Our Cast Basalt Manufacturing Plant

BMW Steels Ltd. has state of the art basalt manufacturing plant situated in Bhagwanpur, Haridwar, Uttarakhand.

Cast Basalt (BASALT450®)

Cast Basalt is a durable and highly abrasion resistant material produced by melting and reheating basalt rock. The process yields a dense, lustrous coloured/black ceramic with exceptional hardness, scoring 8 on the Mohs scale (diamond is 10). To achieve these properties unique composition is required in Cast Basalt for remarkable resistance to abrasion, friction and chemical wear.
Unfortunately Indian basalt deposits lacs required chemical and physical properties. To achieve world class Basalt product BMW undertook a massive R&D activity.

Cast Basalat

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Typical Composition of Cast Basalt

Typical Composition (%)
Al203Si02Fe203/Fe0Ca0Mg0K20Na20Ti02
1050121010332

Typical Mechanical Properties of Cast Basalt

Density2.8 - 3.1 gm/cc
Surface hardness, Mohs Scleapprox. 8 (Diamond is 10)
Comprehensive resistance2,500 - 4,500 kg/cm ²
Bending Strenght250 - 450 kg/cm ²
Application temperature
range upto		approx . 620K
(approx .350 C)
Chemical StrengthResistance to acids and
alkali
Water absorption0.5% (maximum)

Typical Mechanical Properties of Cast Basalt

Indian Basalt deposits does not have required chemistry so they lag in achieving required physical Parameters.

BMW Team has collected 750 samples from length and width of country’s deposits. But no single stone could achieve the desired parameters. Therefore Basalt sample from two or more stones are blended to achieve required chemistry.

Cast Basalt Products

1. Cast Basalt Cylinders

BMW manufactures Cast Basalt cylinders in various sizes, as per the client's requirement. Basalt Cylindrical Liner are manufactured by Centrifugal Cylinder Casting.

Centrifugal Cylinder Casting

2. Cast Basalt Tiles

Basalt Tiles casting is shown in the attached clip. Basalt Tiles can be of different shapes like rectangular, hexagonal and Trench Liners depending on their application. Basalt Tile liners are manufactured by Casting by directly pouring molten basalt into various shapes of moulds.

Tile Casting

3. Skid Pan Tiles

In 1979, the Automotive Research Association of England tested Cast Basalt Skid Pan tiles at their track, confirming their suitability for automotive safety testing over six years. Today, the automotive industry globally uses these specially designed tiles in low-friction test facilities, including in India. BMW's Cast Basalt tiles are widely accepted for their durability and smoothness. Available in polished or unpolished forms, they maintain surface smoothness due to high wear resistance. Standard dimensions are 200x200mm with thicknesses between 25mm to 40mm, with curved options for circular tracks.

4. Cast Basalt Lined Equipment

With our innovative approaches, we have established ourselves as a reliable manufacturer of Cast Basalt in Ash Pipeline Bends. These bends find wide usage in various areas such as pipelines for hydraulic, chemicals, electric power, mining, metallurgy, coal, and many more. Cast Basalt Liners have outstanding corrosion and abrasive resistance; as a result, they easily withstand high working pressures. Enclosed with cement mortar inside metal pipes, the liners prevent inner wall of the pipes from early wearing. Moreover, flexible Joints of our Ash Pipeline facilitate quick fitting & connection and smoothness in performance.

Cast Basalt Lining Solutions

Cast basalt lining is an effective solution for protecting equipment in the coal industry, especially in coal preparation plants and coal-fired power plants. Its high wear resistance and durability make it ideal for conditions of intense abrasive and chemical exposure.

In general, the choice of lining material depends on the specific operating conditions and equipment requirements. Cast basalt lining is excellent for conditions with high abrasiveness and chemical exposure.

Usage of cast basalt lining in the coal industry

Wear in the coal industry:

  • Abrasive wear :
    • Very good against abrasive wear of equipment due to friction by Fly Ash and Ash Slurry.

  • Erosive wear :
    • Protects surface degradation from the flow of Fly Ash and Ash slurry particles.

  • Corrosive wear :
    • Effective at arresting corrosive wear due to Chemical effects from chemical storage, and especially due to effect of SOx.

  • Impact wear :
    • Basalt is poor against impact wear so it should be avoided against impact.

    Technological equipment protected by cast basalt lining:

  • Conveyors and transport systems :
    • Used for removing Fly Ash and Ash slurry. Cast basalt protects surfaces from abrasive wear.

  • Pipes and chutes :
    • Used for transporting Fly Ash dust and Ash Slurry Lines for ash handling. The lining prevents wear and corrosion.

  • Bunkers and silos :
    • Protective lining for storage of coal and feeder for processing. Cast basalt reduces wear on walls and the bottom of equipment

  • Cyclones and separators :
    • Equipment for particle segregation of pulverized coal. Cast basalt increases the lifespan of internal components.

    Application Areas

    Basalt lining is used in various industries to reduce wear and tear in mechanical components.

    1. Powerplants

    Basalt Lining in Ash Handling Line

    Basalt Lining in Ash Handling Line

    Basalt Lining in Coal Hopper

    Basalt Lining in Coal Conveyor System

    2. Sewage Plant

    Basalt Sewer Systems

    3. Cement Plants

    4. Steel Plant

    Flume Tunnel

    Basalt Lining in Ash Handling Line

    Our R&D in Basalt

    Basalt Fiber:

    BMW has addressed the development of a potential new form of Basalt i.e. Basalt fiber. Basalt Fiber is created by fusing basalt rock and then fibers are drawn. These fibers have heat stability, thermal and sound insulation qualities, durability and vibration resistance. It contains filaments that are classified as mineral fibers. They are superior to most of the fibers in mechanical & chemical- physical qualities

    These qualities enable basalt fiber to be used as reinforced composits, since they have superior corrosion and fire resistant qualities.the manufacture of basalt fiber requires melting of basalt rock to about 1400°C. This melt is then extruded through small nozzles to produce continuous filaments of basalt fiber.