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High Heat Expansion Joints Green Steel

April 14, 2025
Expansion joints refractory lined metal expansion joints

Manufactured for the Heat: Refractory-Lined Metal Expansion Joints Installed at Biocarbon Plant

Standard solutions won’t hold up when your process demands performance under extreme conditions. US Bellows engineered and manufactured more than 60 custom refractory-lined metal expansion joints for a new biocarbon production facility in Columbus, Mississippi. These units are designed to perform in the intense operating conditions required to support sustainable aluminum and steel manufacturing.

Refractory-lined metal expansion joints are critical in protecting piping systems operating at high temperatures—up to 2,800°F, like in this project. They allow pipes to expand and contract to help prevent stress on the system. The refractory lining is made of insulating materials to act as a thermal barrier and protect the underlying metal structure from extreme temperatures.

Refractory-lined metal expansion joints are critical components in systems like a biocarbon production facility due to the extremely high temperatures and abrasive materials involved in the process.

Project Spotlight: Supporting a Greener Future in Metal Production

Refractory-lined metal expansion joints
Refractory-lined metal expansion joints

These Refractory-lined metal expansion joints were manufactured for a new biocarbon production facility that will process over 160,000 metric tons of renewable biocarbon annually, supplying a critical resource for producing green steel and aluminum. Located adjacent to a major aluminum rolling mill, the site is part of a broader initiative to reduce industrial reliance on fossil fuels..

US Bellows delivered these units to meet strict project specs, ensuring seamless integration, long-term durability, and compliance with all temperature and pressure conditions.

US Bellows supplied more than 60 Refractory-lined metal expansion joints for this project. These units varied in size from 56 to 144 inches in diameter and were designed to accommodate temperatures ranging from 1,600°F to 2,800°F and pressures up to 15 psi. The most robust expansion joints—exposed to the highest thermal and mechanical stress—are installed near the combustor and furnace. Lower-temperature units are located along the process exhaust lines. Each expansion joint was fabricated with a carbon steel shell, cover, and hardware, while the bellows were made from Incoloy 800 for superior high-temperature resistance.

Industry: Green Steel

A green steel industry aims to produce steel by replacing coal with renewable energy sources, like biocarbon, significantly reducing carbon emissions. Biocarbon, derived from sustainable biomass, acts as a renewable substitute for fossil-based carbon in steelmaking, contributing to a more sustainable production process

The biocarbon facility in Columbus, MS, will process forest and sawmill residues to produce over 160,000 metric tons of biocarbon annually. It is strategically located next to a flat-rolled aluminum mill, requiring approximately 900,000 metric tons of aluminum slab supply

Our Refractory-lined metal expansion joints are helping this facility maintain thermal integrity and system flexibility during production, contributing to lower emissions and improved energy efficiency.

Full Support for Green Steel Manufacturing

Piping Technology & Products, the parent company of US Bellows, manufactures a full range of engineered solutions for high-temperature, high-performance industrial systems:

  • Refractory-lined metal expansion joints
  • Engineered pipe shoes and anchors
  • Metal and fabric expansion joints
  • Slide plates and pre-insulated supports
  • High-temperature insulation systems
  • From renewable energy facilities to aluminum and steel production, we help EPCs deliver complex systems on spec, on time, and built for the future.

    Need help specifying a piping support system for a high-heat application?

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    11′ Fabric Expansion Joints Designed for a Gas Turbine Exhaust

    April 4, 2025

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    U.S. Bellows, Inc. fabricated rectangular fabric expansion joints for a gas turbine. They are 136″ L x 54″ W 12″ face-to-face. The frame and liner are fabricated from stainless steel and the fabric belt is 1-ply PTFE. The expansion joints are designed for 600°F at +/- 100″ water column.Dye penetrant examination was performed on the welds prior to shipment.

    In gas turbine installations, fabric expansion joints are essential for managing the high-temperature exhaust gases that flow from the turbine into downstream components such as heat recovery steam generators (HRSGs), bypass stacks, and emissions control systems. These joints are typically installed in the rectangular ductwork that channels exhaust flow, and they provide the flexibility needed to absorb thermal expansion, vibration, and slight misalignments between components. Because gas turbines operate at extreme temperatures and may cycle frequently, fabric expansion joints are engineered with high-performance materials—such as PTFE, silicone, or high-temp insulation layers—to withstand intense heat, pressure fluctuations, and corrosive gases. Their ability to handle large movements and simplify maintenance access makes them a preferred solution over rigid metal joints in many turbine exhaust applications.

    Rectangular fabric expansion joints are a critical component in industrial ducting systems where flexibility, thermal movement, and vibration isolation are essential. These joints are widely used in power plants, refineries, steel mills, cement plants, and other heavy industrial environments—particularly in systems that carry hot gases, air, or exhaust rather than liquids. Their lightweight and flexible design allows them to absorb multi-directional movements and misalignments that occur in large duct systems, especially around boilers, precipitators, scrubbers, and stacks. Fabric joints can be customized with layers of insulation, reinforcement, and protective coatings to handle high temperatures, chemical exposure, and particulate-laden flows—making them a smart, cost-effective solution in challenging service conditions.

    PT&P REF. ORIGINAL POST 02162014

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