Product Development

Coating on refractory brick lining

Published

8 years ago

February 28, 2018

admin

Though refractory brick lining is installed with a purpose to protect the metallic shell of the kiln but often it is practised to have a good layer of coating on the brick lining. A majority of experts attribute it to the skills of a kiln operator.
A good protective coating on the refractory lining in the burning zone is always preferred to prolong the life of a refractory. Replacement of refractory bricks costs a large amount of money, loss in production while the kiln is down for lining replacement. In short replacement of refractory is an undesirable condition in any kiln.
Although refractories in the burning zone have to be replaced from time to time, a kiln operator has the capacity to increase or decrease the life of the lining by his ability to control the coating in the burning zone.Types of coatings
Coating is a mass of clinker or dust particles that sticks to the wall of the kiln, having changed from a liquid or semiliquid to a solidified state. The solidified particles stick to the surface of the coating (CS in Fig. 1), or the refractory surface (BS) when no coating exists, as long as the temperature of the surface of the coating is below the solidifying temperature of the particles. Coating continues to form until its surface reaches this solidifying temperature. When the kiln operates under such condition at equilibrium, the coating will maintain itself.
There is a temperature drop between the coating surface (CS) and the kiln shell (KS), the heat flowing in the direction indicated by the arrow (Fig. 1) (Heat always travels from a place or body of high temperature to a place of body of lower temperature). This heat transfer is governed to a great extent by the conductivity of the refractory and the coating. The better the conductivity of the refractory, the better the chance of coating formation, explained by the fact that the more heat that travels in the direction of the arrow. A kiln feed with a high liquid content at clinkering temperatures is more effective in coating formation than a feed low in liquid.
Kiln feeds with a high liquid phase (easy-burning mixes) have a high content of fluxes: the iron, alu?mina, magnesia, and alkalis. On the other hand, hard-burning mixes (low in iron, alumina, magnesia, and alkalis, and high in silica and lime) do not have a favourable influence on coating formation. Alkalis entrained in the gas stream promote the formation of coating and rings also because of their high fluxing characteristics.
Because the surface temperature is probably the most important factor in the formation of a coating, it is obvious that the flame itself has a significant effect on coating formation because the shape of the flame directly governs the surface temperature at any given point in the burning zone. A flame that is too short, snappy, and wide can erode the coating because of the great heat released over a short area with this kind of flame. A long flame is more favourable to coating formation in?the burning zone. It is observed that short flames are desirable for better control of the burning operation, but the flame should be shortened only to the extent that it will not harm the coating.
Once we ensure all favourable factors for good coating formation, it is then up to the kiln operator to control the coating during operation of the kiln. It is his responsibility to form and maintain a good solid coating in the burning zone.Operating conditions
Operating conditions are just as important for coating formation as all the other factors mentioned above. Assume that a kiln will be operated from one extreme of temperature to the other, that is, a cold, a normal, and a badly overheated kiln; that the same kiln-feed composition is burned in all three examples; that the solidifying temperature is around 1,3000 C; and that 24 per cent liquid is formed at the point of investigation, under ideal operating condition.
First, consider the cold kiln (Fig. 2). In this case almost no coating is formed. The coating surface temperature as well as the feed temperature is too low to produce the necessary amount of liquid matter that would promote coating formation. The condition in this example is commonly referred to by kiln operators as the kiln being in a ‘hole.’ This example also supports the widely known fact that no new coating can be formed while the kiln is cold.
In the normal kiln (Fig. 2), enough liquid (24 per cent) is present to form a coating. Temperature of the coating when it emerges from the feed bed, as well as when in contact with the feed, is below the solidifying temperature of the feed particles. The particles will adhere to the wall and solidify, and will continue to do so as long as the surface temperature of the coating remains below the solidifying temperature of 2,4000 F (1,3150 C). Whenever the wall reaches this temperature no new coating will form. The coating is in equilibrium.
In the hot kiln (Fig. 2), because of the extremely high temperatures of the feed and the coating, too much liquid is formed. As all temperatures are above the solidifying temperature, the coating transforms from a solid back to a liquid again. In such a condition, coating will come off, and the feed because of its high liquid content will ‘ball up.’ Needless to say, this condition is extremely harmful to the kiln and to the refractory.
Most basic refractories, are not able to withstand prolonged exposure to the high flame temperatures without this protective coating. As was mentioned in the previous chapter, the burning zone is divided into three subzones namely the upper-transition 1 the sintering, and the lower-transition zones. Because of the lower liquid content in the feed and because of the frequent temperature changes, the upper- and lower-transition zones are areas where formation and maintenance of coating is the most unstable.
Shifting burning zone locations produce a similar shift in the location where coating is formed; thus, unstable coating conditions are most frequently observed in the upper and lower end of the burning zone. This is clearly supported by the fact that most rotary kilns experience the most frequent refractory failures in these two critical areas. It should be noted that since the upper and lower burning zones are also within the vicinity of the first and second tires, brick failures are not only the result of variations in burning-zone conditions but, are also often the direct result of excessive tire clearance and shell ovality. Both the frequent falling out of coatings in these areas and the formation of too much coating can lead to troublesome ring formations.
Ring formations in the lower-transition zone (i.e., at the kiln discharge) are referred to as nose rings. Others refer to these as ash rings when the kiln is coal fired. Ring formations in the upper-transition zone are referred to as clinker rings. These ring formations can in many instances be so severe that they force operators to shut down the kiln and shoot these rings out with an industrial gun.
The possible causes are many and no one single factor has yet been found that would be the main cause for all the rings formed. What seems to be true for one particular kiln might be completely wrong for another kiln. On many coal-fired kilns, operators have found a relation?ship between the fusion temperature of the coal ash and the frequency of ring formation. There appears to be more ring formation when the fusion temperature is low, i.e., when the ash contains larger amounts of fluxing iron and alumina and less silica. However, this could not be the only cause for such ring formations because natural gas- and oil-fired kilns, which have no ash deposits in the burning zone, can have just as many ring problems as the coal-fired kilns.
Hence, solutions for the elimination of rings in the burning zone are predominantly found by a process of elimination. First, all probable causes are listed and then each suspected cause is eliminated or changed until hopefully an answer is found.
It is of interest that half of the causes of ring formation can be somehow controlled by the kiln operator and action taken to stabilise the flame and the kiln operation that might be beneficial in lessening the frequency of ring formation.Ring formation
Less frequent but nevertheless equally troublesome are the so-called feed rings that form in the calcining zone of the rotary kiln. It has been found that the majority of these rings and heavy coatings in kilns are associated with one of the following factors:

