Cast basalt aggregate refers to crushed basalt stones that are used as a component in the production of cast basalt products.
Basalt is a volcanic rock that is formed from the rapid cooling of lava. It is known for its high strength, durability, and thermal resistance, making it suitable for various applications in industries like construction, transportation, and manufacturing.
In the production of cast basalt products, such as pipes, tiles, and linings, the basalt aggregate is mixed with a binding agent, usually epoxy resin or cementitious material. The mixture is then cast into a desired shape and cured to form a solid product.
Cast basalt products, reinforced with the aggregate, exhibit excellent resistance to abrasion, corrosion, and impact. They are commonly used in applications where high wear and chemical resistance are required, such as in lining chutes, hoppers, pipelines, and tanks.
Overall, cast basalt aggregate plays a crucial role in the manufacturing of cast basalt products, providing them with the desirable properties that make them suitable for heavy-duty industrial applications.
When it comes to basalt, we generally only know that it is often used to make stone aggregates, and it is an ideal aggregate raw material. But in fact, basalt can also be made into fine powder and used as a mixing material for cement. The effect is ideal, and it can also save coal consumption, which has good economic and social benefits. Guilin Hongcheng basalt vertical mill will introduce you.
Basalt is a good raw material for producing cast stone. Cast stone is a material made of basalt after melting, casting, crystallization, and annealing. It is harder and more wear-resistant than alloy steel, and stronger than lead and .
Casting as a method of basalts processing consists of melting of the aggregate in a furnace at temperatures in the range of 1400 Deg C, pouring into the mold, centrifugal casting and subsequently cooling of the castings, with relaxation of internal stress.
cast basalt aggregate 5-10mm
Usually, stones in engineering are classified according to gradation (particle size), there are two kinds, one is continuous gradation and the other is single-grain grade.
cast basalt aggregate 5-15mm
Basalt is a common mineral in the earth's crust and belongs to the nature of volcanic rock. The main components are silicon oxide, aluminum oxide, iron oxide, etc. It is usually black, and sometimes it is gray-green, dark purple, dark red, etc. The texture is relatively dense, and its specific gravity is heavier than that of granite, limestone, and shale. Basalt has high durability, many joints, is not easy to be mined in large blocks, and is rarely used as decorative stone. Porous basalt is also called pumice. When mixed into concrete, it can reduce weight, be strong and durable, and have the functions of sound insulation and heat insulation. It is a good aggregate material for lightweight concrete in high-rise buildings.
Basalt is also the best material among the stones used in the construction of roads, railways, and airport runways. It has the advantages of strong compression resistance and corrosion resistance, wear resistance, low crushing value, less draft, and poor conductivity. In addition to construction purposes, basalt is also an ideal raw material for cast stone. It can form alloy steel, which is harder and more wear-resistant than lead and rubber. It can also be used as a lubricant in an advanced steel casting process to prolong the cast film. Lifespan; it can also be drawn into glass filaments, and the basalt glass filament cloth made of it is stronger in alkali resistance and high temperature resistance than ordinary glass filament cloth. At the same time, it is also widely used in garden landscape, mainly as rockery, bonsai and so on.
In addition to the above uses, basalt has another use with good application prospects, that is, finely ground basalt into stone powder, which can be used as a mixture of cement instead of clay, which can increase cement production, shorten setting time, improve cement performance, and enhance cement flexural resistance Compressive strength, and due to the low melting point of basalt rock powder, the firing temperature can be reduced by 70~100°C during cement calcination, saving coal. The activity of basalt rock powder is equivalent to that of volcanic ash, slag, obsidian, etc. It can produce both ordinary portland cement and volcanic ash portland cement.
Basalt is a volcanic rock, a durable and hard stone. Basalt sand and stone are available in every degree.
Basalt is a type of volcanic rock formed by the cooling and solidification of molten lava that come out of the cracks of the earth's crust.
Basalts are generally dark black in color. Basalt is a hard and hard stone and it is used in ballast, gravel and sandblasting industry. It is used in basalt sandblasting industry that does not contain free silica. Basalt is a rock with a hardness of 6.5 mohs and a density of 2.77 gr / cm3, which contains 45-50% SiO2. Basalt sand is used in scraper in the range of 0.5-1.6mm, 1.0-2.0mm and 1.5-2.7mm.
