Cooling Zone Burning Zone

I -Tyre
4550

I Man hole door

At 11.1 Mtr.
0.412 0.60 1.0 1.4

Month-Year Reasons 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Jan-18 Repaired 0.0 - 1.2 ALMAG

85
Aug-18 LINING Done 0.0 - 2.0 ALMAG
CRC

2.0 - 8.0 TOPMAG AF 8.0 - 18.0 Mtrs ANKRAK Z1

85
Oct-18 Repaired 0.2 - 1.4
0.0 - 0.2
ACOMON 70 ALMAG 5.2 - 11.4 TOPMAG AF
85

Detailed Report

Jan-18 0-1.2 Mtrs ALMAG 85

Aug-18 Annual Shutdown

Oct-18 Repaired
 Ambuja Cements Limit
Unit- Rabriyawas
Burning Zone Transition Zon
II -Tyre

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

27.4-28.8 Mtrs
ALMAG AF

8.0 Mtrs ANKRAK Z1 18.0 - 25.0 TOPMAG AF 25.0 - 40.0 SORPA MSP 85,

27.4-28.8 Mtrs ALMAG

AF
ements Limited
Rabriyawas
Transition Zone Ca
II -Tyre

II Man hole door

At 42 Mtr.

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

49.2-50.6 MTRS
DALCR60

25.0 - 40.0 SORPA MSP 85,320/620

49.2-50.6 Mtrs DALCR

60
 Calcining Zone
III -Tyre
5500
G.Gear

Inlet
Total lining

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 67.77 Done in (Mtrs.)

(including castable)

LAST
RING
KIB9

63.4-67.7 MTRS DALCR 60

Last Ring KIB 9

 Life AchieveTotal Prod. Refra. Consu.

(Days) (MT) (Kg/T of Clinker)

cluding castable)
 Cooling Zone Burning Zone
I -Tyre
4550

I Man hole door

At 11.1 Mtr.
0.412 0.60 1.0 1.4

Month-Year Reasons 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
(-

May-16 PRESENT
0.17 -

Mtrs)
0.0
70 LI

0.0 - 1.6
1.6 - 8.0 TOPMAG AF 8.0 - 18.0 Mtrs ANKRAK Z1
LINING ALMAG 85

May-17 PROPOSED 0.0 - 1.6 ALMAG

CRC

LINING 1.6 - 8.0 TOPMAG AF 8.0 - 18.0 Mtrs ANKRAK Z1

85
Jan-18 Repaired
0.0 - 1.2 ALMAG 85

Detailed Report

Jan-18 0-1.2 Mtrs ALMAG 85

 Ambuja Cements Limit
Unit- Rabriyawas
Burning Zone Transition Zon
II -Tyre

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

.0 Mtrs ANKRAK Z1 18.0 - 28.0 Mtrs REXAL 2S EXTRA R2 28.0 - 40.0 Mtrs TOPMA

8.0 Mtrs ANKRAK Z1 18.0 - 28.0 TOPMAG AF 28.0 - 40.0 SORPA MSP 85,

ALMA
AF
G

27.4-28.8 Mtrs ALMAG

AF
ements Limited
Rabriyawas
Transition Zone Ca
II -Tyre

II Man hole door

At 42 Mtr.

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

28.0 - 40.0 Mtrs TOPMAG AF 40.0 - 50.0 Mtrs DALCAST 60

28.0 - 40.0 SORPA MSP 85,320/620 40.0 - 50.0 DAL CR 60 50.0 - 60.0 DA

DALCR
60

49.2-50.6 Mtrs DALCR

60
 Calcining Zone
III -Tyre
5500
G.Gear

Inlet
Total lining

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 67.77 Done in (Mtrs.)

(including castable)

50.0 - 60.0 Mtrs DALCAST 60 WITH CAM

60.0 - 67.7 Mtrs ALUMINA 50 %
LINING

50.0 - 60.0 DAL CR 60 WITH CAM 60.0 - 67.7 Mtrs ALUMINA 50 %

KIB9

Last Ring KIB 9

 Life AchieveTotal Prod. Refra. Consu.

