Pulverised Fuel Piping Systems
Greenbank offers a comprehensive range of lining materials designed to combat erosion and have more than 50 years of expertise on their applications in handling Pulverised Fuel for Coal Fired Boilers.
Basalt and Alumina and now Zalcon are the most well known and applicable lining materials for Pf piping systems in today’s Coal Fired Generation Industry. Other linings include, Nickel and Chrome alloys and Silicon Nitride Bonded Silicon Carbide.

Cast Basalt
Cast Basalt is a material formed from Basaltic Rock/Slag combined with crystallising agents. When cast it has two exceptional qualities. Firstly the abrasive resistance, which is a most important factor, becoming several times higher than that of iron or steel. Secondly, it has a high degree of chemical resistance. It is suitable for the lining of pipework, chutes, bunkers, cyclones and hoppers. Cast Basalt has become the world standard for ash slurry pipework at fossil fuel power stations. An all round cost effective and adaptable lining material that extends the life of equipment where affected by erosion.
When handling Pulverised Fuel in bends we would recommend Alumina Ceramics such as Zalcon be combined with basalt and used to handle the increase in wear activity due to changes of direction of the flow of the Pf.

Zalcon™ Zirconium Alumina Ceramic
Zalcon is an advanced fusion cast ceramic, developed specifically to resist impact and sliding abrasion in arduous conditions. It is cast at approximately 1800°C into virtually any required lining shape, eliminating many joints which cause premature failure in other ceramic linings. Its resistance to impact and thermal shock makes it the perfect liner in areas where aggressive materials are handled adjacent to heat sources.
The interlocking crystalline structure of Zalcon gives the material superior physical characteristics. It’s co-efficient of friction improves with wear and enhances the flow of the material being handled. Zalcon is the state of the art answer to abrasion in cyclones, pump casings.

Zalcon has been successfully applied to handling pulverised coal [Pf] and in processes using pneumatic conveying of abrasive materials such as foundry sand, coke, glass batch etc. Zalcon has much greater resistance to heavy impact and thermal shock than bonded alumina ceramics -with at least the same resistance to sliding abrasion.

Alumina Ceramic
Alumina is the most effective and widely used material in the family of engineering ceramics. Alumina ceramics has been developed and optimized for maximum wear resistance and corrosion resistance. High density, diamond like hardness, fine grain structure and superior mechanical strength are the unique properties that make it the material of choice for a wide range of demanding applications.
Alumina is used in similar applications to Cast Basalt but has greater resistance to wear especially in high velocity lean and dense phase systems.

Industries Served:

Greenbank provide our customers with the full range of lined pipework include Straight Pipes, Bends and Elbows, Tees and Y-pieces

Casings
Design pressure: 10 bar (150psi) at 100oC
Material: mild steel to BS EN10025/S275 (or equivalent)
Standard Casing thickness: 3 - 6 mm (Other thickness of casings available to suit design Parameters)

Linings
Up to 500 N.B. 20-25 nominal thick, Basalt, Zalcon or Alumina segments, jointed with CBP No.1 resin bonded cement, grouted with Portland Cement/Sand mixture.
Over 500 N.B. 30mm nominal thick, Basalt, Zalcon or Alumina tiles, bedded and jointed with CBP No.1 resin bonded cement.

Flanges
As well as our standard Fixed and Rotating Flanges Greenbank also supplies Adaptor Flanges, Viking Johnson Coupling and Victaulic Joints to suit our customers’ applications and requirements.

Finish
Surface coating is to our standard protection finish, which is a red oxide primer. Other finishes are available to suit our customers’ specific requirements.