Abrasion Resistant Pipes for Pneumatic and …abresist.com/PDFs/Pipes2006.pdflining material. Pneumatic Conveying With pneumatic conveying abrasion normally occurs in the pipe bends

AbrasionResistant Pipesfor Pneumatic and Hydraulic Systems

01.06

The Wear Protection People

Abresist_Pipes_01_06 11.01.2006 13:09 Uhr Seite 29

2

The High Cost of Abrasion

Pneumatic and hydraulic conveying has many advantages. But, many of the users of theseconveying systems face the sameproblem: high levels of abrasionwithin the pipelines.

Because of the high abrasivenessof many bulk materials conveyed,the pipes can be severely worn.Even thick walled steel or castiron pipes are worn through in ashort period of time.

This results in unscheduled shut-downs, pollution of the plant andenvironment as well as the high cost of materials and labor for repairs and replacements.

Quite often the problems of abrasion are accepted as unavoidable. Piping systems maybe supplied with thicker walls and marginally better materials,but this just delays the inevitableat unreasonable costs. These practices are avoided in plants that want to operateeconomically and dependably.

This brochure will provide youwith information on importantaspects of abrasion protection. It will outline various possibilitiesfor optimum plant utilization andcost savings through the use ofabrasion resistant linings.

The highest cost in many situations is the lost productiontime due to unplanned outages.The money saved by using lowcost steel piping componentscan result in a much higher cost later.

Abrasion resistant pipes and fittings save money as repairfrequency is greatly reducedand production time is increased.

In some instances, a single avoided repair will pay for theadded abrasion protection.

Material Replacements, extra Laborand Lost Production can be Avoided


3

Simple SolutionsUsually don’t Last

Concrete filled wear boxes are a short term solution.

This method of repair increases turbulence as it wears, leading to more severe abrasion, loss of efficiency and product degradation.

Costs go up when the repairlocation is difficult to reach.

Preventive abrasion protection inthis location is extremely valuable.

The wear pattern gets moresevere as the patch is worn.

Simple but not very efficient:Welded patches on steel pipes.

Critical areas subject to abrasivefailure exist in any plant transpor-ting or processing bulk materials.Even materials that appear harm-less are often abrasive since thequantities and velocities in whichthey are transported can destroya system component within ashort time.

The transport of bulk materials inmany basic industries, e.g. coal-fired power stations, is associatedwith heavy wear of the systemcomponents. Not only is the original equipment investmentlost, plant shutdowns and pro-duction loss combine to destroythe capital base of the company.

This is unacceptable in view ofcompetitive pressure on theworld markets.

The solution to this problem isreliable abrasion protection. Ofvital importance is the selectionof the appropriate material and its correct application.


4

Critical Zones

The entire length of a hydraulicpipeline needs to be protected against abrasion. Under typical conveying conditions and general operating procedures,ABRESIST has proven to beextremely effective.

To reduce the severe abrasion of the bends in pneumaticsystems, abrasion resistantpiping components with internallinings – such as ABRESIST –should be used.

Because of continuing turbulence in the straight sections after bends, abrasionresistant pipes should be installed. Recommended length: 10 times the inside diameter or 1 - 2 meters on the smallerdiameters.

Dense Phase ConveyingDense phase conveying is limited to materials with specific characteristics. The basic principle is the pulsating forward movement of air and material plugs.

Even with a relatively low initialvelocity, dense phase conveyingcan have a high rate of abrasion.This is dependent upon the sizeand particle hardness of the conveyed material.

Pipe Chain ConveyersPipe chain conveyers are mechanical flow conveyorsystems that are completely enclosed with circulating conveying chains.

With pipe chain conveyers materials can be transported up to distances of 50 m and forcapacities of approx. 65 m3/h.

The advantage of these systems is in the transportation of wet or sticky materials. Wear problems can developdepending upon conveyed materials and conveying conditions, all of which can beovercome with the appropriatelining material.

Pneumatic ConveyingWith pneumatic conveyingabrasion normally occurs in the pipe bends and in the subsequent straight sectionswhere the conveyed material is subject to a high degree ofturbulence. Compared to laterstraight sections, service life will be shorter.

Hydraulic ConveyingWith hydraulic conveying theeffects of gravity on the bulkmaterials being transportedcause wear in pipelines alongthe lower section of the pipe.


