Cast basalt composite pipes represent a revolutionary advancement in industrial pipeline technology, specifically engineered to meet the demanding requirements of modern power generation facilities. These innovative pipeline solutions combine the natural durability of volcanic basalt with advanced composite engineering to deliver unparalleled performance in the most challenging operational environments.

The foundation of cast basalt composite pipe technology lies in the unique properties of basalt itself, a volcanic rock that has been transformed through controlled melting and casting processes into an exceptionally hard and durable material. When integrated into composite pipe structures, this material creates pipeline systems that demonstrate remarkable resistance to the abrasive and corrosive conditions commonly encountered in power plant operations.

Power generation facilities face numerous challenges in their material handling systems, particularly when dealing with abrasive media such as bottom ash, fly ash, coal dust, pyrite, and flue gas desulfurization (FGD) slurry. Traditional steel piping systems often suffer from rapid wear and frequent replacement requirements, leading to increased maintenance costs and operational downtime. Cast basalt composite pipes address these challenges by providing wear resistance that is typically 5 to 10 times greater than conventional steel alternatives.

The manufacturing process of cast basalt composite pipes involves the precise fusion of basalt at temperatures exceeding 1400°C, followed by controlled cooling and shaping into pipe sections. This process creates a material with exceptional hardness, typically measuring 8-9 on the Mohs scale, while maintaining the structural integrity necessary for high-pressure pipeline applications. The resulting composite structure combines the wear resistance of cast basalt with the structural strength of steel backing, creating an optimal balance of performance characteristics.

One of the most significant advantages of cast basalt composite pipes in power plant applications is their exceptional resistance to chemical corrosion. These pipes can withstand exposure to virtually all acids and alkalis, with the notable exceptions of hydrofluoric acid and hot phosphoric acid. This chemical resistance is particularly valuable in power plant environments where various chemical processes and treatments are employed, including water treatment systems, emission control processes, and fuel handling operations.

Temperature resistance represents another critical performance characteristic of cast basalt composite pipes. These systems can operate effectively at temperatures up to 300°C while maintaining their structural integrity and wear resistance properties. Additionally, they demonstrate excellent thermal shock resistance, capable of withstanding temperature variations of at least 150°C without compromising performance. This thermal stability makes them ideal for applications involving hot ash handling, steam systems, and other high-temperature processes common in power generation facilities.

The smooth surface characteristics of cast basalt composite pipes provide significant operational advantages in material handling applications. Unlike traditional steel pipes that may develop rough surfaces due to wear and corrosion, cast basalt pipes maintain their smooth interior finish throughout their operational life. This smoothness reduces friction losses, minimizes the risk of material buildup and blockages, and ensures consistent flow characteristics even when handling sticky or moisture-laden materials.

Installation and maintenance considerations for cast basalt composite pipes have been carefully engineered to minimize operational disruption. These pipes are available in various connection methods, including flanged connections, grooved connections, and welding connections, allowing for seamless integration into existing pipeline systems. The lightweight nature of the composite construction, despite its exceptional durability, facilitates easier handling and installation compared to solid cast iron or steel alternatives.

The environmental benefits of cast basalt composite pipes align with the increasing focus on sustainable industrial practices. The production process generates minimal waste, and the materials used are largely recyclable. The extended service life of these pipes reduces the frequency of replacement, thereby minimizing the environmental impact associated with manufacturing and disposal of pipeline components.

Size specifications for cast basalt composite pipes are designed to accommodate a wide range of power plant applications. Standard sizes range from DN15 to DN400, following established standards such as GB/T 28897-2012. Custom sizes and configurations can be manufactured to meet specific project requirements, with larger diameter pipes available for major material handling systems. Typical wall thicknesses range from 17.5mm to 30mm, depending on the pipe diameter and application requirements.

The economic advantages of implementing cast basalt composite pipes in power plant operations extend beyond the initial material cost considerations. While the upfront investment may be higher than conventional steel piping, the extended service life, reduced maintenance requirements, and decreased downtime result in significant long-term cost savings. Comparative studies have shown that cast basalt pipes can provide service lives of 60-120 months compared to 3-8 months for conventional steel pipes in similar abrasive applications.

Quality assurance and testing protocols for cast basalt composite pipes ensure consistent performance and reliability. Each pipe section undergoes rigorous testing for dimensional accuracy, material composition, and performance characteristics. Testing includes abrasion resistance measurements, thermal cycling tests, pressure testing, and chemical resistance verification to ensure compliance with industry standards and customer specifications.

The versatility of cast basalt composite pipes extends beyond traditional ash handling applications in power plants. These pipes are equally effective in coal handling systems, limestone processing, gypsum handling, and various chemical processing applications within power generation facilities. Their ability to handle both pneumatic and hydraulic conveying systems makes them suitable for a wide range of material transport requirements.

Future developments in cast basalt composite pipe technology continue to focus on enhanced performance characteristics and expanded application possibilities. Research and development efforts are exploring advanced composite formulations, improved connection systems, and specialized coatings to further extend service life and performance capabilities in increasingly demanding applications.

The selection of cast basalt composite pipes for power plant applications represents a strategic investment in operational efficiency, environmental responsibility, and long-term cost effectiveness. As power generation facilities continue to face increasing demands for reliability, efficiency, and environmental compliance, these advanced pipeline solutions provide the performance characteristics necessary to meet these challenges while delivering exceptional value throughout their extended service life.

Main Specification Of Cast Basalt Lined Pipe and Fittings
Cast Basalt Pipe DN (mm)	Standard Steel Pipe OD (mm)	Cast Basalt Thickness (mm)	Length (mm)
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	20 25
500	600	25
550	650	25
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.

