Now a days, due to high cost of traditional fuels, most of the cement plants are switching to Alternative fuels like Pet Coke, Tyres, Municipal Solid waste, Pharmaceutical waste, Agro-waste, Plastics etc. Due to higher use of these alternative fuels, many plants are facing severe coating problem in their feed pipes due to which frequent cleaning of feed pipes required and many times, plant need to take small breakdown for cleaning purpose. Along with this coating issue, hazardous chemical produced from Alternative fuels react with castable and reduces its overall life. Due to which major portion of refractory need to be repaired in every shutdown. Also due to refractory wear its thickness decreases over the time and plants faces radiation losses which leads to more fuel consumption to maintain the inside operating temperature.
In general, as a traditional practice, low cement castable is used for lining in feed pipes in cement Industry. The feed pipes are generally brought to the ground position for refractory activity. Many preparatory arrangements must be performed before the start of casting in Feed pipe. These activities include mainly cleaning and applying anti corrosion paint on the inner surface of shell. Marking and welding of steel anchors and ensuring plastic caps on the tips of both legs of anchors. Fixing of hysil blocks to the shell in between anchors. Fabrication of forma for desired radius and all required support to fix them inside the pipe.
After all preparatory arrangements, Mixer machine and water arrangement must be made near the casting area. During casting, proper mixing, vibration and firm support must be ensured to achieve good casted panels. After casting one complete ring of panels minimum 6-8 hours idle time is required before doing casting for the next panel. Though it is a conventional practice, but it requires involvement of highly skilled manpower, more engagement of machineries, tools and tackles and very precision supervision to achieve smooth and strong casted panels.
But now, HASLE has introduced its PRECAST solution for feed pipe which provides much more benefits in comparison to the traditional practice. As the name suggests, the precast elements were manufactured and fired under controlled conditions in HASLE workshop and confirms to all technical parameters without any deviations ensuring its performance during operation. The precast lining requires less skill manpower, no major preparatory activities, no major equipment and tools and tackles for installation except measuring tools and PPES and consumes less time almost half the time required for traditional refractory lining in feed pipe.
The hot face surface offered by precast element is anti-coating friendly and highly resistant to alkali due to its compact structure (Low porous) and smooth surface finish. The precast lining offers longer refractory life in feed pipe due to its highly anti corrosion properties of the raw materials and because of lesser mechanical/pneumatic impact on refractory during cleaning of coating material.
The thickness of HASLE precast is lesser than the traditional castable lining in feed pipe which ultimately reduces the overall weight of feed pipe. Due to the non-use of metallic anchors and high abrasive properties, this practice offers less or no heat accumulation inside refractory structure which also increases the refractory life of feed pipe. Also, the use of compressible ceramic fibre blanket as an insulating/separating medium in the back up layer helps to offer a highly thermal efficient lining as compared to the traditional castable and hysil lining.
Feed pipes are placed on high altitudes, so its dismantling and then fixing at its operational position is very risky job also as Precast lining provides easy installation and longer life resulting in less number of manpower requirement in maintenance of same. So it improves plant safety index.
HASLE like to offer this precast solution for Feed pipes in cement Industry keeping in view of high coating, thermal loss in this area and safety index of plant.
HASLE precast in feed pipe will provide a low maintenance, longer refractory life and be a partner in achieving SDG goal by reducing the heat losses through refractory in this area.