Economy & Market

When Ash Sticks, Everything Stops

Published

12 months ago

November 20, 2025

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Jigar Shah, Head – Application Engineering, ACM SBU, Henkel Adhesive Technologies India, looks at the smarter way to keep power flowing.

In cement manufacturing, where uptime is everything, captive power plants are the backbone of uninterrupted operations. But even the most robust systems can be brought to a halt by something as deceptively simple as ash.
Ash buildup—especially in high-humidity environments—is a recurring challenge for maintenance teams. It clings to the inner walls of hoppers and silos, chokes flow paths, and forces shutdowns that no one has time for. And when the monsoon rolls in, the problem only intensifies.
This is the story of how one thermal power plant in India tackled the issue—not with more manpower or heavier hammers, but with a surface engineering solution developed by Henkel’s Loctite team. The application of Loctite® PC 7337 Anti-Stick Coating helped the plant shift from reactive maintenance to preventive control, restoring flow and reliability where it mattered most.

The sticky truth
Ash is an inevitable by-product of coal combustion. In captive power plants, fly ash is collected in electrostatic precipitators (ESPs) and directed to ash hoppers. Bottom ash, meanwhile, is sluiced with water into Hydrobin tanks—large cylindrical silos where solids settle and water is drained off for further treatment.
In theory, it’s a straightforward process. In practice, it’s anything but.
Ash particles are fine, abrasive and hygroscopic. They absorb moisture from the air, especially during the rainy season, and form stubborn layers on metal surfaces. Over time, this buildup narrows flow paths, increases system pressure, and eventually brings operations to a standstill.
At the plant in question, maintenance teams were routinely forced to shut down operations to manually clear out ash deposits. Sometimes that meant hammering on hopper walls. Other times, it meant full system stoppages. Either way, the cost—in time, labour and lost production—was significant.

A new approach
Rather than redesign the system or increase maintenance frequency, the plant’s engineering team explored a different path: surface modification.
They partnered with Henkel’s Application Engineering team to trial Loctite® PC 7337—a polymer-based anti-stick coating designed specifically for abrasive, high-moisture environments. The goal was simple: prevent ash from sticking in the first place.
Loctite PC 7337 was applied to the internal surfaces of the Hydrobin tank and ash hopper. The coating offered a low-friction, hydrophobic barrier that repelled fine particles and resisted wear. But as with any industrial solution, success depended on proper preparation and execution.

Application in action
The coating process followed a meticulous five-step protocol:
1. Surface preparation: Initial cleaning involved the removal of oil, grease and other contaminants. Abrasive blasting followed, creating a surface profile of 40–60 microns to ensure strong mechanical bonding.
2. Dust removal: All residual dust was cleared to prevent contamination and ensure a clean substrate.
3. Coating application: Loctite PC 7337 was mixed and applied to a wet film thickness of 200–250 microns. No heat curing was required—ambient conditions were sufficient.
4. Curing: The coating was left to cure for 24 hours, forming a durable, glossy finish.
5. Inspection: Final checks included dry film thickness measurement, visual inspection and holiday detection to confirm coating integrity.
The result? A smooth, frictionless surface that ash simply couldn’t cling to.

Real-world results
Post-application, the plant saw immediate improvements. Ash no longer adhered to the coated surfaces, even during peak humidity. Flow paths remained clear, and the need for manual cleaning dropped dramatically.
Here’s what changed:
• Fewer shutdowns: With ash buildup under control, unplanned stoppages became a thing of the past.
• Improved flow efficiency: Material moved more freely through the system, reducing pressure fluctuations and wear.
• Regulatory compliance: The plant was able to meet its monthly ash disposal targets, aligning with environmental mandates from the National Green Tribunal (NGT).
• Cost savings: Reduced maintenance and downtime translated into measurable financial benefits.

