Abrasion resistant piping systems are widely used at coal-fired power plants for a variety of purposes, including the conveyance of coal ash slurry to nearby settling ponds, the transfer of limestone slurry to absorber spray towers for removal of sulfur dioxide (SO2) and hydrogen chloride (HCl) from flue gases and for transporting away the calcium sulfate by-product of the flue gas desulfurization process.
Ceramic lined pipe
Ceramic lined pipe is made through self-propagating high-temperature synthesis (SHS) technique.
Ceramic Tile Lined Pipes
Ceramic Tile Lined Pipes have very uniform coating of specially formulated ceramic material that is affixed to the inner of the pipe and gives a very smooth surface.
Ceramic sleeve lined Pipe
The ceramic tube or ceramic sleeve sintered as a whole part, and then assemble it into the steel pipe with our high-strength-temperature-resistant epoxy adhesive.
Concrete Pump Pipe
The Concrete Pump Pipe is made of special quality steel which is quenched and carried out carburizing chemical treatment on the inner wall.
Bimetal Clad Pipe
Bimetal Clad Pipe is cast with mold vanishing vacuum suction casting cladding process.
Rare earth metal wear resistant pipe
Rare earth metal wear resistant pipe and Bend are cast with mold vanishing vacuum suction casting cladding process.
Cast basalt lined steel pipe
Cast basalt lined steel pipe is composed by lined with cast basalt pipe, outside steel pipe and cement mortar filling between the two layers.
Ultra high molecular weight polyethylene pipe
Ultra-high molecular weight polyethylene (UHMW-PE) is a new kind of engineering thermoplastics with more than 3 million viscosity-average molecular weight.
Silicon carbide alloy ceramic wear tube
Reaction bonded SiC is made by infiltrating compacts made of mixtures of SiC and carbon with liquid silicon.
Tubes Erosion Shields
Boiler Tubes Erosion Shields are used to reduce excess wear of boiler tubes within the extreme conditions prevalent inside a fossil fuel fired boiler, Sunny Steel is able to manufacture and supply erosion shield solutions to protect and reduce wear in all applicable boiler related situations.
- Outside of bend
- Inside of bend
- Side of bend
- Finned tube shields
The recommended Abrasion resistant pipe
After Analyses and research, it was thought that the main facts which affect drilling pipe abrasion resistant ring failure were abrasive property of formations, selection of high-abrasive material, and wielding technique.
Please view the recommended Abrasion resistant pipe, bend, elbow, tee, reducers as below:
Abrasion Resistant Pipe Solutions
Conveying highly abrasive materials, steel piping systems are under constant attack often over long distances. To combat abrasion and keep piping systems in service as long as possible, the industry solution has been to install abrasion resistant (AR) pipe much harder on the Brinnell Scale than standard steel pipe. The harder the inner wall, studies have shown, the better it resists gouging or plowing action of abrasive sliding particle flow.
Unfortunately, this type of abrasion is only one type of wear experienced within the piping system. Impact abrasion, where a slurry meets the inner pipe wall at closer to 90° such as at the bends, elbows, laterals or tees in the system, has a decidedly unwelcome effect on the inner wall of the pipe.
At sharper angles, abrasive material actively “chips” away at a more brittle inner wall, eroding the surface from the inside out. So predominant is the problem that frequent replacement, repair, and the associated maintenance expenses at the bends, elbows, laterals and tees in the system are accepted as the norm.
“When you have a sharp impingement angle, the abrasive material in the slurry can chip away at a brittle inner pipe wall,” said SumXu, chief engineer, Pipe. “On the other hand, a more ductile inner wall deforms on impact and is better suited to withstand impact abrasion over time.”
So, the solution would appear straightforward. For sliding abrasion, an extremely hard interior pipe wall for the straight lengths of pipe and a more ductile inner wall at the directional transitions? Not so fast. Turns out size transitions and directional changes can experience both abrasive and impact wear.
According to SumXu, the variety of considerations that need to be addressed when it comes to abrasive wear illustrates the difference between simply ordering a piece of pipe and the broader field of piping system design.
“Designing a piping system is really a balancing act and each system is different,” SumXu said. “In some cases, if the abrasive material is softer than the steel used for the bends and it’s not moving very quickly, even an impact situation will not wear away the pipe. If the abrasive material is very hard or being conveyed at a higher velocity, alternative solutions at the directional transitions are required.”
According to SumXu, solutions include induction hardened pipe bends, installing wear tiles and inserts, lining the bend with various abrasion resistant materials and designing in longer radius bends when possible.
Induction Hardening of the Bends
Strength and wear resistance can be improved by the addition of alloying elements to the steel during the pipe manufacturing process. This material is commonly referred to as AR200 (abrasion resistant) piping.
Strength and wear resistance can also be increased with secondary processing of the steel, including heat treating by induction hardening. Induction hardened pipe can last up to three to eight times longer than mild steel, with only a moderate price increase.
