Basalt cast stone tube is produced from basalt, through crushing, melting, centrifugal casting, annealing and quality control.
Wear and corrosion resistance, acid and alkali resistance, with small resistance coefficient and water absorption close to zero. Widely used in mines, thermal power plants, coal mines, steel mills and other material delivery pipeline, cost-effective, service life can be extended.
This greatly improves the products adaptive capacity of 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.
Basalt cast stone tube is produced from basalt, through crushing, melting, centrifugal casting, annealing and quality control. Wear and corrosion resistance, acid and alkali resistance, with small resistance coefficient and water absorption close to zero. Widely used in mines, thermal power plants, coal mines, steel mills and other material delivery pipeline, cost-effective, service life can be extended.
Cast Basalt Lining Systems from Sunny Steel are designed and manufactured to industry standards using high grade materials and construction techniques.
The fused cast basalt is one of the most frequently used wear protection materials. Cast basalt cylinder has the characteristics of low water absorption, high compressive strength and good wear resistance. Cast basalt cylinder is characterized by excellent resistance to almost all acids and alkali. It is widely used in pneumatic and hydraulic pipeline systems, chain conveyor systems, wet chain conveyors, chutes, hoppers, transport channels, feeder conveyors, separators, cyclones etc.
Our factory can produce cast basalt pipe of nominal diameter φ40mm ~ φ800mm, which φ600mm above the large-diameter, 1000mm length tube is the exclusive production of cast basalt pipes.
Adopt centrifugal casting manufacturing casts basalt pipe reducer. Molten lava in the vacuum state is poured into the high-speed rotation the centrifuge. In fixed standard time to exit the centrifuge into the annealing furnace. Cast basalt pipes have an excellent performance of high abrasive and high corrosion resistance. Often in the form of cast basalt pipe reducer appeared in various operating conditions the pump outlet location.
As hydraulic or pneumatic conveying worn or corrosive wear resistance, corrosion resistant lining material pipe can effectively protect the pipe prolong the service life of pipelines.
The whole production process of cast basalt wear resistant materials are completely finished under the monitoring of internal control procedures for the safe and orderly.
Our factory can produce cast basalt pipe of nominal diameter φ40mm ~ φ800mm, which φ600mm above the large-diameter, 1000mm length tube is the exclusive production of cast basalt pipes.
Adopt centrifugal casting manufacturing cast basalt pipe reducer. Molten lava in the vacuum state is poured into the high-speed rotation the centrifuge. In fixed standard time to exit the centrifuge into the annealing furnace. Cast basalt pipes have an excellent performance of high abrasive and high corrosion resistance. Often in the form of cast basalt pipe reducer appeared in various operating conditions the pump outlet location.
As hydraulic or pneumatic conveying worn or corrosive wear resistance, corrosion resistant lining material pipe can effectively protect the pipe prolong the service life of pipelines.
The whole production process of cast basalt wear resistant materials are completely finished under the monitoring of internal control procedures for the safe and orderly.
Cast basalt pipe can be divided into straight pipe, elbow, three-way (four-way) pipe and variable diameter pipe, etc.
Basalt is substantially more erosion-resistant than iron or steel.
In fact, over time, as the pipe experiences more friction from the media being transported, the coefficient of friction increases—creating even more beneficial flow outcomes.
Basalt-lined pipes are perfect for many applications including slurry lines for all mineral processing and hydraulic conveying. They’re commonly used for fine material conveying.
Cast basalt is an all-round cost-effective and adaptable lining material that extends the life of equipment.
As the wear surface, the cast basalt ceramic is 8 Mohs hardness, whose wear resistance is 10 times that of hi-chrome cast iron alloy pipes. It can make little wear loss of the pipe during running, which extend the service life of the equipment largely.
-50-350 ℃ is ideal temperature for the cast basalt ceramic lined pipe, and the inner wall of the pipe is cast basalt plates or tubes which have unique chemical properties of wonderful acid and alkali resistance.
The density is 3.63g/cm³, which is only half of the steel to reduce the load of equipment largely.
Welding, flange, flexible joint are available for fix with the equipment.
