UPGRADED THERMAL INSULATION FOR MINIMIZING HEAT LOSSES

CEMENT MFG. FLOW CHART

MINES

CRUSHING

STACKER & RECLAIMER

RAW MILL

BLENDING & STORAGE

COAL STORAGE

COAL CRUSHER

COAL MILL

PYRO PROCESSING

GYPSUM PURCHASE COAL

CLINKER SILO CEMENT MILL PACKING & DESPATCH

SLAG OR FLY ASH

THERMAL INSULATIONS IN CEMENT PLANT

DESIGN CRITERIA (FOR PROPOSED SYSTEM):
Ambient temperature Surface Temp Maximum heat loss Wind Velocity Finish : : : : : 40 C 60 C 100 kcal / m2hr. 0.0 m/sec. Aluminium-20 G (0.2 emissivity) GI-24 G (0.3 emissivity)

MATERIAL CODE :
Rockloyd Resin Bonded Rockwool Mattresses 100-120 Kg/M3 Rockloyd Resin Bonded Rockwool Mattresses 150 Kg/M3 For operating temp. up to 400 C Temperature above-400 C

Preformed Pipe Sections For All Temperatures 144 Kg/M3 & up to 350 mm NB Rockloyd Rockwool Pipe Sections-144 Kg/M3 Up to 650 C

THERMAL INSULATIONS IN CEMENT PLANT

SECTION SUB-SECTION OPERATING TEMP. ( C) 200-225 300 100 100 100 280 280 100 280 240 100 ROCKLOYD MATTRESS DENSITY 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 INSULATION THICKNESS (MM) 90 140 25 25 25 65-140 140 25 140 140 25

REVERSE AIR BAG HOUSE FOR KILN / RAW MILL DUCT FROM PH FAN TO MILL DUCT FROM MILL TO CYCLONE RAW MILL DEPARTMENT DUCT FROM CYCLONE TO MILL FAN DUCT FROM MILL FAN TO RABH PIPING FROM RABH TO BAGHOUSE FAN (Pipe Dia 15 mm 600 mm) DUCT FROM RABH FAN TO STACK RECIRCULATION AIR DUCT PREHEATER FAN TO RABH THROUGH BYPASS DUCT BAG HOUSE FAN RAW MILL FAN

Approximately Heat Loss 90-100 Kcal / Sqm. Hr.

Surface Temp. = 60 C

THERMAL INSULATIONS IN CEMENT PLANT

SECTION SUB-SECTION OPERATING TEMP. ( C) 300 300 300 100 100 100 100 310 95-120 300 80-110 80-110 80-100 ROCKLOYD MATTRESS DENSITY 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 100-120 Kg/m3 INSULATION THICKNESS (MM) 140 140 140 25 25 25 25 150 35 140 25 25 25

DUCT FROM PH FAN TO DEDUSTING CYCLONE DUCT FROM CYCLONE TO BOOSTER FAN DUCT FROM BOOSTER FAN TO MILL DUCT FROM MILL TO EXPLOSION VENT & THEN TO BAG FILTER DUCT FROM BAG FILTER TO MILL FAN COAL GRINDING DEPARTMENT DUCT FROM FAN TO ATOMOSPHERE RECIRCULATION AIR DUCT COAL MILL BAG FILTER FAN COAL MILL BOOSTER FAN COAL MILL BAG HOUSE DUST COLLECTOR FINE COAL BIN DEDUSTING PIPE

Approximately Heat Loss 90-100 Kcal / Sqm. Hr.

Surface Temp. = 60 C

THERMAL INSULATIONS IN CEMENT PLANT

SECTION SUB-SECTION OPERATING TEMP. ( C) 296-450 296-450 296-450 ROCKLOYD MATTRESS DENSITY 100-150 Kg/m3 100-150 Kg/m3 100-150 Kg/m3 INSULATION THICKNESS (MM) 135-275 135-275 135-275

CYCLONE PREHEATER DEPARTMENT

DUCT FROM PH CYCLONE TO FAN INLET CHUTE UNDER TOP CYCLONE PH FAN

Approximately Heat Loss 90-100 Kcal / Sqm. Hr.

Surface Temp. = 60 C

THERMAL INSULATIONS IN CEMENT PLANT

SECTION SUB-SECTION OPERATING TEMP. ( C) 100 ROCKLOYD MATTRESS DENSITY 100-120 Kg/m3 INSULATION THICKNESS (MM) 25

CEMENT MILL FAN

CEMENT MILL BAG HOUSE

100

100-120 Kg/m3

25

CLINKER GRINDING PLANTCEMENT MILL

DUCT FROM CEMENT MILL TO BAG HOUSE

90

100-120 Kg/m3

25

DUCT FROM BAG HOUSE TO FAN

95

100-120 Kg/m3

25

RECIRCULATION AIR DUCT TO STACK

95

100-120 Kg/m3

25

RECIRCULATION DUCT

95

100-120 Kg/m3

25

Approximately Heat Loss 90-100 Kcal / Sqm. Hr.

Surface Temp. = 60 C

THERMAL INSULATION
Thermal Insulation is the system which is provided to retard flow of heat and is used as a barrier between two bodies of different temperatures to Either a) reduce the heat loss from a hot body or b) reduce the heat ingress into a cold body.

INSULATION AUDIT SERVICES

Lloyd insulation audit is the only scientific

methodology available indigenously for quantified analysis of performance of existing insulation

systems in a plant. assist in

Observations and recordings a database for existing

developing

performance levels and for determining technoeconomic feasibility for upgradation of insulation.

LLOYD RANGE OF PRODUCTS

ROCKLOYD ROCKWOOL MATTRESS / BLANKET faced with one side GI or SS wire netting.

ROCKLOYD ROCKWOOL MATTRESS

SPECIFICATION CONFORMANCE
IS BS : : 8183 1993 3958 Part-3 C 592-80

ASTM :

APPROVED FOR A-60 CLASS INSULATION .* *The only product in India.

ROCKLOYD ROCKWOOL MATTRESS

TECHNICAL SPECIFICATIONS
1 2 Standard Densities Application Temperatures Standard Thickness* Standard Size 100, 120, 150 Kg/m3 -1000C to +8000C

3 4

25, 40, 50, 65, 75mm 1520 x 1220mm

* Other thickness from 20 to 100mm insteps of 5mm can also be made available.

LLOYD RANGE OF PRODUCTS

TECHNICAL PROPERTIES OF ROCKLOYD LRB MATTRESS TEST 1 Bulk Density (Kg/m3) 2 Shot Content Over 500 Microns Over 250 Microns 3 Moisture Content 4 Moisture Absorption 5 Sulphur Content RESULTS 100.34 to 121.15 to 104.68 125.72 2.88% 7.16% 0.118% 0.127% 0.159% 2.47% 6.98% 0.115% 0.120% 0.156%

LLOYD RANGE OF PRODUCTS

TECHNICAL PROPERTIES OF ROCKLOYD LRB MATTRESS TEST Incombustibility % Loss in Weight Chloride Content Alkalinity Average Fibre Dia RESULTS The material is Incombustible 1.41% 0.0018% 8.2 3.86 Microns 97.4% 1.35% 0.0017% 8.2 3.86 Microns 96.7%

7 8 9

10 Compressibility and Resilience

LLOYD RANGE OF PRODUCTS

TECHNICAL PROPERTIES OF ROCKLOYD LRB MATTRESS TEST 11 Heat Resistance Test at 6500C for 96 Hrs. 12 Remarks RESULTS O.K. No fusion of fibres observed The material conforms to IS : 8183-1993