Several years ago, SumXu’s company released its Ultra 600 series induction hardened pipe, a unique single wall pipe with a 250 Brinnell hardness number (BHN) ductile outer surface that tapers to a 600 BHN inner wall surface.
The process begins with a steel pipe manufactured to a proprietary chemistry developed by , followed by induction heating, and finally water quenching of the inner surface to create the single wall pipe.
At 600 BHN the inner wall of the pipe can withstand the sliding abrasion of most common mining slurries, while its more ductile outer surface behaves like mild steel and can be cut and welded with proper procedure in the field, configured into a variety of fittings, and can accept the standard end options of flanges, weld rings and couplings.
Using this proprietary process, can create pipe in various diameters up to 40 inches in varying lengths and wall thickness. The same technology is used to create the bends, elbows, laterals and tees with the same hardness profile.
Based on the premise that when two objects meet the harder object wins out, induction hardened pipe for both straight lengths and directional transitions is often sufficient for slurries of “softer” material such as coal and limestone. In some cases, mild steel pipe with induction hardened bends may work as well.
Increasing the Radius of the Bends
Another legitimate technique to mitigate the effects of impact abrasion is using induction hardened pipe in long radius bends. “If there is enough room, you can design the bend with an impingement angle of less than 15°, which is a small enough angle that you no longer have impact abrasion but essentially sliding abrasion,” SumXu said. “With a large enough bend, for all intents and purposes you have made it a straight pipe.”
Because is able to induction harden the pipe during the bending process, they can vary the arc rad
Application of Abrasion resistant pipe in Dense Medium System
Serious wear and tear of the pipeline not only caused a lot of material waste and media running, running, dripping, leakage, and frequent pipeline maintenance replacement, increasing the labor intensity of workers, increased production costs.
As the medium pipeline is the transmission of high hardness, abrasive strong media suspension, the pressure of the feed cyclone into the tube, in addition to transport media suspension, but also includes coal and gangue. Therefore, compared with the slime mixed pipeline, the media pipe wear speed faster, especially the pressure pipe, such as the cyclone into the material tube, disengage sieve into the material and so on. According to the different materials and flow channels, the general life of the metal pipe material in about a few months to a year or so.
Coal preparation plant site
Many types of Abrasion resistant pipe, pipe diameter needs to be measured on-site
In recent years, wear-resistant technology and the rapid development of wear-resistant materials, Abrasion resistant pipe technology in addition to metal mines, construction, power plants and other areas of application, in the field of heavy media coal preparation has also been widely promoted, greatly improving the heavy pipe Of the service life, reducing the maintenance workload and material consumption, and promote the rapid development of heavy media coal preparation technology.
Commonly used wear-resistant media tube
Common wear-resistant pipe mainly stone pipe, ceramic wear-resistant pipe, alloy wear-resistant pipe. Cast stone is a natural rock as the main raw material, by ingredients, melting, burning, annealing made of an inorganic non-metallic materials. It has excellent wear resistance, corrosion resistance.
China's metallurgical, thermal power, mining, chemical building materials and other departments are widely used cast stone materials. The main raw material for the production of cast stone is the broadly distributed basalt and diabase, which are basic magmatic rocks, and the chemical composition is relatively stable. Cast pipe than the alloy tube wear, tough, and has a high corrosion resistance, can be resistant to hydrofluoric acid and overheating of any acid and alkali corrosion. But the cast stone tube density is high, brittle, impatient impact, easy to break, the production process is complex, installation and maintenance is not convenient.
Ceramic wear tube is made of self-propagating high temperature synthesis centrifuge. The seamless steel pipe on the centrifuge tube mold, in the steel pipe by adding iron and aluminum powder mixture. This mixture is called aluminum heat in chemistry. Centrifuge tube mold rotation to a certain speed, the Mars ignited aluminum heat agent, aluminum heat agent immediately burn their own, burning quickly spread, and in the spread of a violent chemical reaction, aluminum heat agent after the reaction of corundum and iron, At the same time release a lot of heat, is the original material in the steel pipe and the reaction after the product, even if the melting point of 2045 ° corundum will all melt, because the reaction is very fast, only a few seconds, the molten reactant in the centrifugal force, Size to be separated. Iron is centrifugal force thrown to the inner wall of steel, Al2O3 is distributed in the inner layer of iron. As the steel pipe quickly heat and heat transfer, Al2O3 and Fe quickly reached the freezing point, and soon stratified solidification. The final formation of ceramic wear-resistant tube from the inside out, respectively, corundum ceramic layer, iron-based transition layer, and the external steel pipe layer. High temperature molten iron liquid.
