The PRODUCT
Abrasion-Resistant Elbows for Pneumatic Conveying Systems
At Ultra-Air Systems, we specialize in long-life elbows for the lumber & sawmill, veneer and wood products industries and other forms of dry pneumatic conveying. Our Ultra 600 Induction-Hardened Elbows are a breakthrough in wear-resistant elbows for conveying abrasive materials like green sawdust, grains and seeds, or sand.
- 8,000+ hours service life: Induction-hardened steel elbows last much longer than AR 235 or AR 400 elbows, for significantly lower lifetime costs.
- Improved performance and reduced plugging: A smooth interior with a uniform radius improves conveying performance and reduces the likelihood of plugging, minimizing maintenance and unplanned downtime.
- Weldable exterior: Our unique process results in an ultra-hard interior of 600 Brinell and a workable, weldable exterior for welding flanges and supports.
- Fits where you need it: With many standard sizes available, there is an Ultra Air product that will meet your requirements.
Long-Wear Elbow Sizing and Product Specs
- Heavy-duty elbows: Centerline radius of 5x the diameter. Made from Schedule 40 pipe, which adds thickness as the diameter gets larger.
- Super-duty elbows: Centerline radius of 5x the diameter. Made from Schedule 80 pipe, which starts out thick and keeps getting thicker. Provides 30% more of the 600 BHN interior.
- Long-sweep elbows: Centerline radius 12x the diameter. Made from Schedule 80 pipe.
Our abrasion-resistant elbows are available in several standard sizes for fitting into your conveying system. Don’t see your size? Contact us for options.
About Wear-Resistant Elbows
Long-life, wear-resistant elbows offer a new alternative for conveying systems for green sawdust and other abrasive materials. The industry has long relied on wear back (or flat back) elbows for fuel delivery systems and other blowpipe systems. These elbows have a replaceable wear surface that is designed to be switched out as the wear surface degrades—as often as every six months or 2,000 hours. This is an expensive and labor-intensive process that requires the system to be shut down while the replacement back is fitted.
Long-wear blowpipe elbows made of induction steel offer a better option. Induction steel elbows last 4x as long as a traditional AR 235 elbow, significantly reducing total lifetime costs. These elbows also outperform flat backs when it comes to system performance and plugging. A long-life elbow made of induction steel will:
- Cut total lifetime costs by half or more compared to traditional wear-backs.
- Significantly reduce maintenance costs by minimizing plugging and blockages.
- Minimize shutdowns for elbow replacement and maintenance.
FAQ
What is induction-hardened steel?
Induction-hardened steel is created by a process in which steel is heated to a high temperature using an induction heating coil. The steel is then cooled quickly, usually by quenching in oil or water. This process hardens the surface of the steel by altering the microstructure of the metal, making it more resistant to wear, abrasion and impact.
The induction hardening process is typically used on steel parts that will be subjected to high levels of wear and tear. The hardening process only impacts the surface of the material treated, leaving the core of the material softer and more ductile. This combination of a hard surface and a softer core allows the part to withstand high loads and resist wear, while still maintaining good toughness and ductility.
For induction-hardened steel piping, the interior surface is exposed to the hardening process, leaving the outer surface workable and weldable. This combination makes induction-hardened pipe bends ideal for pneumatic conveying systems for abrasive materials such as sawdust. Learn about the process.
What is the best abrasion-resistant elbow for material transport?
The best elbow for conveying abrasive materials such as green sawdust, wood chips, shavings, grain, seeds and other dry particulate matter is one that is long-lasting and able to withstands high levels of abrasion. Currently, the longest-lasting elbow in the industry is an abrasion-resistant induction steel elbow. These long-life elbows are ideal for fuel delivery systems in sawmills and other pneumatic conveying systems used in the lumber, woodworking, agricultural, chemical and mineral processing industries.
Traditionally, wear back elbows (or flat back elbows) have been used in the lumber and woodworking industries in fuel delivery systems, which carry green sawdust from saws and planes to the burners. They are also used in systems for conveying grains, seeds, and dry raw materials such as sand, plastic pellets and cement powder in other industries. These conveying systems may have several hundred feet of piping with multiple changes of direction requiring an elbow. Wear back elbows may require replacement as often as every six months in these systems, driving up costs and downtime.
A longer-lasting elbow reduces costs for maintenance and replacement of the elbows and minimizes downtime for elbow replacement. Induction-hardened steel piping, which can have an interior hardness of 600 Brinell, lasts significantly longer than an AR 235 or even AR 400 wear back elbow—up to four times as long. This reduces the total lifetime costs of the elbow and, therefore, the entire conveying system.
How long do induction-hardened elbows last?
Induction hardening creates a highly durable, wear-resistant elbow. For high-volume, low-pressure pneumatic conveying of abrasive materials like green sawdust, an induction-hardened steel elbow will last about 8,000 hours or two years under normal working conditions. That’s about 4x as long as a traditional AR 235 wear back or flat back elbow subjected to the same conditions.
What are the applications for long-life elbows?
Our induction-hardened steel elbows were specifically designed for high-volume, low-pressure pneumatic conveying systems for abrasive materials like sawdust. We primarily serve the lumber, milling and woodworking industries, but our long-life elbows could be used in other types of blowpipe systems as well.
How do induction-hardened long-life elbows reduce costs?
Induction-hardened steel elbows cost slightly more upfront but save considerable money over the lifetime of the product. That’s because they last about 4x as long as a traditional wear back elbow—up to two years or more, compared to just six months for a wear back exposed to the same level of abrasion. That means, in a two-year period, the wear back for the elbow will be replaced three times, with associated material and labor costs. In contrast, the induction-hardened steel elbow is installed once and requires no further replacements and little maintenance over its lifetime. As a result, the two-year cost of a wear back system can be two to three times more than the two-year cost of an induction-hardened elbow of the same diameter (especially when installed at higher elevations requiring manlifts and cranes).
Choosing the Right Elbow Fitting for Low-Pressure Pneumatic Conveying
Not sure which type of abrasion-resistant elbow is right for you? Read our guide: