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We provide an Innovative & Cost-Effective Industrial solution for the purpose of False Air arrestment.

Welcome You Vineet Kumar Sharma

Ketan Goel

Significant Savings in Energy through False air reduction.

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2nd NATIONAL WORKSHOP CUM TECHNOLOGY EXHIBITION FOR

PROMOTING ENERGY EFFICIENT AND CLEANER PRODUCTION FOR

SUSTAINABLE INDUSTRIAL GROWTH

Safety Thought: Safety Should be thought of as an investment, not a cost.

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Energy Consumption Impacting Production Cost

• Electrical and Thermal energy accounts for 40 to 50% cost of cement manufacturing.

*Approximate Average Value taken for calculation purpose only

Description UOM Value

Specific Electrical Energy consumption

Kwh/t Cement 75*

Specific Thermal Energy consumption

KCal/Kg Clinker 750*

Specific CO2 emission net Kg/t Cementitious material

530 to 650*

Specific CO2 emission for Electricity Production

Kg/MWh 820*

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Our contribution

• Global Warming

• Environment issues

• Energy Conservation issues

Our Product range help to cope with

We help to reduce energy consumption by decreasing false air content in the system hence increasing efficiency of

manufacturing process in Cement Plants, Thermal Power Plants, Green Power Plants, WHRS etc.

PAT

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False air is any unwanted air entering the system between two points.

Point-1 Point-2

GAS

The exact amount of false air is difficult to measure. An indicator of false air amount can be the oxygen increase between two points (usable for gas stream containing less than 21% of oxygen).

What is False air

Disadvantages of False Air: (1) Increase in Electrical Energy Consumption (2) Increase in Thermal Energy Consumption (3) Reduction in Productivity (4) Unstable and disturbed operation (5) Frequent human exposure to unsafe areas while arresting false air 5

Our Product Portfolio

• Arrest Master 1001





• Application Areas:

Cement Plants

Power Plants

Green Power Plants

WHRS & Steel Plants

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ARREST MASTER 1001

Product Highlights Two Component System

• Part A & Part B (1:1 Mix Ratio). • Temp. Resistance: 180⁰C • For Upper Cyclones, VRM’s &

Power plants. • Density: 2.5 g/cm3 • Compressive Strength: 500-

525 Kg/cm2 • Non shrinkable properties &

no tools required for application.

• Pot Life: 30 Min. • Setting Time: 5 min at 80⁰C

FALSE AIR ARRESTING COMPOUND 7

Cyclone Main Door

Before After

ARREST MASTER 1001 8

Flapbox

Before After

9 ARREST MASTER 1001

Downpipe Flanges

Flange Flange


Dispersion Plate

• Side View • Front View


Manhole door (Pre-Calciner vessel Upcomer duct)

Before After


VRM Section

Cleaning Application


VRM Section- Master Roller Door

Before After


ARREST MASTER 1002


• Part A & Part B (1:1 Mix Ratio).

• Temp. Resistance: 150⁰C

• For Bag-house & Bag-filters of (Raw Mill, Cement Mill, Coal Mill).

• Density: 2.3 g/cm3

• Compressive Strength: 425-450 Kg/cm2

• Non shrinkable properties & no tools required for application.

• Pot Life: 20 Min.

• Setting Time: 10 min at 80⁰C


CVRM Bag-house : Top Door

Full view (Bag-house 1) Full View (Bag-house 2)


CVRM Bag-house : Top Door

After After


VRM- Hopper door

Before After


ARREST MASTER 1003


• Part A & Part B (3:2 Mix Ratio) • Temp. Resistance: 500⁰C (For

high Temperature areas) • Application Areas: Bottom

Cyclones, Calciner, Boiler Main Doors.

• Density: 3.0 g/cm3 • Compressive Strength: 300-

325 Kg/cm2 • Non shrinkable properties &

excellent resistance to thermal shock.

• Inorganic Glass Ceramic Compound.

FALSE AIR ARRESTING COMPOUND

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Hot air damper

After Close-up


Flap valve door (K-line, 5th cyclone feed pipe connected to pre-calciner vessel).

Before After


ARREST MASTER 1004


• Part A & Part B (3:2 Mix Ratio). • Temp. Resistance: 800⁰C (For high

Temperature areas). • Density: 2.3 g/cm3 • Compressive Strength: 200-275

Kg/cm2 • Non shrinkable properties &

excellent resistance to thermal shock.

• Inorganic Glass Ceramic Compound.

• Pot Life: 20 Min. • Setting Time: 5 min at 200⁰C


ARREST MASTER 2001

Product Highlights High Vibrations Area

• One Component system.

• Temp. Resistance: 180⁰C

• Application Areas: VRM Section, Fans, Hammering System of GPP.

• Density: 1.04 g/cm3 (at 25’C).

• Ultimate Elongation (S2 dumbbell): 200 %

• Excellent adhesion to most metals & excellent durability.

• For areas having vibrations.


Bellow of Mill roller

After Close- up


Mill inlet duct

Before After


Packaging of Arrest Master

Part A Part B

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Advantages of Arrest master Series over Conventional Methods and Products

Property Conventional Method/Products

Arrest Master

Life of application Short As long as desired

Method and time required for application

Experienced meson required and takes long time

easy and less time taking, any body can do application

Effectiveness Less and decreases with time

High, Remains effective till whole life

Resistance to thermal shock

Less, cracks and damage occurs due to thermal shock

High, can withstand against thermal shock and shrinkage and expansion

Venerability to plant start-stop

High, required to replace after few start stops

Less, remains intact even after many start stops

Requirement of repair and recheck

frequent Nil

Ability to withstand vibrations

Not able Can withstand up to 7mm/s vibrations (AR-2001)

Working temperature less High up to 800 Deg C 27

Savings through False air reduction

Case Studies:

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1) Single String Preheater 2) Double String Preheater 3) Cement Mill VRM

Single String Pre Heater 1% FALSE AIR REDUCED AT PREHEATER OUTLET

Date 19th Nov,2016

Type Of plant Five stage ILC

Kiln length 65 Metrs

Kiln Dia 4.2 Metrs

Heat Consumption 750 K Cal/Kg-Clinker

Type of Cooler Grate cooler

S No Particulars Unit Values

1 Parameters

1.1 Kiln Feed TPH 315 1.2 Clinker Factor 1.62 1.3 Barometric Pressure at site mmWg 10036 1.4 Ambient Trmp Deg C 25 1.5 Power Cost Rs/Unit 3.2 1.6 Coal CV K Cal/Kg Coal 7800 1.7 Coal Cost Rs/Kg 8 1.8 PH Out let pressure mmWg 800

Pressure at PH fan Inlet mmWg 850 1.9 PH Out let temp. Deg C 300

1.1o Flow at PH Out Let m3/Hrs 731000 1.11 Flow at PH Out Let Nm3/Hrs 311333

2 False air 1% 2.1 False air Volume m3/Hrs 7310 2.2 False air Volume Nm3/Hrs 3113 3 LOSS in Power

3.1 Loss on account of PH Fan KwH 20.96 3.2 Loss in money Rs/Hr 67.06 3.3 Annual Loss due Power In Lacs 5.31 4 Loss in Heat