Why it worked
The coating’s performance came down to two key properties: abrasion resistance and hydrophobicity.
In lab tests, Loctite PC 7337 showed excellent wear resistance, losing only 9 mg after 1000 cycles under a 1 kg load using CS-17 wheels (ASTM D4060). That’s critical when dealing with fine, abrasive particles like fly ash and clinker dust.
Equally important was its ability to repel moisture. The coating’s low surface energy and high contact angle created a hydrophobic barrier that prevented wet ash from bonding to the surface—a common failure point for traditional coatings.
It also proved effective across a wide range of particle sizes. From cement fines under 45 microns to pulverized coal (79–120 microns) and clinker dust (3–30 microns), Loctite PC 7337 maintained its anti-stick properties. Even particles up to 1 mm showed only moderate adhesion during internal trials.

Beyond power plants
While this case focused on a thermal power plant, the implications for cement manufacturing are clear. Many of the same challenges—fine particle buildup, moisture-induced sticking, and flow disruptions—occur throughout the plant.
Potential applications for Loctite PC 7337 include:
• ID fan coatings: To prevent dust accumulation and maintain airflow efficiency.
• Pump linings: To reduce wear and improve slurry flow in wet handling systems.
• Silo and hopper interiors: To prevent bridging and rat-holing in cement and fly ash storage.
• Chutes and ducts: To enhance flow and reduce maintenance in pneumatic conveying systems.
By proactively addressing surface behaviour, cement plants can reduce maintenance burdens, extend equipment life, and improve process reliability.

A shift in mindset
This project highlights a broader shift in industrial maintenance philosophy—from reactive fixes to preventive strategies. Instead of waiting for problems to arise, forward-thinking plants are investing in solutions that stop issues before they start.
Surface engineering, particularly with advanced coatings like Loctite PC 7337, is a powerful tool in this shift. It allows operators to tailor equipment surfaces to their specific material and environmental challenges, rather than relying on generic designs or brute-force maintenance.
And while the coating itself was a key enabler, the real success came from collaboration. The plant’s willingness to try a new approach, combined with the technical support of Henkel’s Loctite team, created a solution that was both practical and scalable.

Small change, big impact
Sometimes, the biggest operational wins come from the smallest changes. In this case, a 250-micron of Loctite PC 7337 made the difference between constant maintenance and consistent performance.
For cement plants navigating the complex demands of energy efficiency, environmental compliance, and cost control, solutions like these offer a compelling path forward. They’re not flashy. They don’t require massive capital investment. But they work—and they work where it counts.
Because when ash sticks, everything stops. And when it doesn’t, everything flows.

ABOUT THE AUTHOR:
Jigar Shah, Head – Application Engineering, ACM SBU, Henkel Adhesive Technologies India, has 20+ years of experience. He drives efficiency and sustainability through innovations.

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Leonard Unveils Dual-Head Robotic Arm for Hazardous Industrial Demolition

Published

7 days ago

October 30, 2026

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Leonard unveils Descender Duo, a dual-head robotic demolition arm designed to improve industrial safety and reduce shutdown time by up to 50 per cent.

Industrial robotics and refractory services specialist Leonard has launched Descender Duo, a dual-head robotic demolition arm designed to improve safety, accelerate maintenance and reduce shutdown times in hazardous industrial environments. The system made its debut at Lisahally Power Station in Northern Ireland, removing 25 tonnes of slag material within hours.

Developed for the cement, metals, waste-to-energy and petrochemical industries, Descender Duo enables remote-controlled refractory demolition, anchor cutting and welding, and refractory spraying inside boilers, calciners and silos. Its vertical-access design eliminates the need for personnel to enter confined, high-risk spaces during these operations.

Weighing less than two tonnes, the pre-assembled system requires an access opening of just 1.2 m². Supported by an external overhead hoist, it uses electrically operated hydraulic stabilising legs to secure itself inside vessels. The robotic arm offers 360-degree rotation and is suited to vessels approximately 9 m in diameter, with its operating reach extendable through strategically positioned access points.

Equipped with two independently controlled robotic heads, Descender Duo can perform identical or different tasks simultaneously, including refractory demolition, anchor cutting and spraying. Its remote-control system incorporates live camera feeds, allowing operators to monitor operations without entering hazardous environments.

According to Leonard, the technology can deliver time savings of up to 50 per cent compared with manual methods. Its ability to operate at temperatures exceeding 100°C allows maintenance to begin as early as 24 hours after burner shutdown. An all-electric power supply further supports cleaner and more cost-efficient operations.