LLOYD RANGE OF PRODUCTS

ROCKLOYD PIPE SECTIONS - pre-formed pipe section of pipe dia upto 350mm NB

LLOYD RANGE OF PRODUCTS

ROCKLOYD AL. FOIL LAMINATED PIPESECTION

ROCKLOYD PIPE SECTION

SPECIFICATION CONFORMANCE
IS BS : : 9842 3958 Part-4 C 547-95

ASTM :

ROCKLOYD PIPE SECTION

TECHNICAL SPECIFICATIONS
1 2 3 4 5 6 Standard Densities 144, 150 & 160 Kg/m3

Application Temperatures -1000C to +8000C Standard Thickness* Diameter Range** Standard Length Facings (if specified) 25, 40, 50, 65, 75mm 12.5mm to 350mm Nominal Bore 0.5, 0.75, 1.0 mtrs. Kraft Paper, Scrim Cloth, Canvas or Aluminium Foil

*Other thickness from 20 to 100mm insteps of 5mm can also be made available. ** Outer diameter of pipe to be specified.

LLOYD RANGE OF PRODUCTS

TECHNICAL PROPERTIES OF ROCKLOYD PREFORMED PIPE SECTION
TEST 1 Bulk Density (Kg/m3) 2 Shot Content Over 500 Microns Over 250 Microns 3 Moisture Content 4 Moisture Absorption 5 Sulphur Content RESULTS 144.62 to 148.25

2.67% 6.76% 0.110% 0.119% 0.128%

LLOYD RANGE OF PRODUCTS

TECHNICAL PROPERTIES OF ROCKLOYD PREFORMED PIPE SECTION
6 TEST Incombustibility % Loss in Weight Chloride Content Alkalinity Average Fibre Dia RESULTS The material is Incombustible 0.97% 0.0018% 8.1 3.85 Microns 96.9%

7 8 9

10 Compressibility and Resilience

LLOYD RANGE OF PRODUCTS

TECHNICAL PROPERTIES OF ROCKLOYD PREFORMED PIPE SECTION TEST 11 Heat Resistance Test at 6500C for 96 Hrs. 12 Remarks RESULTS O.K. No fusion of fibres observed The material conforms to IS : 9842-1994

THERMAL INSULATION
HOT PIPELINE INSULATION APPLICATION SPECIFICATIONS FOR HORIZONTAL / VERTICAL PIPELINES For single layer insulation up to maximum thickness of 75mm 1. Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. 2. Providing and fixing MS flat ring of size 25x3mm, over pipe having diameter more than 150mm NB, at every 1150 mm distance having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt.

THERMAL INSULATION
3. Providing and fixing the recommended insulation thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G . 4. Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface .

5. Providing and applying aluminium sheet as cladding over the MS flat ring already provided at 1150mm distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS94. 6. Providing and applying 22G aluminium band at every 450mm C/C over the cladding to secure it firmly to its place.

THERMAL INSULATION
7. Providing and applying 22G aluminium band at every 450mm c/c over the final layer of insulation to secure it firmly to its place. 8. Providing and applying Aluminium sheet as cladding screw over the MS flat ring already provided at 1150mm distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94. 9. Providing and applying 22G Aluminium band at every 450mm c/c over the cladding to secure it firmly to its

THERMAL INSULATION
HOT PIPELINE INSULATION APPLICATION SPECIFICATIONS HORIZONTAL PIPELINES FOR VERTICAL &

For multiple layer insulation above 75mm thickness. 1. Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. 2. Providing and fixing MS flat ring of size 25x3mm over pipes having diameter more than 150mm NB at every 1150mm distance having L shaped lugs with a packing of ceramic paper duly riveted and tightening it over the surface with nut and bolt.

THERMAL INSULATION
3. Providing and fixing the first layer of insulation in recommended thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G. 4. Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface. 5. Providing and fixing the second / subsequent layer of insulation in recommended thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G. 6. Butting each joints and stitching the mattress properly with GI Wire of 20G to secure it firmly to the surface.

