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, black-coloured ceramic with exceptional hardness, scoring 8 on the Mohs scale (diamond is 10). To achieve these properties, a unique composition is required in cast basalt, providing remarkable resistance to abrasion, friction, and chemical wear.
Unfortunately Indian basalt deposits lacks 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 do not have the required chemistry, so they lag in achieving the required physical parameters.

The BMW team has collected 750 samples from deposits across the length and breadth of the country. However, not a single stone could achieve the desired parameters. Therefore, basalt samples from two or more stones are blended to achieve the 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 worldwide 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 their high wear resistance. Standard dimensions are 200 × 200 mm, with thicknesses ranging from 25 mm to 40 mm, along 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 ash pipeline bends. These bends are widely used in various sectors such as hydraulic pipelines, chemical industries, electric power, mining, metallurgy, coal handling, and many more. Cast basalt liners offer outstanding corrosion and abrasion resistance; as a result, they easily withstand high working pressures. Enclosed with cement mortar inside metal pipes, the liners prevent early wear of the inner pipe walls. Moreover, the flexible joints of our ash pipeline system facilitate quick fitting, secure connections, and smooth 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 involving intense abrasion and chemical exposure.

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

Usage of cast basalt lining in the coal industry

Wear in the Coal industry:

  • Abrasive wear :
    • Provides excellent resistance against abrasive wear caused by friction from fly ash and ash slurry.

  • Erosive wear :
    • Protects surfaces from degradation due to the flow of fly ash and ash slurry particles.

  • Corrosive wear :
    • Effective in reducing corrosive wear caused by chemical exposure, especially due to the effects of SOx.

  • Impact wear :
    • Cast basalt performs poorly under impact conditions; therefore, it should be avoided in applications involving heavy 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. The lining prevents wear and corrosion.

  • Bunkers and silos :
    • Provides protective lining for coal storage and feeder systems. Cast basalt reduces wear on equipment walls and bottoms.

  • Cyclones and separators :
    • Used 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 focused on the development of a potential new form of basalt, i.e., basalt fiber. Basalt fiber is created by fusing basalt rock and then drawing it into fibers. These fibers offer heat stability, thermal and sound insulation properties, durability, and vibration resistance. Basalt fiber contains filaments that are classified as mineral fibers. They are superior to most other fibers in terms of mechanical and physico-chemical properties.

    These qualities enable basalt fiber to be used in reinforced composites, as it provides excellent corrosion and fire resistance. The manufacture of basalt fiber requires melting basalt rock at about 1400°C. This molten material is then extruded through small nozzles to produce continuous basalt fiber filaments.