First Deployment Demonstrates Shutdown Efficiency

The system was first deployed at Burmeister & Wain Scandinavian Contractor’s (BWSC) Lisahally Power Station in Londonderry, Northern Ireland. The facility generates electricity from grade C waste wood, supplying approximately 40,000 homes and businesses.

Leonard and BWSC collaborated to develop a customised solution for the plant’s 26-metre furnace, where extensive external pipework created significant access challenges.

Mark Leonard, Managing Director, Leonard, said, “It required new thinking and rather than step away from the problem we were committed to solving it for the customer, with the customer. We’re relentless in our approach to tackling complex challenges, head-on. We took our years of cement plant experience, coupled with our working knowledge of the BWSC plant, and designed, engineered and tested a completely new vertical solution within just seven weeks from that initial conversation with the customer. That solution was the Descender Duo as we know it today.”

Traditionally, the furnace required a cooling period of up to 36 hours before preparatory work could begin, followed by manual slag removal using rope-access personnel. With Descender Duo, work commenced just 24 hours after shutdown, reducing downtime by up to one day.

The deployment removed 25 tonnes of slag within hours, eliminated the need for at least six workers to enter the hazardous furnace interior and saved 26 hours in the shutdown programme.

“The effectiveness exceeded expectation,” said Martin Doran, Plant Manager at Lisahally Power Station.

“When the Descender Duo concept was first discussed, we had to spend some time with the team from Leonard looking at how it was going to be moved into the furnace. Every site is different and that presented its own challenges, but nothing that the team couldn’t overcome. Once it was installed we were hugely impressed by its efficiency.”

Expanding Industrial Robotics Applications

Descender Duo joins Leonard’s existing portfolio of robotic maintenance solutions, including the Axis horizontal-access arm, Nano confined-space access arm, Charger cement mill media recharging system and Calibre cement mill media grading system.

Headquartered in Northern Ireland, Leonard provides robotic refractory demolition, installation, inspection and industrial maintenance services across the cement, metals, energy, biomass, glass and civil engineering sectors.

Formerly known as G Leonard, the company has more than 35 years of industry experience and operates across Europe, North America, the Middle East, Africa and Asia-Pacific.

The latest innovation reinforces Leonard’s focus on replacing hazardous manual processes with robotic systems that improve workforce safety, enhance operational efficiency and minimise industrial downtime.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

1 week ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

Fornnax Wins AIRIA’s Special Export Award for Rubber Machinery in 2025-26

Published

3 weeks ago

October 19, 2026

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Fornnax Technology Pvt. Ltd. has been honoured with the Special Export Award – Rubber Machinery for 2025–26 by the All-India Rubber Industries Association (AIRIA), in recognition of its highest exports of tyre recycling plants to the European region.

With more than a decade of experience in India’s tyre recycling industry, Fornnax has contributed to the development of advanced recycling technologies and infrastructure. The company currently holds a 90% market share in India’s domestic tyre recycling sector, while exports account for 30% of its business, spanning markets such as Europe, Australia and the GCC.

The award marks another milestone for Fornnax, whose tyre recycling lines and advanced shredding technologies are supporting the growth of the circular economy in India and international markets.

Commenting on the recognition, Mr. Jignesh Kundaria, Founder and Director of Fornnax, said:

“This honour from AIRIA is a reflection of an incredible journey we have undertaken over the years. When we started Fornnax, there was no established recycling industry in India to follow. We chose to build for the future instead. Today, when you see India’s tyre recycling sector, it has already transformed into a dynamic, high-growth industry and we are extremely proud to have played our part in building it.”

Unlike standalone equipment suppliers, Fornnax focuses on developing complete, high-capacity recycling infrastructure. Its integrated systems combine multiple stages of shredding and size reduction to enable efficient, continuous operations. This system-level engineering approach helps recycling operators improve throughput, equipment reliability and operational consistency.

The recognition reinforces Fornnax’s commitment to developing engineering technologies that contribute to a more efficient and circular recycling ecosystem.

Looking ahead, the company aims to expand its international presence while continuing to develop advanced shredding and recycling solutions to address the growing volumes and evolving requirements of the global recycling industry.

For more information, visit: www.fornnax.com