5

Operating Limitations

Quite often, design and process conditions oppose the optimalrouting of pipelines for minimal wear.

The radius of a pipe bend strongly influences the rate of abrasive wear.

Design SolutionsIt is possible to reduce wearproblems with design solutions.Avoiding particular installation arrangements and avoiding tight bends is one way.

Quite often design solutions arelimited by unavoidable obstaclesand required process conditions.

For example, it is only possible to reduce the conveying velocityin a few cases. Many times thisreduction would change the planteffectiveness or the reduced velocity could possibly result inline plugs and shut-downs, orlower the conveying systemcapacity to an unacceptablelevel.

It is usually more important to maintain or increase the produc-tivity with higher velocities and toaccept the resulting higher wearrates.


6

Materials to ReduceRepair Expense

To achieve both technical and economical wear protection, many factors have to be taken into account.The choice needs to be based on the application.

The best solution for long life and economical abrasion protection depends upon the proper selection of the lining material as well as a knowledge of expected cost.

A wide range of different materials with different characteristics can be chosen to protect againstwear. Pipe linings made of mineral, metallic or

ceramic materials have proven to work well.

Example of a Wear Protected Pipe Bend

Steel casing

Good flow characteristics

due to permanentlysmooth surface

Mortar

Wear resistant lining also inthe area of turbulent flow

Simple installation withflanged connections

Lining

MortarSteel

Clear Advantages■ long lifetime

■ maintenance free operation

■ no operation interruption

■ no production losses

■ no contamination of the conveyed materials due to abrasion, mixture or oxidation

■ physiologically harmless, suitable for food products

■ smooth surface to achievegood flowability and to avoid plugs

■ reduced pressure losses and lower energy cost

■ no spilled material to clean up


7

Application Examples

Depending on the lining material,pipes with an ID of up to 525 mm will be lined with cylinders.

The different manufacture andinstallation methods of the variouslinings allow protective coveragein many special situations such aspipe branches, intersections,square-to-round and conical transitions.

Industry Material

Cement (wet process) Raw kiln feed

Chemical industry Slurries with solids

Coal fired power stations Bottom ash, fly ash, pyrites, scrubber sludge,limestone

Coal mining & preparation Raw coal slurries, magnetite, tailings

Iron & steel Blast furnace slag, furnace scrubber slurry, mill scale

Phosphate Phosphate ore, tailings

Potassium & salt industry Potassium salts, kieserite, salts

Refuse incineration Slag, non-combustible residue

Sand & gravel plants Sand, gravel

Sewage treatment Sludge, storm water, grit, sludge ash

Industry Material

Abrasive products Grinding wheel granules, shingle granules

Aluminium plants Calcined Alumina, bauxite, electrode carbon, crushed bath

Breweries, grain Corn, barley, soybeans, malt, cocoa beans, processing, feed mills, sunflower seeds, rice hullsmalting plants

Cement Clinker dust, limestone, cement, fly ash, coal, blast furnace slag, petro coke

Chemical plants Caustic lime, fertilizers, lime dust, chrome ore, paint pigments, plastic pellets with glass fibers

Coal fired power stations Coal, fly ash, pyrites, slag, ash, limestone

Coal mines Coal dust, mine waste for backfilling

Foundries Molding sand, dust collection

Glass plants Batch, cullet, quartz, kaoline, feldspar, nepheline

Iron & steel Sinter dust, limestone, lime injection, iron carbide, alloy additives, carbon injection, iron oxide

Mineral mining plants Kiln feed, ore concentrate, coal, tailings, dust

Mineral wool & Perlite, stone dust, refractory fibers, production insulation products wastes, dust from sawing operations

Refuse incineration, Domestic and industrial refusevacuum refuse collection systems

Sewage treatment Limestone, organic fertilizer, bio solids

Technical carbon Technical carbon, dust, graphite for electrodesproducts

We Solve Wear Problems in Plant Components and Pipes

Examples in Pneumatic Conveying

Examples in Hydraulic Conveying

Pipe with larger internal diametersare protected with custom madetiles. Thin ceramic tiles can beused to reduce the weight.The material choice is based onthe severity of the working conditions.


8

ABRESIST LiningsWear Resistant Fused Cast Basaltfor Friction Induced Abrasion

The idea to melt stone is age-old.However, the melting of basalt started with lab tests only at the beginning of the last century. Further development overcamecrystallisation problems andmade commercial success possible.

