GRAPHALLOY® Flange Blocks Improve Damper Reliability in Ammonia Facility SMR Operations

A major ammonia production facility upgraded the damper actuators on its steam methane reformers with GRAPHALLOY flange blocks and copper-grade bushings, replacing roller-element bearings that were failing in high-temperature, contaminated air. The plant had seen more than three years of reliable operation from GRAPHALLOY components in a similar installation and chose the same solution for this project. The new assemblies were installed in March 2025 and are performing as expected in temperatures up to 420°F.

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GRAPHALLOY® Pillow Blocks - The Problem Solvers

Cost-Saving Solutions for Harsh Environments

• GRAPHALLOY^® 845 series flange units have reduced maintenance costs in Chicken Roasters by more than 50% after replacing standard ball bearing units.
• 400°F temperatures caused failure in pillow blocks on a Hot Strip Mill Run Out Table.  GRAPHALLOY 448 pillow blocks were able to withstand the temperature as well as the quench spray.
• Conveyor running above a 1020°F zinc bath presented a problem for traditional bearings. GRAPHALLOY 318 flange units provided years of trouble free operation.
• A vacuum at 1500°F is an environment that most bearings cannot handle. GRAPHALLOY 963 pillow blocks have been running for more than a year without problems.
• Six years of maintenance free operation was the result of the GRAPHALLOY replacements of spherical roller bearing pillow blocks on a salt cake conveyor.
• Fish screens in the Columbia River is a great application for submersible GRAPHALLOY pillow blocks.
• Harsh chemical wash down required replacing 24 of 96 ball bearing pillow blocks on a weekly basis.  GRAPHALLOY 845 pillow blocks have run for more than six years with an annual savings exceeding $20,000.
  
  

GRAPHALLOY^® Pillow Blocks and Flange Units

• Come in FDA accepted grades 
• Impervious to temperature extremes from -400°F to +750°F 
• Withstand wash down and harsh chemical environments 
• Available in split and solid bushings and housings

Pillow Block Assemblies Designed for Long-Life

Pillow Block and Flange Block Assemblies from Graphite Metallizing are equipped with a GRAPHALLOY ^® bushing and are designed for long-life operation. They are easy to install and will operate successfully under a variety of conditions.

Depending on the application, our Pillow Blocks and Flange Blocks are available as in split, solid, solid, self-aligning, cast iron, stainless steel and in a two-bolt or four-blot arrangement.

GRAPHALLOY Pillow Block and Flange Block Assemblies eliminate maintenance and frequent replacements while providing increased reliability.

Visit our website to learn more about GRAPHALLOY Pillow Blocks and Flange Blocks.

Solutions With GRAPHALLOY® 4-Bolt Flange Inserts

High temperatures were causing premature failures of 4-bolt flange bearings in this glass manufacturer’s lehr. Bearings had to be heavily greased in an attempt to keep them running.

Unfortunately, the excessive use of grease was causing a safety and fire hazard. Chronic failures were still occurring, resulting in frequent down time and lost production.

An economical solution was found by retro-fitting the existing housings with GRAPHALLOY® 845 Series Inserts. The inserts have now lasted more than a year without a single failure or need for replacement. Using GRAPHALLOY 4-Bolt Flange Inserts has saved this company over $150,000 to date.

New GRAPHALLOY® Stainless Steel Flange Block Suitable for Wet or Submersible Applications

A new series of GRAPHALLOY® self-lubricating bushings mounted in stainless steel flange blocks is now available from Graphite Metallizing Corporation. The new series combines the corrosion resistant and self-lubricating properties of GRAPHALLOY with the application and installation versatility of a flange block.
GRAPHALLOY Stainless Steel Flange Blocks are available in 2-bolt and 4-bolt configurations,come in a wide range of base dimensions, and can accommodate shaft diameters from .5" (12.7 mm) to 3.75" (95.2 mm).

GRAPHALLOY is suitable for temperatures of 750°F/399°C and above in non-oxidizing environments or with oxidation -resistant grades.

GRAPHALLOY Stainless Steel Flange Blocks provide increased reliability and years of trouble-free operation. These flange blocks deliver lifetime cost and operating advantages in high temperature ovens, low speed and stationary applications such as dampers, and other hard to lubricate environments - all places where other bushings will not operate.