Stretching lining lifetimes

Nestled between trees outside Chandrapur in Maharashtra state, India, lies Ambuja Cement’s Maratha Cement Works Unit. Ambuja Cements Ltd. is a member of Holcim, the global leader in innovative and sustainable building solutions. Among the leading cement companies in India, with a capacity of 29.65 million t, Ambuja Cement has five integrated cement manufacturing plants and eight cement grinding units across the country. Ambuja Cement’s plants operate on Indian coal and approximately 11 – 12 % alternative fuels and are continuously seeking ways to operate in a more efficient and sustainable fashion.

The company has focused on environmentally friendly practices since it started operations in 1983, At the start of 2021, Ambuja Cements Limited became the first ever cement company to make it to the ‘A’ list in global water stewardship by the CDP (formerly the Carbon Disclosure Project) based on its disclosure in 2021. At the core of the company’s modus operandi is embracing sustainability one step at a time. Achieving more sustainable production entails lowering the use of natural resources, reducing the use of fossil fuels, and optimising energy use – installing HASLE’s precast modular lining has been part of the solution for the Maratha Cement Works Unit.

Solving short lining lifetime in the kiln inlet arch

In early 2015, the cement plant had been experiencing problems with short lining lifetime in the kiln inlet arch. The plant had been using a low cement castable to line the arch, but unfortunately, the lifetime of the lining was always less than one year. The installation required proper form-work and skilled workmen to achieve the desired shape and quality lining, and the time required for both installation and curing was extensive, due to the location and shape of the arch.

Needing a long-lasting and sustainable alternative, Ambuja Cement’s Maratha Cement Works Unit turned to HASLE for a suggestion on how to solve the short lining lifetime in this area. After analysing the operating conditions, HASLE’s team of engineers suggested lining this critical process area with a unique precast modular lining. The precast modular lining is a hot face refractory lining for the critical areas of high temperature industries; it is durable and resistant to abrasion, chemical attack, and coating, resulting in a significantly longer lifetime than the existing alternatives on the market. Since its creation, it has stood the test of time and will typically last two-to-three times longer (or more) than a traditional cast lining. Soon after, it was decided to install HASLE’s precast modular lining in the kiln inlet arch – a decision which has since proved to be very beneficial for the plant. The installation took place in August 2015, and as always, a team of HASLE supervisors participated on site to ensure that the optimal installation technique was used.

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Read the article online at: https://www.worldcement.com/special-reports/19082022/stretching-lining-lifetimes/