Extending the Life of Pneumatic Transport Pipes in the Recycling Industry

The Integra™ service team at Welding Alloys España successfully completed a critical pipework repair for a major customer in the recycling industry. The application involved the pneumatic transport system of waste materials. These systems are exposed to continuous abrasion, particularly at bends and elbows where material flow changes direction.

For several years, the customer had relied on Ni-Hard tubes, which required frequent replacement due to rapid wear. In 2022, they approached Welding Alloys seeking a more robust, longer-lasting solution that would reduce downtime and improve the efficiency of their maintenance operations. Our repair increased service life and reduced component replacement frequency in these high-wear zones.

Developing a proven alternative to Ni-Hard

When the customer contacted Welding Alloys about the problem, the team began work on developing a welded solution capable of offering longer service life. A series of on-site trials and qualification tests were carried out to confirm the mechanical performance and operational suitability of the overlay.

The first welded tube was installed after successful testing and has continued to operate at full load. A subsequent inspection recorded cracking outside the welding zone, while the overlay remained intact, confirming the robustness of the welded solution.

Robotic welding for complex pipe geometry

The component repaired was an induction-formed elbow curve, a geometry that presents challenges for consistent internal protection. Using our robotic welding system, a uniform internal overlay along the entire curvature of the pipe was applied. The internal surface was hardfaced with a complex carbide alloy wire manufactured by Welding Alloys, chosen for its abrasion resistance and suitability for severe wear environments.

The Integra™ team carried out the on-site fitting in situ, delivering a solution that drastically extends the service life of pipework handling abrasive waste streams and provides significantly better wear protection than Ni-Hard components.

Delivering customer value through longer service life

By replacing the previous Ni-Hard tubes with a durable welded solution, the customer can expect:

• Significantly extended service life
• Reduced frequency of replacements
• Lower maintenance costs
• Improved operational uptime
• A repeatable, scalable in-situ repair process

With further qualifications already underway, Welding Alloys is ready to support increased volumes as the customer prepares to roll out the solution across additional sections of their pneumatic transport line.

Looking for a solution for worn pipe sections? Contact us.