Cast basalt sand is used in all phases of architectural structures in different thicknesses and sizes, in the lower and upper structures, floor and facade coatings, in city roads, pavements, terraces, aquariums, garden arrangements and as abrasives.
The Basalt Fiber Power is also named as The Basalt Grated Fiber;
It is formed by adopting the ball milling and windmill grind way after the basalt fiber been chopped, it could be used for variety of anti corrosion coatings, resin, reinforced nylon material enforcement.
The chopped basalt fiber usually chopped to 400mesh，the diameter of the fiber is between 9-18μm, the length is between 30-50μm. The highest temperature could reach to 1000℃.
The wear resistance performance of the basalt fiber powder is very nice, it is widely used in friction material, such as the brake plate, the polishing wheels, the grinding wheel, the friction plate, the wear resistant pipe, the wear resistant bearing etc.
The basalt fiber powder(the basalt fiber) is also the comprehensive optimal substitute product of the asbestos, the corrosion resistance, the wear resistance, the high temperature resistance and low temperature resistance properties are higher than asbestos, it is low poison, environmental and it is not harm to people, it do not make any pollution in production and using process.
The powder with water form paste cement which is used as an adhesive or filler.
Basalt stone is to break into pieces and then mill. At last it is made of cast basalt. It has high performance of abrasive and corrosion resistance, it can be configured to acid(base)clay. Mixing cast basalt sand and cast basalt hybrid can be made of corrosion-resistant concrete. It has good wear resistance and high mechanical strength. Based on customers' need, casting basalt powders can produce various types of clay, such as sodium sillicate clay, central chloride resin clay, furan resin and so on. Cast powder commonly used atandard 80MESH-500MESH.
|
Cast Basalt Pipe DN （mm） |
Standard Steel Pipe OD （mm） |
Cast Basalt Thickness （mm） |
Length |
| 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.
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.
Cast basalt can be used for the lining of pipework, chutes, bunkers, cyclones, and hoppers. It has become the global standard in areas such as ash slurry pipework, often used at fossil-fuel power stations. It is an all-round cost-effective and adaptable lining material that extends the life of equipment in pipe or tile form where affected by erosion.
Cast basalt is well-proven in a variety of industries as a cost-effective, long-lasting lining material used to extend the operating life of equipment manufactured or lined with lower-wearing materials such as steel, cast iron, rubber, and polyurethane.
Cast basalt lined steel pipe, as both a wear—resistant and corrosion—resistant materials, the transport properties of wear or corrosion of materials, after thirty years of practical verification, cast basalt lined steel pipe can be well done.
Cast basalt is also used in cement plants for making air separators, chain conveyor, silica hoppers, nozzles, coal hoppers, cement hoppers, cyclones, raw mill ducts, chutes, thick slurry lines, mixers, grate cooler housing, coal ventury etc.
Cast basalt composite pipes used for years
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 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.
Shipping packing
Wear-resistant cast basalt slabs
Cast basalt composite pipeline for ash discharge port of power plant
Cast basalt tiles are packed in wooden cases
Cast basalt tiles are delivered to sea port
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 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
Refining basalt to a finely crystallised glass ceramic, SunnySteel’s cast basalt wear resistant material provides an extremely durable, long-lasting lining for static plants bearing large volumes of abrasive and/or corrosive matter.
Supplied as both a pipe and tile lining solution, cast basalt is ideally suited for wet material handling applications with lower impacts, such as coal chutes, ash sluiceways, ash pipelines at power stations and hydraulic granulated slag or sand conveying. Basalt delivers high resistance to wear corrosion and temperatures up to approximately 400 °C.
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.
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.
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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.
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
Ceramic lined pipe is made through self-propagating high-temperature synthesis (SHS) technique.
Cast basalt lined steel pipe is composed by lined with cast basalt pipe, outside steel pipe and cement mortar filling between the two layers.
Ceramic tile lined pipes have very uniform coating of specially formulated ceramic material that is affixed to the inner of the pipe.
The material of the rare earth alloy wear-resistant pipe is ZG40CrMnMoNiSiRe, which is also the grade of rare earth alloy steel.
Tubes Erosion Shields are used to protect boiler tubing from the highly erosive effects of high temperatures and pressures thereby greatly extending tube life.
The ASTM A213 T91 seamless tubes are primarily used for boiler, superheater, and heat-exchanger.
