Cast basalt is a mineral material which, thanks to its special characteristics, is superbly suitable as wear protection.
Cast basalt offers the following advantages
Manufacture and properties
Cast basalt is produced by melting selected natural basalt – broken into sizes of 20–50 mm – in shaft furnaces at temperatures around 1,300°C, followed by casting into the desired moulds. Of fundamental importance is the subsequent tempering process, in which the molten basalt forms, uniform, spherulitic crystals that contribute to its physical properties such as extreme hardness and abrasion resistance.
Product range and formats
Cast basalt wear parts are produced as:
Monolithic straight cylinders are available up to a diameter of 700 mm with wall thicknesses ranging from 20 to 30 mm and a standard length of 500 mm.
Areas of application
Cast basalt is the most frequently used wear protection material. The main areas of application are the wear resistant linings for:
Bunkers, silos, tanks
The walls and outlets of bunkers, silos, and other tanks used for the storage of bulk materials are subject to strong abrasive wear. Strong friction, wear occurs when emptying is compounded by impact wear during the filling process.
A wear resistant lining with hexagonal or rectangular cast basalt tiles has proven to be a successful and economical solution. Special form pieces are manufactured for the flutes and the bunker saddles. Circular bunkers and silos are lined with radial, rectangular, or hexagonal form pieces that precisely match the required circumference.
To improve adhesion, corrugated wire mesh is spot-welded to the vertical steel walls.
Cyclones, separators, and classifiers
Screening, separating, grading, classifying – increased abrasive wear is frequently encountered during these processes. Cast basalt linings are often a standard component.
The transport of abrasive media, in fact of virtually all granular materials, in enclosed pipelines has the advantage that it is non-polluting, generates neither dust nor smell, and even saves valuable space. Completely lined pipes can be manufactured with the following maximum lengths:
Cast basalt lined piping is extremely wear resistant and is used wherever highly abrasive materials are conveyed pneumatically or hydraulically, for example:
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.