By the mid-twenties our companysuccessfully produced an abrasion resistant material basedon basalt. Today, under the tradename ABRESIST, fused castbasalt has become a proven product.

ABRESIST fused cast basalt has been used successfully foryears as a universal material for abrasion protection. Dependingon the application and geometry,it can be used with temperatures up to 350 °C / 662 °F.Installed as original equipment,ABRESIST is an excellent solutionto wear problems before theystart.

During the manufacture of ABRESIST, selected basalt ismelted and cast into molds, thenmoved into an annealing furnace.Due to the casting process, precise cylinders from 40 mm to525 mm internal diameter can beproduced for pipes and bends.Special tile shapes are engineeredfor larger pipe diameters andother equipment.

ABRESIST has an extremely hardand smooth surface. The materialis corrosion resistant to mostacids and alkalis. This makesABRESIST very effective for pipelines where abrasion and corrosion occur together.

ABRESIST

Fused cast basalt is a mineralbased wear protection materialfor plant components when theconveying material produces friction induced abrasion.

Installation: cylinders or shaped components in cement mortar. In special cases epoxies or synthetic mortars may be useddue to strong mechanical stresses and/or vibration.Where higher temperatures are concerned, potassium silicate mortar may be used for installation.

Application temperature: up to350 °C / 662 °F depending on application and geometry.

Advantages: highly abrasionresistant, smooth surface thatlasts, no corrosion.


9

With lifetimes of more than 30 years, ABRESIST pipelines have been used for the hydraulic conveyingof ash on all continents. This plant in the U.S. hasover 10,000 meters of 294 mm ID pipe in service.

Hydraulic ash conveying at an Indian coal fired power station (four units 250 MW each).

Hydraulic ash conveying pipe being manufactured atthe Abresist Corporation plant in Indiana, U.S.A.

Pneumatic piping components used in a separator at a cement plant.


ABRESIST Linings

10

ABRESIST develops an extremelysmooth surface after a short period of operation. Plugs in pneumatic conveyingpipelines are avoided, even with moist materials. Likewise, plugging problems are avoidedafter shut-downs due to the corrosion resistant properties. Dust collection system in a

mineral wool plant.Lifetime: several years for the

handling of abrasive mineralwool fibers.

Internal protection of pipelines against abrasion and corrosion.


11

Cement industry example: conveying pipelines to thecement silos are protected by ABRESIST in the bendsand subsequent straight sections.

Almost 3,500 ft of pipe and more than 390 fittingscrisscross this coal preparation plant in Canada. Pipe installed initially in 1986 is still working and conveying coal.

Fly ash pipe-lines in a coalfired power station.

Hydraulic conveying pipeline for ore in Far East.


12

KALCOR LiningsZirconium Corundum Wear Protection withHigh Temperature and Abrasion Resistance

With the growing knowledge ofpreventive wear protection thedemand for durable materialswith extended service life hasincreased.

■ KALCOR, a fused cast corundum, was developed forextreme abrasion protection and high temperatures of up to 1000 ºC / 1832 ºF. Aluminaand zirconia are melted in anelectric arc furnace and castinto tiles, shaped componentsand cylinders.

■ KALCOR-S is cold cast and sintered. This materialwithstands temperatures up to 1250 °C / 2282 °F.Further advantage: good thermal shock resistance. The fabrication process allowstiles and cylinders to be madewith relatively thin walls.Asymmetric cross sections for pipe bends are possible.

KALCOR

Zirconium corundum based onalumina and zirconia for plantcomponents, where extremewear and/or high temperaturesoccur.

Installation: cylinders or shaped components in cement mortar or special mastics. Mechanicalfixing is also possible.

Application temperature: up to 1250 °C / 2282 ºF depending on application and geometry.

Advantages: highly abrasion resistant, temperature resistant, corrosion resistant.

KALCOR lined pipe.

Asymmetric cross section

of a pipe lined with KALCOR-S.


13

KALCOR protection easily applied in high wear areas: special cast shapes or cut components(diamond tipped tools only).

Proven for PF-bends: KALCOR lined elbows and pipe last many years.

KALCOR bendwith specialdeflectors to distribute theconveying stream of coal.