And the Al2O3 liquid, contact with the inner wall of the steel pipe, so that the inner wall of the steel pipe in the semi-molten state, so that the formation of iron and steel pipe metallurgical structure, iron layer and corundum ceramic layer between the liquid formation of a strong combination of its combined strength (that is, Laminated strength)> 15MPa; ceramic wear-resistant tube crushing strength (that is, from the tube outside the tube when the strength of ceramic crushing)> 350MPa.
Ceramic tile lined pipe & fittings
Ceramic tile lined pipe and the traditional steel pipe, wear-resistant alloy cast steel pipe, cast stone pipe and steel pipe and other essential differences. Ceramic tile lined pipe is a seamless steel pipe, the inner layer is corundum, this corundum is molten state under the action of centrifugal casting. Corundum layer hardness up to HV1200 ~ 1400, it is better than the ordinary combination of corundum grinding wheel performance is much better, can be corundum grinding wheel wear off.
Ceramic tube wear resistance is mainly by the inner layer of a few millimeters thick corundum layer, which wear-resistant alloy cast steel pipe, cast stone pipe both by the composition and organization, but also by the thickness of the anti-wear has been a qualitative leap. The same specifications and unit length of the quality of Ceramic tile lined pipe only wear-resistant alloy steel pipe 1/2, cast pipe 1/3; the cost per meter project reduced by 30% to 40%; so ceramic wear pipe in addition to performance Superior, the project cost also has obvious advantages.
Ceramic tile lined pipe with good thermal shock resistance, this performance in the construction of useful. As the outer layer of steel, coupled with the inner temperature does not crack, in the construction, the flange, purge mouth
And so can be welded, can also be used direct welding method for pipe connection, which wear-resistant alloy cast stone pipe and cast stone pipe in the construction is not easy welding and welding can not be better. In case the production site due to special reasons, ceramic wear tube rupture situation, can be immediately emergency welding to ensure safe production and prevent environmental pollution. It should be noted that the thickness of the ceramic layer in the Ceramic tile lined pipe is not uniform, and it is possible to break out during the transportation, installation, tapping and bending deformation between the two stands, resulting in uneven wear during operation and affecting the use Life, and even cause short-term local steel pipe damage.
Use and maintenance of Abrasion resistant pipe
First of all, in addition to alloy tube, the current commonly used wear-resistant pipe is to rely on a layer of composite wear-resistant materials to improve the life of the pipeline. No matter what the process, wear-resistant layer and the grass-roots bonding strength and then large, is also a combination of heterogeneous materials, can not achieve a seamless. So the installation, especially the welding process requirements are high.
Second, although the hardness of the composite layer is large, but often very brittle, especially ceramic wear-resistant tube, ceramic layer of the impact resistance is relatively poor. Therefore, in the transport, installation, maintenance process should be strictly prohibited to fall, knock, hit, to avoid the composite layer and the base of the separation. For the composite wear-resistant pipe, if the wear-resistant layer after damage, its wear resistance is lost. For example, in the production of blocking, the use of beat the way to clear the block. On the ordinary pipe can be, but by the wear-resistant layer of the pipeline should be strictly prohibited.
In the pipeline installation process, often due to improper welding lead to wear parts of the wear-resistant layer is more or less destroyed, the general impact of the range of about 2 ~ 5mm in the weld, and even may be part of the shedding, resulting in the resistance of the region Grinding down. Therefore, part of the coal preparation plant in the new plant design, often according to the pipeline design drawings, directly to the manufacturer customization, especially the elbow, tee, elbow, distribution and so on. This puts a higher demand on the design of the medium pipe. There are some plants to take into account the design and construction level, often in the first use of the processing can be better general pipeline, after the normal operation of the system, and the system pipeline after the measured, according to the test drawings to the pipeline manufacturer custom wear pipe.
When necessary to be replaced. Old factory transformation can also be used this approach.
Abrasion Resistant Pipe FAQs:
Because the outer surface behaves like mild steel, the product can be cut and welded with proper procedure in the field, configured into a variety of fittings, and can accept the standard end options of flanges, weld rings and couplings.
Warranty
We are Quality Department tests and ensures all of our products are 100% inspected unreported. To an offer we customers additional corps of mind, all our products carry a 24-month warranty against defects or faulty workmanship.We fluid-flow products such as pipe and fittings, chokes, orifice plates, etc, carry a warranty against, erosion, defects, and/or faulty workmanship.
The warranty is determined to each creator and the maximum duration maximally in service. Should any of the RS fail within the warranty period, We'll replace or repair the defective product (s) at No. end user. Please contact the Sunny steel for details on the How to obtain a warranty for our products.
Inspections
As part of our quality regimen, 100% of incoming raw materials, semi-finished products, as well as finished products are thoroughly inspected prior to being entered into our inventory.
We have established multiple hold points throughout fabrication as well as a comprehensive final inspection for all products.
Abrasion Resistant Pipe Solutions
Conveying highly abrasive materials, steel piping systems are under constant attack often over long distances.
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