CASE STUDY-MODULAR LINING AT SMOKE CHAMBER/RISER DUCT AT A CUSTOMER IN INDIA COMPANY OVERVIEW : The customer is a 25 years old, large Cement producer in.

CASE STUDY-MODULAR LINING AT SMOKE CHAMBER/RISER DUCT AT A CUSTOMER IN INDIA

COMPANY OVERVIEW :

• The customer is a 25 years old, large Cement producer in Western India.• 5 production Units with 9 kilns.• Cement capacity of 27MTPA.• Most profitable and low cost cement producer in World.

CASE STUDY-MODULAR LINING AT SMOKE CHAMBER/RISER DUCT

Country: India

Plant group name: XX

Plant name: XX

Main equipment supplier: Polysius

Production capacity: 4400, 4400 and 3500 TPD

Number of production lines: 3

Run factor: 0,95

Main fuel: Coal/Baggase/Industr. waste

HASLE ASSOCIATION & PERFORMANCE :

• One of the Oldest & Regular user of HASLE products in India.• Started with 5 MT of D52A way back in 1994.• First installation of Modular Lining in Smoke Chamber in India at their plant in 1995.• Due to excellent performance in 1st Line ,Modular Lining standardized for all

expansions.• Subsequently standardized use of Modular Lining in Smoke Chamber and Riser Duct

areas in all New Lines at Project stage itself.• Longest Life of 7 years achieved at one of the Unit.

Excellent performance in 1st Line ,Modular Lining is standardized for all expansion projects

The Installation of Modular Lining in Smoke Chamber and Riser Duct areas

( Arrangement of Modular Lining)

( Arrangement of Modular Lining)

The Installation of Modular Lining in Smoke Chamber and Riser Duct areas

The Installation of Inlet Arch

PRECAST MODULAR LINING IN SMOKE CHAMBER / RISER DUCT:

• The Customer had alkali and sulphur attack problems in kiln inlet area resulting coating/jamming.

• Good amount of production was being lost due to reduced areas of operation.• Heavy use of blasters/poking didn’t produce any satisfactory results.• The fuel used has been Coal, Baggasse ,Waste Materials and Pet Coke.• Use of HASLE Precast Modular Lining with D39A material produced instant results by

eliminating jamming and providing smooth flow of material in applied critical areas.• Within 6 months of trouble free operation customer ordered extension of areas.• There was no looking back after this.• New areas ,new orders and repeat orders.

CONCLUSION :

Performance of Modular Lining at this plant was the beginning of an unending era of

use of Modular Lining in India. The customers just multiplied as the coating/jamming was

a frequent problem at many plants and there was no consistent satisfactory solution

available.

HASLE R&D spent more time on this Anti-Coating Modular Lining to counter heavy

use of alternate fuels being used more and more by industry today.

Till date HASLE has executed almost 50 orders for Modular Linings for Smoke

Chamber/Riser Duct areas in India for all Major Cements producers.