Internal cycle of the volatile constituents from the kiln feed and fuel (alkalis, sulphur, chlorides).
Kiln-feed fineness.
Irregular and insufficient control (frequent fluctuations) of the feed? end temperature and kiln draft.
Excessive dust generation within the rotary kiln proper.

Analysis of the materials from these rings or excessive coating builds invariably showed high contents of calcium sulphates, potassium chloride and/or alkali sulphur. Efforts to alter the internal and external cycle of volatile components in the gas or feed stream have in many instance resulted in less frequent ring formations. Causes for ring formation

Coal fineness too coarse
Low fusion temperature of coal ash
Kiln feed high on liquid content (silica, A/F ratios and or lime saturation factor low)
Incomplete calcination of the feed as it enters the burning zone
Frequent changes in chemical composition and fineness of kiln feed
Excessive dust generation in the cooler and burning zone
Kiln speed too slow and feed loading too high
Variations of flame temperature and length during normal operation
Changes in secondary air temperatures
Burning zone temperature and location varies too frequently and by too large a range
Increased volatility of, and frequent changes in, alkali and sulphur contents in the fuel and feed

Economy & Market

Power Build’s Core Gear Series

Published

3 days ago

February 19, 2026

admin

A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

Economy & Market

Conveyor belts are a vital link in the supply chain

Published

8 months ago

June 16, 2025

admin

Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

Economy & Market

Impactful Branding

Published

3 years ago

July 17, 2023

admin

Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.