Cast basalt composite elbow is a type of piping component used in industrial applications where highly abrasive or corrosive materials are being transported.
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A cast basalt composite elbow is a type of pipe fitting used in high-abrasion applications. It is made by casting basalt rock into the shape of an elbow and then binding it with a composite material. This process produces a high-strength, wear-resistant material that is ideal for handling abrasive materials like sand, gravel, and mining slurries.
Cast basalt composite elbows are commonly used in mining and mineral processing, where the abrasiveness of the materials being handled can cause regular pipe fittings to wear out quickly. They are also used in power generation, chemical processing, and other heavy industries where abrasion resistance is a concern.
The benefits of cast basalt composite elbows include their durability, resistance to wear and erosion, resistance to chemical attack, and their ability to handle high temperatures. They can also be customized to fit specific pipe sizes and angles, making them a versatile option for many different applications.
Cast basalt composite elbow is made by molding layers of cast basalt around a steel pipe elbow, creating a composite structure that combines the toughness and wear resistance of cast basalt with the strength and flexibility of steel.
The cast basalt layer of the composite elbow provides excellent abrasion and corrosion resistance, reducing the need for frequent maintenance and replacement. The steel core provides support and structural integrity, enabling the elbow to withstand high pressure and mechanical stress. The combination of these materials results in a piping component that is both durable and versatile, making it an ideal choice for a range of industrial applications.
Some of the benefits of cast basalt composite elbows include improved process efficiency, reduced downtime and maintenance costs, and increased safety and reliability. They can be used in industries such as mining, power generation, chemical processing, and more, and are often employed in areas of high wear and tear, such as bends and transitions in pipelines.
In summary, cast basalt composite elbow is a piping component designed to provide excellent resistance to abrasion and corrosion while maintaining structural integrity under high stress conditions. Its unique construction enables it to withstand the toughest industrial environments and provide reliable, long-lasting performance.
|
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 pipe can be divided into straight pipe, elbow, three-way (four-way) pipe and variable diameter pipe, etc.
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 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.
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 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
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.
