What is cast basalt pipe?

Cast basalt pipe is a type of pipe made from basalt rock using a casting process. Basalt is a volcanic rock that is formed from the solidification of lava. Cast basalt pipe is manufactured by melting raw basalt at high temperatures and then pouring it into a mold to take the shape of a pipe.

The resulting cast basalt pipe has excellent properties such as high hardness, resistance to abrasion, and good heat resistance. It is known for its exceptional wear and corrosion resistance, making it suitable for various applications where the pipe needs to withstand harsh conditions. Cast basalt pipe is commonly used in industries such as mining, steel making, power generation, and chemical processing, where it is used to transport abrasive materials, corrosive fluids, and hot gases or liquids.

After selective quarrying, the volcanic rock is melted at a temperature of around 1500ºC and cast into molds or spun into cylinders. The castings so produced are then subjected to heat treatment cycles in special kilns to produce re-crystallized basalt. The product thus produced inherits inertness of parent material. Its micro crystalline, non-porous texture being denser and more homogenous than raw basalt, acquires exceptionally high abrasion resistance.

Technical details

• 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 a perpendicular angle is low like all other ceramics, but it can be increased with proper installation by reducing the angle of impact. Cast Basalt can be used to mitigate sliding abrasion. 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 approximately 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 450ºC.
• Life: Life of basalt-lined pipe is estimated to be 7 to 10 times that of Cast Iron, and 3 to 4 times that of Ni-hard Steel.

Application area

1. Thermal Power Stations: Raw Coal Chutes/ Hoppers, Feed Bunker/Coal Bunker, Ash Pits, Crushers, Bottom Ash, Disposal Slurry, Dust Lines/ Bends, Pipeline/Bends, Fly Ash. Trenches below Hopper and pipelines, Pulverized Coal Piping
2. Cement Plants: Dynamic Air Separators, Raw Mill Ducts/ Chutes, Drag Chain Conveyor, Grate Cooler Housing, Air Separator/ Cyclones, Coal Handling, Coal Hopper/ Chutes, Cement Conveying, Slurry Lines/ Bends Lines/ Bends, Discharge Boxes / Bankers, Lime/Silica Hoppers/Chutes, Chain Conveyor Housing, Mixers/Nozzles, Coal Venturi, etc. 
3. Steel plants: Coke sorting unit, Coal bunkers / sinter bunkers, Lime bunkers, Coke breeze, Sinter plant cyclones, Sinter plant flow conveyors, Iron slurry line, Thick slurry lines, Air lift pipes, Telescopic pipes, Granulated slag, Hot mill flume, etc.
4. Coal Washery: Coal Washing Plants, Coal Transportation, Conveyor Chutes/Pipes, Floatation Cells, Media Sumps, Centrifuges, Cyclones, Sieves,etc.

What size is a cast basalt pipe?

Straight pipe lengths come in diameters from 50mm to 700mm, and 500mm in length. It is also possible to line lobster back bends with bend diameters ranging from 50mm to 700mm. The thickness of the basalt depends on the diameter. It ranges from 20mm to 25mm.

What is basalt lining?

Cast basalt lining is a wear resistant solution that is based on minerals. It handles and processes the components that convey abrasive elements. The cast basalt liners and tiles are manufactured by melting volcanic rocks. They are then casted in the form of different shapes including cylinders and tiles.