Cast Basalt Liners

What is Cast Basalt

Cast basalt is a volcanic mineral material known for its exceptional abrasion resistance, complete impermeability to moisture, high compressive strength, and resistance to most acids and alkalis. It is entirely corrosion-proof, making it ideal for harsh industrial environments.

It is produced by melting selected natural basalt, crushed into 20–50 mm fragments, in shaft furnaces at approximately 1,300°C. The molten basalt is then cast and crystallizes into a uniform phaneritic structure, resulting in excellent hardness and wear resistance.

Cast basalt has a minimum hardness of 8 on the Mohs scale (diamonds are rated 10), making it extremely effective for abrasion and erosion protection.

Like other ceramics, it is sensitive to impact. Under normal service conditions, cast basalt withstands temperatures from -40°C to +350°C, but it should not be subjected to thermal shock.

Sizes: Cast basalt products come in the form of tiles, formed pieces, and segments. Straight pipes are spun-cast with nominal bores from 32 to 600 mm, wall thickness 20–30 mm, and standard lengths of 500 mm. Smaller bores, pipe segments with radii of 40–3000 mm, and special formed pieces are usually sand-cast. Steel molds can be used for higher volumes, producing 30–40 mm thick linings.

Cast basalt-lined pipes are widely used in abrasive and ash handling systems such as chutes, troughs, funnels, silos, dust collectors, rotary flow machines, conveyors, and feeders. In chemical plants, they can be used to line pickling tanks or store corrosive substances.

Customized specifications and shapes are available to meet specific project requirements.

Performance Characteristics

Friction Resistance: Cast basalt becomes polished with use, reducing friction and improving flow, especially under wet conditions.
Impact Resistance: While direct 90° impact resistance is low, it can be improved through proper installation. Composite basalt pipes enclosed in mild steel offer better durability than bare Ni-hard pipes.
Chemical Resistance: Highly resistant to acids and alkalis (except hydrofluoric acid), ensuring long-term corrosion resistance.
Weight and Sizes: Standard tiles are 200 × 200 × 30 mm, weighing around 90 kg/m². Bends and pipes are lined with basalt cylinders from 50NB to 500NB.
Temperature Resistance: Operates effectively up to approximately 450°C.

Design Aspects

The bend radius should be at least 3 times the nominal bore.
A straight basalt-lined pipe 5 to 12 times the nominal bore should follow every bend to minimize turbulence and wear.

Cast Basalt Wear-Resistant Material

Refined into a finely crystallized glass ceramic, Sunny Steel’s cast basalt linings offer extremely durable protection for static plants handling large volumes of abrasive or corrosive media.

Available in both pipe and tile form, cast basalt is ideal for wet material handling systems with lower impacts, such as coal chutes, ash sluiceways, and pipelines at power stations. It provides excellent resistance to wear, corrosion, and temperatures up to ~400°C.

Laboratory

Our factory is equipped with professional technical research and design personnel who can provide product optimization design and services.

S6 JAGUAR Wavelength Dispersive X-ray Fluorescence Spectrometer

Pendulum Friction Coefficient Tester

XJJ-50 Single Beam Impact Testing Machine

HV-5 Vickers Hardness Tester

CMT-100 Microcomputer Controlled Electronic Universal Testing Machine

MSY-A Friction and Wear Testing Machine

Manufacturing Process

Industrial Technology

Processing Technology and Application of Cast Basalt Lined Pipe

Cast Basalt Production Process

Cast basalt is a silicate crystalline material manufactured through a high-temperature refining process. It is produced using natural igneous rocks such as basalt, diabase, or selected industrial waste slag as the primary raw material.

These materials undergo melting, casting, controlled crystallization, and annealing, resulting in a dense, highly wear- and corrosion-resistant product.

Cast Basalt Product Portfolio

Cast basalt slabs
Cast basalt pipes
Cast basalt lined steel pipes

Jacketed basalt pipes
Basalt-lined expansion joints and valves
Basalt powder and putty-based wear protection compounds

Industry Applications: These products are widely used in power generation mining coal handling metallurgy chemicals construction especially in areas exposed to heavy wear or chemical corrosion.

Structure of Cast Basalt Lined Pipe

A cast basalt lined pipe typically consists of three layers:

Inner Layer

Cast basalt ceramic for abrasion and corrosion resistance

Outer Layer

Steel pipe for structural strength

Intermediate Layer

Cement mortar for bonding and chemical passivation

Composite Benefits: This composite structure ensures high durability, pressure resistance, and corrosion protection.

The cement mortar creates an alkaline environment on the inner steel surface, forming a passive protective film that prevents corrosion. Overall, the cast basalt lined pipe is ideal for transporting abrasive or corrosive media in complex operating conditions.

Types and Customization

Available Pipe Types:

Straight pipes

Elbows

Tee & Cross

Reducers

Elbows are designed with turning radii and center angles based on user requirements and share the same diameter series as straight pipes.

Large Diameter Applications: For non-standard or large-diameter applications (DN ≥ 800 mm), cast basalt plates are bonded to the steel pipe's inner surface using suitable cement types depending on the operating environment.

Key Advantages

Excellent wear and corrosion resistance
Wide applicability across industries
Minimal limitations on pipe size and shape
Cost-effective for long-term use
Handles high pressure and temperature conditions

Application Area of Cast Basalt Products

Cast basalt can be used for the lining of pipework, chutes, bunkers, cyclones, and hoppers.

Usage

Install

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 material, has proven effective over 30+ years of practical use.

It is also widely used in cement plants for components such as air separators, chain conveyors, hoppers, nozzles, ducts, chutes, and more.