(Days) (MT) (Kg/T of Clinker)

cluding castable)
 Existing Lining Pattern (As installed in June,09 shut down)
Type of Refractory
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr
Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs.
Almag 85 (Make: Refratechnik), 2.012 to 3.412 mtrs. (Cone shape)
Almag 85 (Make: Refratechnik), 3.412 to 7.012 mtrs.
Ferromag F1 (Make: Refratechnik), 7.012 to 23.012 mtrs.
Topmag A1 (Make Refratechnik), 23.012 to 36.612 mtrs.
Kronal 60AR (Make: Refratechnik), 36.612.012 to 53.612 mtrs.
Refratherm (Make: ACE), 53.612 - 63.012 mtrs.
Al-60 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr.
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr

Proposed Lining Pattern for 2010

Type of Refractory
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr
Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs.
Almag 85 (Make: Refratechnik), 2.012 to 3.412 mtrs. (Cone shape)
Almag 85 (Make: Refratechnik), 3.412 to 8.012 mtrs.
Ankral-ZC (Make: RHI), 8.012 to 20.012 mtrs.
Ankral-Z1 (Make RHI), 20.012 to 30.012 mtrs.
Topmag A1 (Make: Refratechnik), 30.012 to 37.012 mtrs.
Kronal-60AR (Make: Refratechnik), 37.012-50.012 mtrs.
Refratherm (Make: ACE) 50.012 to 63.012 mtrs
Al-50 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr.
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr

Proposed Revised Lining Pattern for 2010

 Type of Refractory
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr
Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs.
Almag 85 (Make: Refratechnik), 2.012 to 3.412 mtrs. (Cone shape)
Almag 85 (Make: Refratechnik), 3.412 to 8.012 mtrs.
Ferromag-F1 (Make: Refractechnik), 8.012 to 20.012 mtrs.
Ankral-Z1 (Make RHI), 20.012 to 30.012 mtrs.
Topmag A1 (Make: Refratechnik), 30.012 to 37.012 mtrs.
Kronal-60AR (Make: Refratechnik), 37.012-50.012 mtrs.
Refratherm (Make: ACE) 50.012 to 63.012 mtrs
Al-50 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr.
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr

Proposed Lining Pattern for 2010

Length
Type of Refractory
(mtr.)
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412
Almag-85 (Make: Refratechnik), 0.412 to 8.012 mtrs. 7.600
Ankral-ZC (Make: RHI), 8.012 to 20.012 mtrs. 12.000
Ankral-Z1 (Make RHI), 20.012 to 30.012 mtrs. 10.000
Topmag A1 (Make: Refratechnik), 30.012 to 37.012 mtrs. 7.000
Kronal-60AR (Make: Refratechnik), 37.012-50.012 mtrs. 13.000
Refratherm (Make: ACE) 50.012 to 63.012 mtrs 13.000
Al-50 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4.000
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.700
 Proposed Revised Lining Pattern for 2010
04.11.09
Length
Type of Refractory
(mtr.)
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412
Almag-85 (Make: Refratechnik), 0.412 to 8.012 mtrs. 7.600
Ferromag-F1 (Make: Refractechnik), 8.012 to 20.012 mtrs. 12.000
Ankral-Z1 (Make RHI), 20.012 to 30.012 mtrs. 10.000
Topmag A1 (Make: Refratechnik), 30.012 to 37.012 mtrs. 7.000
Kronal-60AR (Make: Refratechnik), 37.012-50.012 mtrs. 13.000
Refratherm (Make: ACE) 50.012 to 63.012 mtrs 13.000
Al-50 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4.000
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.700

Proposed Revised Lining Pattern for 2010

13.11.09
Length
Type of Refractory
(mtr.)
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412
Almag-85 (Make: Refratechnik), 0.412 to 8.012 mtrs. 7.600
Ferromag-F1 (Make: Refractechnik), 8.012 to 20.012 mtrs. 12.000
Ankral-Z1 (Make RHI), 20.012 to 30.012 mtrs. 10.000
Ankral-R2 (Make: RHI), 30.012 to 37.012 mtrs. 7.000
Kronal-60AR (Make: Refratechnik), 37.012-50.012 mtrs. 13.000
Refratherm (Make: ACE) 50.012 to 63.012 mtrs 13.000
Al-50 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4.000
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.700

