often in the form of fe2p,fe3p in the crystal boundary so that the strength of steel, toughness and wear resistance greatly reduced, carbon content of the high increased p in eutectic form precipitation in the grain boundary. To ensure performance, the following relationships should be followed: c%=11.27-2.761xp%. In production to control phosphorus content ≤0.08%: important, complex, thick wall parts ≤ 0.07%.

Sulfur:

Because of the high manganese content in steel, a large number of MNS can be produced from slag. And because it is smelting in alkaline slag, sulfur can be reduced to below 0.03% smoothly. The low sulfur content has no obvious influence on the strength, toughness and wear resistance of the steel.

Nickel (copper):

Nickel (copper) is an austenite forming element, with an increased presence of austenite in the tissue. The main role of adding nickel in troostite grinding ball is to improve the electrode potential of the substrate, and to improve the corrosion resistance, but it is more economical and the micro-function.