Ceramic Business Unitbhelceramics.com/screenshot/Ceralin_101208.pdf · Ceramic Business Unit CERALIN FOR A TROUBLE FREE TOMORROW. The Company ... Bowl Mill Components l Classifier

If wear is your problemBHEL has the solution...

Bharat HeavyElectricals LimitedCeramic Business Unit

CERALINFOR A TROUBLE FREE TOMORROW

The Company

Ceramic Business Unit

Bharat Heavy Electricals Limited is the largest

Engineering and Manufacturing Enterprise of its

kind in India. It ranks amongst the leading

manufacturers of power plant equipment in

the world.

BHEL has 14 manufacturing plants, 4 power

sector regional centres, 8 service centres, 18

regional offices and over 150 project sites spread

all over India and abroad. It offers a wide

spectrum of products and services for core

sectors like Power Generation, Transmission,

Distribution, Industry, Transportation, Oil & Gas,

Defence and Non-Conventional Energy Systems.

The Ceramic Business Unit (CBU) of BHEL, is a

Strategic Business Unit for Ceramics and

Systems. This business unit deals with High

Tension Insulators, Ceramic Wear Resistant

liners, Industrial Ceramic Products and

associated Systems. CBU is headquartered at

Bangalore and is supported by:

Manufacturing units with “State of the Art”

technology for ceramic products, processes and

applications at

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Electroporcelains Division (EPD), Bangalore

Insulator Plant (IP), Jagdishpur

Advanced Research and Development facilities

for Ceramic products, processes and

applications at

Ceramic Technological Institute (CTI),

Bangalore (A Division of Corporate Research

& Development, Hyderabad)

High Tension Insulators for Transmission and

Distribution lines from 11kV to 800kV

Hollow Insulators for Instrument and Power

Transformers, Switchgear, Electro Static

Precipitators, etc.

Station Post Insulators for Bus Bars support

and for Isolators from 11kV to 400kV

Composite Insulators for Railway Traction

and Transmission applications upto 400kV

Wear resistant Materials for Thermal Power

Plant applications, Steel, Coal Washeries,

Cement, etc.

Industrial Ceramic Products for various

applications

Products

CERALIN

CERALIN a total solution against WEAR

Protection Why?

In steam generating units {Boilers} and associated pulverisers and other auxiliaries, high alumina ceramic material can be used for protection of components against wear due to abrasion and erosion.

Coal is one of the main source of fuel used in power generation. Coal fired boilers adopt the method of pulverising raw coal in pulverisers or mills, conveying the pulverised coal-air mixture from the pulverisers to the boiler burner for producing and utilising steam to generate power. Fine coal particles at high velocities cause failure in many components in the pulverisers and the coal piping system of the boiler. Ceramic lining is provided to the components to extend the life thereby reducing downtime.

Range of Applications

Its superior wear resistance, chemically inert and high thermal stability characteristics make CERALIN suitable for a wide range of applications:

Power Sector : Wear prone components of Bowl / Tube Mill, Fuel Piping.

Steel Sector : Sinter Plants, Rotary Kiln, Coke Oven

Cement Sector : Cement & Raw Mills chutes & Air Separators

Coal Sector : Slurry Pipes, Chutes & Launders

Bowl MillComponents

l Classifier Inner Cone

l Venturi Vane

l Venturi Outlet Collar & Vane

l Multiple Port Outlet

l Mill Discharge Valve

Tube Mill Components

lConnecting Duct

lClassifier Body

lPF outlet Box

lCircular Duct

lInternal Cone

lPF Outlet Venturi

Fuel Piping System

l Transition Piece

l Mill Outlet Elbows & Pipes

l Line Bends

l Orifices

l Fuel Inlet Elbow

CERALIN

To combat the various wear prone areas in

Coal fired Thermal Power Stations, Coal

Sector, Steel Industry, Cement Industry and

others similar applications, BHEL has

indigenously developed High Alumina

Ceramic Wear Resistant materials in its R&D.

Components fitted with CERALIN are used

all over India with a proven performance.

Protective Lining - What?