4.1 Loss on account of heat Kcal/hr 312500

4.2 Loss in money Rs./hr 321

Annual Loss due to Heat In Lacs 17.77

5 Total Loss (Rs) Lacs per annum 30.70

6 Arrest Master 1001 Cost Lacs 1.64

6.1 Pay-Back period In one month Note: Considring 330 days run plant in a year

Conclusion : Arrest Master 1001 : Cost-effective Industrial Solution 29

S No Particulars Plant Details

1.2 Kiln length 55.8 Mtrs

1.3 Kiln Dia 3.8

1.4 Heat Consumption 815 K Cal/ Kg - Clinker

1.5 Type of Cooler Grate Cooler with IKN KIDS

1.6 Calciner Type ICL

1.7 PH Make/Stages KHD/5

S No Parameters Unit Plant Details

2.1 Kiln Feed TPH 210

2.2 Clinker Factor 1.64

2.3 Clinker production TPH 3073

2.4 Barometric Pressure at site mmWg 10017

2.5 Barometric Pressure at sea level mmWg 10336

2.6 Ambient Temperature Deg C 35

2.7 Power Cost Rs/Unit 3.2

2.8 Coal CV K Cal/Kg Coal 7800

2.9 Coal Cost Rs/Kg 8

3 Reduction in False air after using " ARREST MASTER 1001"

3.1 False air across PH (Before/After) % 9.7 7.6 2.11

Parameters Unit Kiln string Pyro string UNIT-I

4 Preheater outlet

4.1 Temperature deg c 391 395

4.2 Draft mmWG -625 -815

4.3 Flow M3/h 228000 325000

4.5 Flow Nm3/h 85179 118249 203429

5 False air = 2%

5.1 False air volume Nm3/h 1797 2495 4292

5.2 False air = 2% M3/h 4938 7043

6 LOSS

6.1 Loss on account of Power in SG fan kwh 11 20 31

6.2 Loss in money Rs./hr 35 65 101

6.3 Loss on account of heat Kcal/hr 231620 325157 556777

6.4 Loss in money Rs./hr 174 244 418

6.5 Total Loss in money Lacs per annum 17 24 41

6.6 Cost of Arrest Master 1001 Lacs 4.2

6.7 Pay back period Month 1.13

Double String Pre Heater

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Glimpse of

15th NCB International Seminar on

Cement, Concrete and Building Materials,

05-08 December 2017,

New Delhi, India

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Some Testimonials from NCBM Seminar

• T. Prasad (VP Project Engineering) – Thyssenkrupp (Excellent Product. Need to be applied at Preheater, Duct Flanges to Conserve heat.

• Rajesh Kothari (Cluster Head) – Ambuja Cements Ltd . (Interesting Product)

• K Ganesh (President) – RV Consulting (Sagar Cement Group)-(Good product & has future)

• Rakesh Nayak (Section In charge) – Dalmia Cement ( Very good product for False Air Arresting)

• Devendra Sinha – JSW Cement (A good option for mind relief for false air ingress points)

• Rabindra Singh- NCBM (Good product with future)

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Our Esteemed Customers

OCL India Ltd. Line- 1 & 2, Rajgangpur, Odisha Dalmia Cement East Limited, Bokaro, Jharkhand Kapilas Cement Manufacturing Works, Cuttak, Odisha Dalmia Cement Bharat Limited, Belgaum, Karnataka OCL India Limited, Medinipur, West Bengal

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J. K. White Cement Works, Gotan, Rajasthan

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Andhra Cements Limited- (Unit: Durga Cement Works)

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Successful trials conducted at Ultratech Cement Ltd: Sewagram Cement Baga Cement Vikram Cement Ambuja Cements Ltd: Rabriyawas Bhatapara Darlaghat Other Groups: My Home Ramco Cements Asian Cement 37

Directors Message “By using the latest technology and quality systems, we are committed to delivering a uniformly high-quality product which meets all our customer requirements.”

Our Vision “Advancement through innovation” We are committed to the relentlessness pursuit of innovation in compact, energy saving, high precision technologies.

Our Values Our values serve as a compass for our action and describe how we behave in the world. Leadership: The courage to shape a better future. Collaboration: Leverage collective genius Integrity: Be real Passion: Committed in heart and mind Diversity: As inclusive as our brand Quality: What we do, we do well

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• Institute for Industrial Productivity

• Bureau of Energy Efficiency

• Knowledge Exchange Platform

• British High Commission, New Delhi

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Children's Park, Ajmer, Rajasthan -305001

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