Abrasion-Resistant Piping has Hard and Soft Sides

UltraTech’s Ultra 600 induction hardened pipe, shown here, has an inner
surface rated at 600 on the Brinell scale—tough enough to withstand most
abrasive materials— and an exterior surface rated at 250 BHN, mild
enough to allow conventional handling, fitting and welding in the field.
When abrasive material is transported through steel pipe in mining applications, typically as pumped slurry, the pipe can quickly be eroded from the inside out, which in more extreme cases can result in pipe leaks and even failure, or significant maintenance costs and downtime for pipe replacement.

Steel piping systems are widely used in mining to convey the product, ore, and tailing slurries to the processing plant, as well as to recycle the debris medium back to the mining area. Other mining applications include steel pipe for drop shafts for conveying product from high elevations, and for backfilling the mine excavation areas utilizing sand fill, classified tailings or paste fill. For these highly abrasive applications, mild steel pipe generally can’t stand up to the abuse for more than a year or two. As a result, mine operators constantly seek piping alternatives to reduce maintenance and prolong system life, at a price point that will not significantly impact the budget.

At Mosaic’s mining operations in Florida, for example, phosphate is mined by draglines and then pumped as a slurry mixture of pebble-sized rock, sand, and clay through 20- to 22-in. steel pipelines to a beneficiation plant located anywhere from 1.5 to 14 miles from the mining site. “The slurry is so abrasive, standard grade carbon steel pipe just wears out too quickly,” said senior pipe technician John Pillard. “The slurry will wear the bottom right out if you don’t have good pipe.”

Today, there are a variety of “abrasion resistant” products and accessories that have entered the market to replace mild steel pipe in high wear areas. Most operate on the premise that when two objects meet, the harder object wins out. As such, products are available in a variety of increasing hardness, measured on the Brinell scale from A-R steel (200 BHN) through iron cast pipe (up to 800 BHN).

However, any product that is very hard throughout the wall thickness is also extremely brittle. Brittleness is unacceptable as piping systems are constantly flexing and moving as a result of pressure surges and spikes, and due to mechanical and physical contact at the facility. However, one type of pipe delivers the best of both worlds: an induction hardened pipe with an abrasion- resistant inner surface that tapers to a strong, yet ductile outer surface.

Manufactured by Port Washington, Wisconsin, USA-based Ultra Tech, this unique pipe is produced under the Ultra 600 brand. Ultra Tech begins with a steel pipe manufactured to a proprietary chemistry, followed by induction heating, and finally water-quenching the inner surface to create a single-wall pipe.

At 600 BHN, the inner surface of this induction hardened pipe can withstand most common abrasives, and tapers to a 250 BHN outer surface that is ductile enough to accommodate normal handling during shipment, installation and maintenance. With this proprietary process, pipe can be created in various diameters up to 40 in., in varying lengths and wall thickness.

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.

According to Pillard, Mosaic uses a combination of Abrasion Resistant (A-R) pipe rated at 230 BHN and the induction hardened Ultra 600. Ultra 600 is generally used for phosphate slurry transport, as well as for a waste discharge line that carries large particles such as limestone and even chunks of wood to a waste pit away from the plant.

Much of the A-R pipe was initially installed prior to a merger in 2004, but since then “more of the induction hardened pipe is taking the place of the A-R pipe simply because it’s a better value,” said Pillard.

Pillard’s primary concern is to “get the most wear for your money.” He estimated in an extremely high wear application at the mine, A-R pipe could wear out in as little as a year and a half, while Ultra 600 could last twice as long in the same application. In a lower (yet still abrasive) wear application, Pillard has seen the induction hardened pipe last as long as six to eight years.

“You don’t want a pipe that is three times better, but costs 10 times as much. That’s not cost effective,” said Pillard. “The Ultra 600 induction hardened pipe lasts a lot longer than mild steel, with only a moderate price increase.” This article was provided by Ultra Tech (www.ultratechpipe.com).

As featured in Womp 2010 Vol 05 - www.womp-int.com