14

ALRESIST LiningsAbrasion and TemperatureResistant High Alumina Ceramics

ALRESIST is a member of theoxide family of ceramics, with the main component aluminiumoxide. Extremely high abrasionresistance is achieved by careful selection of the particle size and distribution.

Most tiles or cylinders are formedby pressing a dry powder of theceramic. Machining of ceramicprior to kiln firing allows themanufacture of components withgeometrically difficult shapes.

ALRESIST can be manufacturedin very thin tiles. This is an advantage when existing plantcomponents have to be lined andspace or weight are of criticalimportance.

ALRESIST AdvantagesHighly wear resistant, smooth surface that lasts, no corrosion,available in various thicknesses.

ALRESIST

Special high alumina ceramicsfor plant components with extreme wear and / or temperature conditions, for thinlinings or for smooth surfaces.

Installation: pipes, shaped components, or thin tiles laid in epoxy mortar, RTV or attachment using KALBOND.

ALRESIST tiles can be vulcanized into rubber mats for installation by gluing. Mechanical fixing by welding is also common.

Application temperature: up to1000 °C / 1832 °F depending onapplication and geometry.

Installation of thin ALRESIST tilesin epoxy mortar. Attachment usingKALBOND or silicone RTV is alsopossible.


15

The thickness of the ALRESIST lining depends onthe severity of the abrasion and pipe diameter.

Pipes smaller than 200 mm diameter will beprotected with ALRESIST cylinders

up to 25 mm thick.

Pipes larger than 200 mm diameter normally are lined with beveled tiles from 6 mm

to 25 mm thickness.

The choice of the rightattachmentsystem isdependent upon tempera-ture, vibration, chemicalattack, etc.

ALRESIST beveled tiles are pre-engineered and cut to shape during manufacture to fit together in therequired configuration.

Highly wear resistant ALRESIST pipe used for oreslurry conveying at a nickel mine in the Far East.


KALSICA LiningsSilicon Carbide Ceramics with ExtremelyHigh Temperature Abrasion Resistance

Outstanding resistance againstwear and thermal shock is achieved with KALSICA. KALSICA is part of the siliconcarbide ceramics group and isavailable in different qualities:

■ silicon infiltrated (KALSICA-S)

■ silicon nitride bonded (KALSICA-A, -N, -P)

High precision can be achieved inmanufacturing KALSICA shapes, formed by pressing or casting, then sintered in a reactor kiln.

Wall thickness from 2 mm for theshaped components is anotheradvantage of using KALSICA wear protection linings.

Expansion joint with 30 mm inside diameter. The thin lining allows an aerodynamically optimal pipe transition.

KALSICA

Silicon carbide ceramics for plant components for extremewear, high temperature and / or thermal shock.

Installation: individual shapes and components laid in mortar,epoxy, or temperature and acid resistant based mastics.Mechanical fixing is also possible.

Application temperature: up to1000 °C / 1832 °F depending onapplication and geometry.

Advantages: highly abrasion resistant, resistant to thermalshocks and manufactured withsmall tolerances.

For extreme wear in pneumaticconveying.

KALSICA lined pipe transition.

16


17

KALCRET LiningsHard Compound can be Trowelled, Cast or Sprayed for Jointless Lining

KALCRET is a mineral basedcement bonded hard compound. KALCRET can be trowelled, cast or sprayed, by the customer,in the workshop or on-site.

The lining is densely packed,using hard minerals that are fixed in a matrix. With a definedparticle distribution and additionalmicro silica, KALCRET has a very high wear resistance andstrength.

KALCRET reaches 75% of itsstrength in 8 hours, the minimumneeded for repair work.

KALCRET is clearly superior to highgrade concretes. Theapplication temperature is up to 1200 °C / 2192 °F, dependingon the situation.

KALCRET is especially useful inprotecting components with a difficult geometry.

Pipes and Pipe Bends Linedwith KALCRETPipes and pipe bends lined withKALCRET are produced with aninside diameter of more than 40 mm. Inside diameters up to600 mm are lined with castableKALCRET where as the use oftrowelled KALCRET is more economical for inside diametersbeyond 600 mm:

■ pipe lengths up to 5000 mm

■ radii of more than 500 mm

■ normally, the lining has athickness of 20 mm, other thicknesses optional

KALCRET

Cement bonded hard compoundfor a jointless lining of plant components where high wear and temperature occur.

Installation: by trowelling, casting in molds or spraying.