THERMAL INSULATION
7. Providing and applying 22G aluminium band at every 450mm c/c over the final layer of insulation to secure it firmly to its place. 8. Providing and applying Aluminium sheet as cladding screw over the MS flat ring already provided at 1150mm distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94. 9. Providing and applying 22G Aluminium band at every 450mm c/c over the cladding to secure it firmly to its

THERMAL INSULATION
APPLICATION SPECIFICATION FOR EQUIPMENTS
1. Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. 2. Providing and fixing MS flat ring of size 25x3mm at every 1150mm distance c/c having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt. 3. Providing and welding GI wire pins of 8 to 10G diameter having length 20mm more than the thickness of insulation at every 300mmc/c(incase of equipments having diameter more than 1000 mm).

THERMAL INSULATION
APPLICATION SPECIFICATION FOR EQUIPMENTS
4. Providing and fixing the recommended insulation thickness of Rockloyd Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm x 24G and piercing it through the GI wire pins. 5. Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface. 6. Bending the pins over the insulation surface.

THERMAL INSULATION
APPLICATION SPECIFICATION FOR EQUIPMENTS
7. Providing and applying 22G AL band at every 450MM C/C over the insulation to secure it firmly to its place. 8. Providing and fixing 22G Aluminium sheet cladding over the MS flat ring already provided at 1150mm C/c duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 40mm. Sealing all the joints with mastic MAS-94.

INSULATION OF EQUIPMENTS

ESP INSULATION
THE CASINGS ARE INSULATED WITH ROCKWOOL

THERMAL INSULATION OF STEAM LINES

Pipelines at ground level exposed to Atmosphere and prone to foot traffic
1. 2. 3. Cleaning the pipe surface properly. Providing and applying metal ring wherever pipe dia is more than 150mm NB. Providing & applying required thickness of Rockloyd Water Repellent Grade Rockwool Pipesections (max. 75mm and upto 350mm nb) of density 144 kg/m3 conforming to IS : 9842 and held in position by 25mm wide Aluminium bands at 450mm Centre to Centre. OR Providing and applying required thickness of Rockloyd Water Repellent Grade Rockwool slabs of density 100 or 150 Kg/m3 conforming to IS : 8183 and held in position by 25mm wide Aluminium bands at 450mm Centre to Centre.

4.

THERMAL INSULATION OF STEAM LINES

Pipelines at ground level exposed to Atmosphere and prone to foot traffic Providing and applying 2nd layer of Rockloyd Water Repellent Grade Rockwool slabs 100 or 150 kg/m3 and holding the same with 25mm Aluminium band. Second layer of insulation to be applied where total thickness is more than 75mm. Providing and applying 0.01mm Aluminium Foil over the insulation surface and joints sealed with 75mm wide Aluminium Tape. Providing and applying 20mm hard setting plaster over the insulation surface and coated with a waterproof paint.

5.

6.

7.

THERMAL INSULATION OF STEAM LINES

Pipelines at ground level exposed to Atmosphere and prone to foot traffic 8. 9. Providing and applying 22G Aluminium Sheet or Colour Coated Steel Sheet cladding. Providing and applying 25mm Aluminium Band or Steel Band at 450mm Centre to Centre.

THERMAL INSULATION OF STEAM LINES

Effect of Wind Velocity Presence of Wind in surrounding takes away heat generated from cladding surface. A strong wind will carry away heat and ensure a lower surface temperature. Windage has effect on insulation thickness reduces with increase in windage. For energy conservation, windage is taken as Zero.

THERMAL INSULATION OF STEAM LINES

Effect of Emissivity Heat coming on top of insulation is emitted out. Polished surface will emit maximum heat (Aluminium) Aluminium calls for higher thickness & GI, Plaster lower thickness Old aluminium will emit lower heat as compared to new sheet.

THERMAL INSULATION OF STEAM LINES

Cladding Cladding corrosion due to condensation on inner side Moisture present on inner side condenses & lower corrosion to cladding sheet. Polysurlyn coated aluminium sheet is now available(earlier bitumen coating underneath).

THANK YOU !!
THANK YOU !!