Esser Twin Pipes are widely used across various industrial markets due to their exceptional wear resistance and durability. Their twin-walled, hardened steel pipeline systems are engineered to withstand the most demanding hydraulic and pneumatic applications. Industries such as concrete pumping, mining, steel foundries, plastic and glass manufacturing, and waste-water handling rely on Esser’s solutions to transport abrasive materials efficiently and safely. These pipes are particularly valued in operations where long service life, reduced downtime, and high performance under extreme conditions are critical.
Fiberglass-reinforced, high-performance plastics have long played an important role in the consumer goods sector. Due to electrification within the green energy transition, these lightweight materials are being utilized in multiple industries to replace heavy parts made of steel: “Less weight saves energy! Manufacturers of the basic materials are upgrading their capacities to be able to meet the growing demand worldwide. These facility engineers value uninterrupted, gentle pneumatic conveyance, avoidance of contamination, and plannable maintenance intervals. In this application, Esser pipelines enable smooth operation for years while also reducing the total cost of ownership over the lifetime of the system.
Cement requires large amounts of energy to produce. Cement plants attach great importance to energy efficiency. A variety of processes are being implemented to reduce energy consumption and CO2 generation. One approach is the low-friction conveyance of refuse-derived fuel (RDF) that reduces the energy consumption of the ventilators. The primary goal is to use the rotary kiln running time until the next planned overhaul and to avoid unplanned downtimes due to pipe clogs or line defects. Unfortunately, this cannot always be avoided and action must be taken quickly. With Esser pipelines designed to use couplings, damaged pipes and bends can be exchanged easily. We are committed to innovation that ensures cement is available in sufficient quantities at affordable prices.
Today, most building materials used in construction are inorganic. These raw materials for production are stored in silos. Transport of material between trucks and silos is done pneumatically with a pressure of approximately 2 bar. Due to their hardness and shape, some building materials are highly abrasive to the steel used in pneumatic pipelines. The greatest stresses on a pipeline are found at the bends, outlets, and the connection pipe to the truck. The Esser team has decades of experience in solving these problems for customers worldwide. We can help to identify the ideal pipeline configuration and materials that will be wear-optimized and reduce your total cost of operation (TCO).
The main materials to be transported in foundries are molding sands and fine dust, which are very abrasive due to their high silicate and metal content. Foundries are often equipped with long sand reclamation pipelines. The most critical parts of these pipe systems are the directional changes, particularly bends of 90° degrees. The hard, abrasive sand being transported pneumatically impacts these elbows, resulting in a high potential of possible failures due to wear. ESSER 900 elbows are used to get a smoother material flow and reduce wear in the critical sections.
Inorganic color pigments are used for coloring in numerous industries such as construction, paints, varnishes, and plastics. They include iron oxide and titanium oxide pigments, among others. The different production processes place high demands on the delivery line. In order to avoid contamination of the conveyed material, pipes are used whose abrasion can be separated or is of no importance in the end-product. In order to reduce production costs and downtimes, trouble-free conveyance and predictable maintenance intervals are vital. Esser Twin Pipes achieve this through an induction hardened inner pipe surface mated to an external pipe that ensures pressure resistance and bending strength.
Sewage sludge can be conveyed both dry and wet. With hydraulic conveyance, the slurry is transported using high-pressure pumps through pipes with a large nominal diameter. The pipeline components must withstand a pressure of 60-130 bar. Pneumatic conveyance usually takes place at pressures near 2 bar. Due to the nature of the material, operators of incineration plants attach great importance to wear-resistant and leak-proof conveyance systems. Our pipe coupling systems, which have been in the field and tested over many years, ensure that your pipeline meets the requirements of the TÜV and does not lose any harmful substances.
Glass is an ancient product that is more modern than ever. The range of applications of glass with unique properties is practically unlimited. The primary raw material of glass is quartz sand (SiO2), with a hardness of 8 on the Mohs scale (approx. 1120 HV), one of the main reasons for extreme wear. Some glass manufacturers have therefore switched to alternative conveying methods. However, where only pneumatic conveying is possible for process or design reasons, ESSER components are in demand. In addition, nickel is a serious problem for flat glass manufacturers. This element can lead to fracture zones in large glass sheets. The nickel content in the melt must be kept as low as possible.
Power plants ensure that industries can produce the goods and services that public and private life require. That is why all power plant operators pay particular attention to safety, high efficiency, low breakdowns, and low emissions. Functionality and reliability are therefore a must, especially in power plants. Scheduled system maintenance must be completed on time and unplanned stoppages must be avoided. The transport of fuels, such as pulverized coal, is subject to strict explosion protection requirements, which are closely followed. Wear must be minimized wherever possible. Service life is monitored, and careful checks are made to select which connections and qualities should be used in an application. All this is done to ensure that the energy we consume will continue to be available in sufficient quantities in the future.
Combined heat and power stations ensure that the energy from electricity production is used efficiently for the benefit of customers, and reduces the environmental impact of production. While these operations can differ in the fuels used, many of the current solutions result in significant wear in the pipeline systems. In classic coal and biomass power plants, abrasive erosion of the inner surface occurs as soon as the fuel is unloaded into the pipeline. The waste product, ash, is also problematic and causes wear on screw conveyors and pipe systems. Since the combustion cannot be stopped at will, fixed inspection and maintenance cycles are planned. This in turn means that all system components must maintain operational parameters until the planned replacement window. Longer-lasting pipeline components from Esser can reduce the frequency of replacement, which will save your operation time and money.
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