Application temperature: up to 1200 °C / 2192 °F depending on application and geometry.

Advantages: highly wear resis-tant, strong and jointless lining,highly temperature resistant.

KALCRET can be trowelled, …

…cast …

…or sprayed.

One benefit of the KALCRET wear protection lining is that the lining can be made thicker in the outer radius of the bend(extrados) which is subject to the greatest wear (asymmetriccross section).


18

Combined LiningsMore Economical due to Similar Lifetimes for all Plant Components

High conveying speeds and abrasive materials quite oftencause early wear in the deflectionpoints of pipelines. This wear isusually limited to the outer radiusof the bends.

In cases involving larger diameters, a combination oflinings, KALCOR or ALRESIST in the outer radius of the weararea and ABRESIST on the innersurface can lead to substantialbenefits.

This way, all parts can achieveapproximately the same lifetimewithout premature failure on one hand or over-protection on the other.

When appropriate lining materials are installed to resist the relevant wear stresses, the combination results in effective and economical protection.

ABRESIST

KALCOR / ALRESIST

Junction points and transitions are critical wear areas due to the turbulence in these sections. KALCOR and ABRESIST lining componentsinstalled in these areas result in comparable surface conditions and lifetimes matching the balance of the lining.

Combined lining withABRESIST and ALRESIST.

Combined lining of ABRESIST and KALCOR. The bend is provided with a KALCOR deflector and an inspection devise.


19

ABRESIST and KALCOR combination within a dust collection system in a steel plant. The raw gasses in the duct have a temperature of 250 °C / 482 °F and are loaded with sinter dust. The impact area opposite the gas inlet is lined with KALCOR.

ABRESIST lined cyclone body in a German chemical

plant: the fine but extremely abrasive silicon powder

requires special KALSICAwear protection at the

entrance and deflection areas.

Deviation pot with replaceable ceramic wear protection. This system is used in pneumatic conveying systems where there is little space for large bend radii. It is lined with ALRESIST and ABRESIST.

PF-pipes in power plants are subject to significantwear. Despite this fact these areas must not be allowed to fail. In this case the PF-distributors arelined with ALRESIST for high wear and KALCOR forthe impact stress.


20

KALFLEX BendsBoth Flexible andWear Resistant

KALFLEX flexible bends are easilyinstalled with normal flanging.The core elements of the systemare abrasion resistant segmentsthat fit into each other. The segments are capable ofmoving in relation to each other,providing the desired flexibility.

The segments are enclosed in arubber jacket containing a fabricinsert, producing the needed stability and tightness.

KALFLEX

� nominal diameters 20-150 mm

� max. temperature 180 °C / 356 °F

� pressure up to 10 bars

� flexible radius and angle positions

KALMETALL-C, Wear Resistant Hard CastThe wear resistant KALMETALL-Csegments are hard castings. KALMETALL-C offers resistanceagainst wear caused by impactand sliding abrasion. Diametersrange from 50 – 150 mm.

ALRESIST, when Wear is Extreme The segments can also be madeof ALRESIST high alumina ceramics, useful in cases ofextreme sliding abrasion.Diameters are available from 50 – 100 mm. When ALRESISTlinings are used, the collars aremade of KALMETALL-C and theflanges are made of steel to provide the strength needed.

2-way divertor valve with 150 mm Ø KALFLEX pipe, 1,851 mm long.


21

Electrical, Pneumatic or Mechanical Systems to Monitor Wear

KALDETECT Wear Detection

Even superior wear resistant linings do not haveunlimited lifetimes, especially in cases of extremelyabrasive materials and harsh operating conditions.This can become critical, e.g. when for environ-mental protection reasons, certain harmful materialscannot be allowed to pollute the environment.

For example: pneumatic conveying lines withinwaste incineration plants that are designed for the

Electrical Wear DetectionThe wear resistant lining is fittedon the cylinder OD with a low voltage electrical circuit.

If the wear resistant lining wearsthrough due to abrasion in thepipeline, the electrical circuit willbe interrupted.

Options in the electrical circuitdesign will allow the system toinitiate an alarm with an indicationof the relevant pipe section orshut down the plant automatically.

Straight pipe sections as well aspipe bends or other lined plantequipment, such as conicalcyclone components, can be fitted with these systems.

The electrical wear detection is available for all of the wear resistant materials and also forcombined linings of any plantcomponents.

Pneumatic Wear DetectionThe steel pipe is twin-walled. With changes of the pressurelevel in the space between thetwo pipes caused by a leak, anindicator or alarm will be activated or the plant will be shut down.

This system can be used forsingle pipes or complete pipelines.

Mechanical Wear DetectionThe steel casing and wear resi-stant linings are fitted with a borehole.

The length of the indicator pinmonitors the thickness or con-dition of the protective liningwhen removed and inspected.

incineration of hazardous waste. The leakage in aconveying line as a result of unexpected abrasionwould cause dangerous or environmentally harmfulsubstances to be released.

For these and other cases systems for lined pipesare offered that monitor possible wear in the liningbefore material leaks into the atmosphere or soil.


22

Design DetailsIndividual Fixing AlternativesDepending on Conditions and Processes

One method proven to resiststrong mechanical stresses is theuse of welded steel inserts.

Gluing with epoxy.

Installation and ErectionA precondition for effective wearprotection is proper installation.Installation and erection of thelining is dependent upon the material and the application, e.g. pipe diameter, temperature, corrosive and acid exposure.

ABRESIST, ALRESIST, KALCOR,and KALSICA normally are laid incement mortar or special mastics.Different mechanical fixings arealso possible.

High TemperatureApplicationsKALCOR, ALRESIST and KALSICA are wear protectivematerials capable of withstandinghigh temperatures. A wide rangeof mechanical fixing methods and design details permit findingcost effective wear protection for any application. Moreover, KALCRET hard compound can be installed by trowelling, castingor spraying.


Flange JointsThe connection of wear resistantpipes to each other or to regularsteel pipes can be done withfixed and / or loose flanges.

Lined pipes can be connected toeach other easily with a fixed collar and a loose turnable flange on one end.

A weld-on counter flange with larger bolt circle diameter on theunlined pipe is a proven solutionto connect pipe.

Unlined pipes, pumps or fittings can be connected with a lined pipe using an adaptor flange.

Gasket Gasket

Gaskets Gaskets are required to provide a tight seal between flanges in pipe sections.

For hydraulic pipe systems, we recommend a minimum 1/8“thick, rubber gasket. For example,gaskets made from SBR compound rubber.

For pneumatic pipe systems,we recommend a minimum 1/8“thick rubber gasket for ambienttemperatures, heat resistantmaterial for temperatures above80 °C / 176 °F.

Another standard connection is to use fixed flanges on both ends.

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24

Design DetailsAlternatives to Flanged Joints are Available forLined Pipe using Different Coupling Systems

Couplings with radial restraint. Couplings with axial and radialrestraint.

Couplings

Welded ConnectionsWhen flanged connections and couplings are not the answer, it ispossible to connect wear resistantpipes by a welded connection.

Threaded JointsWhen a pipeline is stressed by tension, e.g. when vertically suspended, threaded joints can be used.


25

Special Solutions

Expansion Joint SectionsFor longer pipelines wear resistantlined expansion joints of variousdesigns are available to compen-sate for changes in length.

Expansion joints in a hydraulicbottom ash pipeline.

Expansion joints in a pneumatic fly ash pipeline.

Dresser Conversion Flanges

Wedges

Dresser conversion flanges forconnecting to plain end steel or cast iron pipe.

Wedges are used for small directional changes from 0° to 10°.

Two 5° Wedges

0° - 10°

Lined pipe segments can be fitted to accept manometer,flowmeter, temperature indicator and / or wear meter.


26

The Wear Protection PeopleDesign, Manufacture, Delivery and Installation of Tailor-Made Wear Resistant Linings

Abresist Corporation andKalenborn have been dedicatedto plant protection since developing fused cast basalt forwear reduction and cost savings.

ManufacturingThe foundation of the wear resistant systems offered byAbresist Corporation andKalenborn consists of differentmaterials with a wide range ofindividual characteristics:

■ ABRESIST

■ ALRESIST

■ KALCOR

■ KALSICA

■ KALCRET

■ KALMETALL

Starting with fused cast basaltmore than 80 years ago, a widerange of wear resistant materialshas been developed with eachmaterial offering special wearresistant characteristics.

The materials are valuable, butthe knowledge from experiencegathered all over the world inmore than eighty branches ofindustry is just as important.

DesignOur engineers design customized,cost saving solutions for new orexisting equipment.