All the performance of Anti-wear cast stone lined steel pipe / cast basalt lining composite tube makes low project costs, the charges can be about 20-30% less than wear steel piping project.
Full range of Anti-wear cast stone lined steel pipe / cast basalt lining composite tube including straight pipes, bends, elbows, tees,Y-pieces, reducers,crosses and etc can be available from our factory.
Regarding the connection ways, we can provide with the normal way of welding or flange or to customize according to the customer’s requirements.
| 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.
| SiO2 | Al2O2 | Fe2O3 | TiO2 | CaO | MgO | K2O | Na2O | FeO | P2O5 |
|---|---|---|---|---|---|---|---|---|---|
| 43.13-41.12 | 12.5-13.52 | 8.64-9.5 | 2.02-2.62 | 9.05-10.22 | 8.65-10.47 | 1.4-1.75 | 4.62-5.28 | 4.82-6.25 | 1.1-1.38 |
| Category | Attribute |
|---|---|
| Density | 3g/cm3 |
| Compressive Strength | ≥ 450MPa |
| Bending strength | ≥ 60MPa |
| Impact strength | 1.76KJ/M2 |
| Abrasive strength | 0.07g/cm2 |
| Vickers scale | ≥ 720kg/mm |
| Elasticity modulus | 1.67x105MPa |
| Dilatation coefficient (60℃) | 8.92x10-6 |
| Chemical Attack Resistance | |
| 95%-98% H2SO4 | ≥ 98% |
| 20%H2S4 | ≥ 94% |
| 20 %NaOH | ≥ 98% |
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 |
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.
The bend radius should be minimum 3 times of the nominal bore. At discharge end of each bend, cast basalt lined straight pipe of length 5 to 12 times the nominal bore must be used.
Cast basalt pipe can be divided into straight pipe, elbow, three-way (four-way) pipe and variable diameter pipe, etc.
Cast basalt lined pipes exhibit exceptional wear resistance due to several key characteristics:
Cast basalt lined pipes are engineered with a well-thought-out structure. The internal arrangement consists of interlaced pyroxene spheres or feather-like crystallites of 0.05-0.1 mm, enhancing the material's hardness and wear resistance.
These pipes have low water absorption, contributing to their resistance against the deteriorating effects of moisture.
Cast basalt pipes possess high compressive strength, enabling them to endure heavy loads and pressures without deformation.
With the exception of hot phosphoric acid, hydrofluoric acid, and dissolved alkali above 30? cast basalt exhibits excellent corrosion resistance to a wide range of substances, including inorganic acids, organic acids, alkalis, salts, water, and organic solvents.
The material's Mohs hardness reaches 7-8, indicating a high level of hardness that directly correlates with superior wear resistance. Harder materials generally exhibit better resistance to wear and abrasion.
The combination of silicon and oxygen atoms in the silicate mineral structure is bound by strong forces at the atomic and molecular levels, contributing to the overall strength of the material.
While individual cast basalt lined pipes demonstrate good wear resistance in applications like blast furnace tanks, it's important to note the inherent brittleness of ceramic materials. This brittleness may result in breakage during heavy impacts. Additionally, single-piece pasting construction may exhibit signs of aging over extended periods. However, when properly applied and maintained, cast basalt lined pipes remain a popular choice for wear-resistant applications due to their durability and performance.
Cast blast lined pipe and fittings can connect with flange, quick assembly joints and welding.
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.
Beveled ends allow for proper alignment and penetration during welding, ensuring a strong and effective joint. This preparation is commonly used in various industries, especially in piping systems where welded connections are prevalent.
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.
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 basalt is a highly wear-resistant and corrosion-resistant lining material widely used in pipes, chutes, bunkers, cyclones, and hoppers.
Usage
Installation
Cast basalt has become the global standard for ash slurry pipelines in fossil-fuel power stations and other heavy industries. It significantly extends equipment service life in environments with severe abrasion and corrosion.
It is commonly used as a cost-effective lining material for steel, cast iron, rubber, or polyurethane equipment, offering 5–10 times longer service life than traditional materials.
