Product Development

New lining concept by using alumina bricks in place of basic refractories

Published

6 years ago

January 2, 2020

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To achieve desired life of refractories in CRK, it is necessary to understand the characteristics, behaviour and location/zone where refractory will be lined inside the kiln. TRL Krosaki has developed new generation cost effective energy saving alumino silicate refractory (TRL PS-1), which is replacing the higher cost basic quality bricks in transition zone of the CRK.

In 21st century, due to big thrust upon infrastructure development; a huge demand of cement in worldwide, as result cement manufacturers are under tremendous pressure to increase production with quality at a competitive cost. It is quite obvious, longer life of the kiln with minimum downtime and low specific energy consumption help to cater the demand in time. However, to produce cost effective product; cement industries are focusing to use alternative fuels like pet coke, used tyre, oil sludge, municipal waste, etc.[1]. These fuels are having higher content of SO2, NOx, and CO emissions, and dusty in nature which are affecting refractory life of cement rotary kiln causing thermo-chemico mechanical load on the refractory lining[2]. Thus it is important to understand the real mechanism involved in cement rotary kiln (CRK) between refractory lining and kiln feeds at the elevated temperature[3].

To achieve desired life of refractories in CRK; it is therefore necessary to understand the characteristics, behavior and location/zone where refractory will be lined inside the kiln. TRL Krosaki has developed new generation cost effective energy saving alumino silicate refractory (TRL PS-1) which is replacing the higher cost basic quality bricks in transition zone of the CRK[4]. This new developed brick has improved thermal shock resistance, better thin surface coating and better corrosion resistance. A new concept of lining pattern has been adopted by TRL Krosaki by using newly-developed alumino silicate brick for CRK application and accordingly improved quality bricks supplied and lined in CRK of a leading cement manufacturing industry in India. CRK is under operation and till date performance is satisfactory one. This paper presents the new concept of lining of CRK where basic bricks were replaced in phase wise manner with newly-developed alumino silicate bricks (TRL PS-1) in the transition zone.

Product design & experiment
TRLK has developed 70 per cent alumino silicate product by lowering impurities like Fe2O3, TiO2, alkalis, etc. along with addition of special kind of additives in the product can enhance the life of refractory lining of CRK. Table 1 shows the properties of developed product. The product is showing low apparent porosity, good volume stability, high refractoriness under excellent thermal shock resistance with water as well as in air.

To understand the corrosion behaviour of individual CRK input material with developed product; corrosion and penetration study has been carried out through static CUP-test method. Cement raw mix (CRM) and petcoke fines collected from site of one leading cement industry manufacturer in India and samples are analysed through chemical analysis as tabulated in Table 2. Fig. 1 (a) and (b) show the texture of CRM and petcoke fines respectively. Both CRM and petcoke fines have been mixed with ratio of 92:8 to get actual composition of CRK feed material [Fig. 1(c)] i.e. formulation is same as considered by cement manufacturer.

Fig. 2(a) shows the CUP specimens, which have been made from the developed product having cavity dimension of 50 mm diameter and 50 mm height. Fig. 2(b) show the cavities are being filled with individual as well as mix material i.e. cavity-(I)has been filled with desired quantity of petcoke fines only, similarly only CRM is filled in cavity-(II) and cavity-(III) is being filled with mixture (ratio; 92:8) of CRM + petcoke fines. Cut piece of high quality refractory brick has been used as lid cover of all CUPs, which is shown in Fig. 2(c). CUPs are fired in high temperature tunnel kiln at the temperature of 1450G??C/4hrs. Fig. 3 (a-c) shows the physical appearance of fired CUPs followed by slicing to observe internal texture of respective cavities.

Results and discussions
Developed product designed with 92 per cent dense calcined Indian Bauxite and matrix part has been strengthened by incorporation of calcined alumina along with Kaolinite. Certain percentage of Phosphoric acid (PA) has been added in the product along with other binder system. Due to presence of PA and special kind of additives; developed product is showing low porosity as well as high strength and good high temperature properties.

Since developed product having low porosity and dense matrix; individual corrosion and penetration study is showing significant result against only petcoke fines, only CRM and with mix., as shown in Fig. 3 (a-c).In case of only petcoke; only infiltration phenomena has been observed in the cavity but due to presence of different type of oxides like Na2O, K2O, CaCO3, CaMg (CO3)2, and SiO2 in CRM; reaction followed by thin coating phenomena has been observed in the sample cavity due to reaction with Fe2O3, which is coming from the developed product i.e. alumino silicate system.

Similar type of coating behaviour is also observed in the cavity which contains mix (CRM + petcoke fines). In real operating condition of CRK; all the oxides are developing C-S-A-F system and a melt/liquid is being formed due to reaction between C-S-A-F and SO3 – which is entering into the system due to uses of petcoke. The melt which forms at temperature of 1280 degree Celsius and above is favorable for coating formation on refractory surface [5]. Fig. 3(c) depicts similar type of coating at the bottom portion of CUP. But too much melt is undesirable because alumino silicate refractory system quickly destroyed by clinker melt due to induce of undesired excessive C3S phase [5]. However from CUP test, there is no severe infiltration and corrosion phenomena have been observed where mix material has been tested, rather a thin layer of coating phenomena is observed in bottom of the cavity. Measurement and observation details of infiltration, corrosion and coating phenomena have been summarised in Table 3.

In general, both alumina refractory ranged from 40 to 70 per cent and basic quality bricks are used in different zone of CRK lining including monolithics. However, TRL Krosaki has attempted a new refractory lining concept for CRK by replacing basic quality bricks with high alumina fired bricks. After a year of phase wise study on corrosion phenomena and performance of the different quality of refractories used in CRK application; TRL Krosaki has adopted and executed a new lining concept by using newly developed alumina brick in place of basic quality brick as per the lining concept shown in Fig. 4. Developed product has been used completely in place of basic quality brick 3 m before discharge end.

Conclusions
Newly developed product exhibits special characteristics like balanced chemical properties, low porosity, good thermal shock resistance as well as high thermo-mechanical properties. As a result, excellent coating phenomena have been observed in CUP test. Keeping confidence upon characteristics of the newly developed alumino silicate product; TRL Krosaki has replaced the basic quality refractories completely by using this developed product for refractory lining of CRK. And developed product is performing satisfactorily at customer end for this said application.

References
1.Azarniouch, M.K., Philp, R.J., "Wood residues as fuel source for lime kilns " Phase I. Pilot kiln trials", Pulp and Paper Canada, 84 (1), pp. 29-34 (1983). 2.Francey, S., and Tran, H.N., "Impact of Burning High-Sulphur Fuels in Lime Kilns", TAPPI Engineering, Pulping and Environmental Conference, Memphis, TN, October, pp. 11-14, (2009).

3.Welch, J.H., "Phase equilibria and high temperature chemistry in the Ca-Al2O3-SiO2 and related System", in Tylor F.H.W., ed, The chemistry of Cement, London, Academic press, Vol 1, pp 49-88, (1964).

4.Nayak, J.P., Ghosh, B., Adhikari, R., Dey, R., Tripathy, A., Sengupta, S., Panda, P.B. "Development of high performance alumina bricks for alternate fuel application in cement industries", 15th NCB International Seminar on Cement, Concrete and Building Materials, New Delhi, (2017).

5.Javed I. Bhatty, "Role of Minor Elements in Cement Manufacture and Use, Portland Cement Association", Skokie, Illinois, p.24-25 (1995).

Economy & Market

Power Build’s Core Gear Series

Published

5 days ago

February 19, 2026

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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

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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.