Physical Properties

Bulk Density >3.2 gm/cc

Water Absorption < 0.5 %

Hardness (MOHs Scale) > 8

2Cold Pulverising Strength > 3000 kg/cm

Flexural Strength 2

(at room temp.) >2200 kg/cm

Co-efficient of Thermal-6

Expansion 6 to 9 x 10 /°C

Volume of Material lost in cubic

centimeters per ton of ash

(Erosion test result)

The Ceramic tiles are designed with due consideration to the area of application and the type of

fixing required. Curved, flat or weld-on type tiles are designed and engineered to suit the

component configuration and the end requirement.

In coal fired steam generating units the normal operating conditions are:

Flow medium : Pulverised coal mixture

Particle size : 70% less than 75 microns 15% 75 to 90 microns 15% 90 to 150 microns.

3Coal concentration : 0.935 to 1.545 kg/Nm

Ash content : 50% Maximum

Flow velocity : 30 mtr / Sec. Maximum2

Pressure : 0.5 kg / cmo

Temperature : 300 C Max

The components are designed to meet the operating parameters and life expectancy considerations.

Operating Conditions

CERALIN

GRANITE

FELSITE

QUARTZ PORCELAIN

BASALT

CERALIN

33.59

29.64

24.17

TEST CONDITIONS:

Particle Velocity: 50 m/sec3Erodent: Ash concentration of 0.25 kg/ Nm

Period of Test: 60 min0Angle of Impingement: 45

6.20

1.44

Production Facilities

Ceramic Tiles Manufacturing

Hydraulic Press

Ball Mill

High Temperature Kiln

Spray Drier

Ceralin is manufactured using Calcined Alumina

as a raw material. Spray dried powder is then

compacted in Hydraulic Presses to form tiles.

These tiles are then fired in a high temperature okilns at around 1560-1600 C to get required wear

resistant characteristics. Ceralin tiles assembly to

the casing is done by using Mortar, Silicone

adhesives or Weld-on tiles.

Product Assembly

Fixing MethodMortar

FabricatedComponent

Adhesive

Metal Plug

CERALIN

TILES

A. Fixing with Mortar

BendsElbowsPipes

B. Fixing with AdhesiveCone

MDVOrificeVenturi C. Fixing with

Metal Plug

FabricatedComponent

CERALIN

RAW MATERIALS

DRY PRESSING

FIRING

BALL MILLING

SPRAY DRYING

CERALIN TILE

Bharat Heavy Electricals Limited

Bharat Heavy Electricals Limited

(A Government of India undertaking)

Registered and Corporate OfficeBHEL House, Siri Fort, New Delhi - 110 049.Tel: 011-2600 1010 Fax: 011-2649 3021

www.bhel.com

Efforts are constantly being made to improve the product design and hence the products supplied may differ in minor details from that given in the catalogue.

For enquiries please contact:

(A Government of India Undertaking)

Ceramic Business UnitProf. C.N.R. Rao Circle,Opp. Indian Institute of ScienceMalleswaram, Bangalore-560 012 (India)Ph: 080-23442988, 22182247 Fax: 080-23560741, 23344231

www.bhelceramics.com

CERALIN is having major presence in coal fired

thermal power stations, Cement sector & Steel Sector.

Major customers list includes NTPC, DVC, Jindal,

Tata Power, Nalco, Hindaco, HZL, Torrent Power,

State Electricity Boards for their Power Stations,

SAIL and Cement companies.

Customer Profile

“Ceralin Lined Orifices supplied to BTPS have given double the life as compared with Ni-Hard.”

- Kulvinder Singh, Supdt., BMD-I, BTPS, NTPC, New Delhi, India

“Performance of Ceralin Lined Bends of Unit I & II are found very satisfactory since the commissioning”.

- Dy Chief Engineer (GEN), 210 MW TPS, MSEB, Khaperkheda, Maharashtra, India

“The Ceralin Lined Bends supplied & erected by M/s BHEL during erection of 210 MW Unit I, II, III, IV have performed well & lasted for 20000 to 30000 service hrs.”

- Er K Raju, Chief Engineer (GEN), MTPS, Mettur Dam, Tamil Nadu, India

“Ceralin Lined Bends installed in Unit I & II PF lines have given life of more than 25000 hours.”

- Chief Engineer (O&M), RTPS, Raichur, KPCL, Karnataka, India.

What our customers say?