Our Cast Basalt Manufacturing Plant

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

OUR PRODUCT

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 Basalt

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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/cm²
Bending Strenght250 - 450 kg/cm²
Application temperature range uptoapprox . 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.

APPLICATION

Cast Basalt Lining Solutions

Cast basalt lining is an effective solution for protecting equipment in the coal industry, offering exceptional resistance against abrasion, corrosion, and chemical exposure.

The choice of lining material depends on operating conditions and equipment requirements. Cast basalt is ideal for highly abrasive and chemically exposed environments.

Wear in the Coal Industry

  • Abrasive wearProvides excellent resistance against friction from fly ash and slurry.
  • Erosive wearProtects surfaces from particle flow degradation.
  • Corrosive wearReduces chemical damage caused by SOx exposure.
  • Impact wearNot suitable for heavy impact conditions.

Equipment Protected by Cast Basalt

  • Conveyors & transport systemsProtects surfaces handling fly ash and slurry.
  • Pipes & chutesPrevents wear and corrosion in transport lines.
  • Bunkers & silosReduces wear in storage and feeder systems.
  • Cyclones & separatorsIncreases 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

INNOVATION

Our R&D in Basalt

Basalt Fiber

BMW has focused on developing basalt fiber — a next-generation material created by fusing basalt rock and drawing it into fibers. These fibers provide exceptional heat stability, insulation, durability, and vibration resistance.

Basalt fiber consists of mineral filaments and outperforms most traditional fibers in mechanical and physico-chemical properties. It is widely used in reinforced composites due to its excellent corrosion and fire resistance.

The manufacturing process involves melting basalt rock at around 1400°C and extruding it through fine nozzles to produce continuous fiber filaments.