Bharat Heavy Electricals Limited Ceramic Business Unit

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1 Bharat Heavy Electricals Limited Ceramic Business Unit If wear is your problem BHEL has the solution... CERALIN FOR A TROUBLE FREE TOMORROW

The Company Bharat Heavy Electricals Limited is the largest Engineering and Manufacturing Enterprise of its kind in India.

BHEL has 14 manufacturing plants, 4 power sector regional centres, 8 service centres, 18 regional offices and over 150 project sites spread all over

It offers a wide spectrum of products and services for core sectors like Power Generation, Transmission, Distribution, Industry, Transportation, Oil

Ceramic Business Unit The Ceramic Business Unit (CBU) of BHEL, is a Strategic Business Unit for Ceramics and Systems.

CBU is headquartered at Bangalore and is supported by: Manufacturing units with State of the Art technology for ceramic products, processes and

Ceramic products, processes and applications at Ceramic Technological Institute (CTI), Bangalore (A Division of Corporate Research & Development,

2 The Company 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. Ceramic Business Unit 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 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) Products 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

CERALIN a total solution against WEAR In steam generating units {Boilers} and associated pulverisers and other auxiliaries, high alumina ceramic material can be used for protection of

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

Ceramic lining is provided to the components to extend the life thereby reducing downtime.

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

3 CERALIN a total solution against WEAR 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. Protection Why? 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 Steel Sector Cement Sector Coal Sector : Wear prone components of Bowl / Tube Mill, Fuel Piping. : Sinter Plants, Rotary Kiln, Coke Oven : Cement & Raw Mills chutes & Air Separators : Slurry Pipes, Chutes & Launders Bowl Mill Components Classifier Inner Cone Venturi Vane Venturi Outlet Collar & Vane Multiple Port Outlet Mill Discharge Valve Tube Mill Components Connecting Duct Classifier Body PF outlet Box Circular Duct Internal Cone PF Outlet Venturi Fuel Piping System Transition Piece Mill Outlet Elbows & Pipes Line Bends Orifices Fuel Inlet Elbow

Ceramic Wear Resistant materials in its R&D. Components fitted with CERALIN are used all over India with a proven performance.

20 (Erosion test result) 24.17 TEST CONDITIONS: Particle Velocity: 50 m/sec 33.59 29.64 3 Erodent: Ash concentration of 0.

) Co-efficient of Thermal Expansion >2200 kg/cm -6 6 to 9 x 10 / C 2 The Ceramic tiles are designed with due consideration to the area of application and the type of fixing required.

4 Protective Lining - What? 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. Physical Properties Volume of Material lost in cubic centimeters per ton of ash Bulk Density >3.2 gm/cc Water Absorption < 0.5 % GRANITE FELSITE QUARTZ PORCELAIN BASALT CERALIN (Erosion test result) TEST CONDITIONS: Particle Velocity: 50 m/sec Erodent: Ash concentration of 0.25 kg/ Nm Period of Test: 60 min 0 Angle of Impingement: 45 Hardness (MOHs Scale) > 8 2 Cold Pulverising Strength > 3000 kg/cm Flexural Strength (at room temp.) Co-efficient of Thermal Expansion >2200 kg/cm -6 6 to 9 x 10 / C 2 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. Operating Conditions In coal fired steam generating units the normal operating conditions are: Flow medium Particle size Coal concentration Ash content Flow velocity Pressure Temperature : Pulverised coal mixture : 70% less than 75 microns 15% 75 to 90 microns 15% 90 to 150 microns. : to kg/nm : 50% Maximum : 30 mtr / Sec. Maximum : 0.5 kg / cm o : 300 C Max The components are designed to meet the operating parameters and life expectancy considerations. 2 3

Production Facilities Ceramic Tiles Manufacturing Ball

SPRAY DRYING FIRING CERALIN TILE Hydraulic Press High

at around 1560-1600 C to get required wear resistant

Ceralin tiles assembly to the casing is done by using

Product Assembly C E R A L I N T I L E S Mortar

5 Production Facilities Ceramic Tiles Manufacturing Ball Mill Spray Drier RAW MATERIALS BALL MILLING DRY PRESSING SPRAY DRYING FIRING CERALIN TILE Hydraulic Press High Temperature Kiln 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 o kilns at around 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 C E R A L I N T I L E S Mortar Fabricated Component Adhesive Fabricated Component Metal Plug Bends Elbows Pipes Cone MDV Orifice Venturi A. Fixing with Mortar B. Fixing with Adhesive C. Fixing with Metal Plug Fixing Method

6 Customer Profile 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. What our customers say? 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 to 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 hours. - Chief Engineer (O&M), RTPS, Raichur, KPCL, Karnataka, India. Bharat Heavy Electricals Limited (A Government of India undertaking) Registered and Corporate Office BHEL House, Siri Fort, New Delhi Tel: Fax: 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: Bharat Heavy Electricals Limited (A Government of India Undertaking) Ceramic Business Unit Prof. C.N.R. Rao Circle, Opp. Indian Institute of Science Malleswaram, Bangalore (India) Ph: , Fax: ,

Bharat Heavy Electricals Limited. Ceramic Business Unit. ollow. An ISO 9001, & Certified Company

Bharat Heavy Electricals Limited Ceramic Business Unit ollow An ISO 9001, 14001 & 18001 Certified Company Hollow 1 Alternate shed Plain shed 2 1 Flange 2 Porcelain Shell 3 Ground Collar 3 Straight bore