We provide the total package inone source: starting with adviceon application, measurements on-site, design services, manufacture of the lining throughto proper installation.

This is the Abresist Corporationapproach which offers longlasting protection.


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Installation and ErectionProper installation and erectionrequire knowledge based on awide range of experience.

Installation of the engineeredwear resistant linings can be performed or supervised byAbresist Corporation andKalenborn specialists in ourworkshops or on-site all over the world.

About Abresist CorporationAbresist Corporation is the U.S. subsidiary of Kalenborn Kalprotect,the German company that has continued to develop abrasion resistance technology for more than 80 years. We are confident that,whatever your abrasion or impact wear problem is in Canada, Mexicoor the U.S.A., you can get the help you need by contacting us.

We Solve Wear Problems in Plant Components and Pipes


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KALENBORN, ABRESIST, KALCOR, ALRESIST, KALSICA, KALCRET, KALMETALL, KALINOX und KALEN are trademarks of Abresist Corporation and Kalenborn Kalprotect.

This brochure and other technical information are general only. They do not cover any guarantee with legal effect. Technical changes and errors are reseverd.

The Wear Protection People

Ask Abresist Corp. for additional information

Kalenborn KalprotectDr. Mauritz GmbH & Co. KGVettelschoss, Germany

www.kalenborn.de

Abresist Corporation5541 North State Road 13P.O. Box 38Urbana, Indiana 46990, USA

Phone (800)348-0717(260)774-3327

Fax Business (260)774-8188Sales (260)774-3832

[email protected]

dc

kD

L

f

gh

dc

kD

L

g

Pipes / bends with fixed flanges.

Pipes / bends with welded collar and rotating flanges.

Pipes and BendsStandard for ABRESIST and KALCOR

Pipes and Bends

nominal size

inches

d

4“

5“

6“

8“

10“

12“

14“

precise I.D.mm

inches

d100

3 15/16“

1254 15/16“

1505 15/16“

2007 7/8“

2509 27/32“

29411 5/8“

35013 25/32“

pipesmm

inches

c171

6 7/8“

2108 5/16“

2198 5/8“

27310 3/4“

32412 3/4“

36814 1/2“

43217“

bendsmm

inches

c171

6 7/8“

2108 5/16“

2329 1/8“

28611 1/4“

33613 1/4“

38715 1/4“

43217“

Flanges

mminches

D27911“

31812 1/2“

33013“

40616“

44517 1/2“

49019 1/4“

56822 3/8“

mminches

k2299“

26710 1/2“

28011 1/16“

35313 7/8“

39515 9/16“

44517 1/2“

51820 3/8“

Inside diameter Outside diametersteel casing

Outside diam.of flange

Bolt circle diam.of flange

Number of holes

Diameterof holes

Thick-ness

8

8

8

8

12

12

16

mminches

L22

7/8“

227/8“

227/8“

227/8“

227/8“

227/8“

227/8“

mminches

g16

5/8“

165/8“

165/8“

193/4“

193/4“

193/4“

251“

mminches

f206

8 1/8“

2449 5/8“

26010 3/16“

33013“

37214 5/8“

42216 5/8“

49519 1/2“

Outside diam.of ring

mminches

h16

5/8“

165/8“

165/8“

193/4“

193/4“

193/4“

251“

Thick-ness

Rings

40 50 60 65 70 75 80 88 95 100 107 110113 120 125 132 135 146 150 162 170 175 178 185190 200 205 216 225 241 250 260 275 280 294 300310 325 350 375 400 430 450 475 500 525

Standard inside diameters in mmmade in cylinder form. Any size above 525 mm made in tile shapes.

Radi

us

750

mm

2´–

5 1 / 2

“

1000

mm

3´–

3 3 / 8

“

1500

mm

4´–

11 1 /

16“

2000

mm

6´–

6 3 / 4

“

2500

mm

8´–

2 7 / 1

6“

3000

mm

9´–

10 1 /

8“

90o

60o

45o

30o

15o

•••••

•••••

••••

•••

•••

••

Typical bend sizesBends are manufactured in any radii and angle,this table shows some standard sizes.

Steel casingMortar

ABRESIST


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Abrasion Resistant Pipes for Pneumatic and …abresist.com/PDFs/Pipes2006.pdflining material. Pneumatic Conveying With pneumatic conveying abrasion normally occurs in the pipe bends