Ambuja Cement Ltd

Unit-Rabriyawas
05.02.10
PROPOSED KILN LINING PLANNING FOR SHUT DOWN JUNE,10
S.NO TYPE OF LINING PROPOSED INDENTED & LINING REMARK
REFRACTORY LENGTH(MTRS)/ LINING(MTRS)/ AVAILABLE EXCESS/SHORT FALL
AREA CASTABLE(MT LINING(MTRS)/
) CASTABLE(MT
)
1 HASLE CASTABLE 0-0.412=0.412 6 6 0
D-52A (COMPLETE
OUTLET TIP
CASTING
CASTABLE JOB)

2 ALMAG-85 0.412-8.012 7.6 20 12.4 EXCESS

3 FERROMAG-F1 8.012-15.012 7 15.4 8.4 EXCESS
4 ANKRAL-Z1 15.012-22.012 7 7.5 0.5 EXCESS
5 ANKRAL-R2 22.012-29.012 7 7 0
6 TOPMAG-A1 29.012-36.012 7 7.7 0.7 EXCESS
KRONAL-60AR 36.012-52.012
7 16 13 -3 SHORT FALL
REFRATHERM 52.012-60.012
8 8 13 5 EXCESS
50% ALUMINA, 60.012-67.012
9 DALMIA 7 6 -1 SHORT FALL
10 HASLE CASTABLE 67.012-67.712 7 6.75 -0.25 SHORT FALL
D-52A (COMPLETE
INLET SECTOR
CASTABLE JOB)

Ambuja Cement Ltd

 Unit-Rabriyawas
06.10.09
Cost comparision for complete one set for 2009/2010
Lining Installed in July,2009 shut down
1 Euro= 61.80 INR
S.No. Type Of Lining Lining Weight of Cost Total
Refractory Location Length Consumed Cost(Rs)
(Mtrs) Refractory
(MT)
1 Almag-85 0.412-7.012 mtr 6.660.71 Euro 1008.42/MT 4902767
2 Ferromag-F1 7.012-23.012 mt 16.0144.7 Euro 797.72/MT 8208992
3 Topmag-A1 23.012-36.612 m 13.6
121.24 Euro 974.12/MT 6127998
4 Kronal- 60AR 36.612-53.612 m 17.0133.2 Euro 748.72/MT 6848774
5 Refratherm 53.612-63.012 m 9.450.55 Rs21508.38/MT 1220582
6 60% Alumina 63.012-67.012 4.0 34.6 Rs12492/MT 477692
7 Castable-D52A 0.412 & 67.012- 1.112
14.00 Rs60421/MT 845894
TOTAL 558.98 28632700
Projected cost of Lining Proposed for 2010 shut down
1 Euro= 70.0 INR
S.No. Type Of Lining Lining Weight of Cost Total
Refractory Location Length Required Cost(Rs)
(Mtrs) Refractory
(MT)
1 Almag-85 0.412-8.012 mtr 7.6 66.16 Euro 1084/MT 6121072
2 Ankral-ZC 8.012-20.012 mt 12.0 109.1 Euro 660/MT 5043276
3 Ankral-Z1 20.012-30.012 m 10.0 90.9 Euro 1000/MT 6365380
4 Topmag-A1 30.012-37.012 m 7.0 62.9 Euro 911.40/MT 4011719
5 Kronal-60AR 37.012-50.012 m 13 103.64 Euro 823.20/MT 5539807
6 Refratherm 50.012-63.012 m 13 66.03 - 1595473
6 50% Alumina 63.012-67.012 m 4.0 30.73 Rs 14732/MT 428161
7 Castable-D52A 0-.412 & 67.012 1.112 14.00 Rs 68196/MT 954744
TOTAL 543.51 30059632
Remarks:
1.Almag-85 price increased by 7.54%
2.Topmag-A1 price decreased by 6.44% due to china supply.
3. Kronal-60AR price increased by 9.95% even after supply from china.
4. Castable D52A price increased by 12.87%
5. Euro exchange increased by 13.27%.
alled in June,09 shut down)
Length (mtr.)
0.412
1.600
1.400
3.600
16.000
13.600
17.000
9.400
4.000
0.700

attern for 2010

Length (mtr.)
0.412
1.600
1.400
4.600
12.000
10.000
7.000
13.000
13.000
4.000
0.700
 04.11.09
Length (mtr.)
0.412
1.600
1.400
4.600
12.000
10.000
7.000
13.000
13.000
4.000
0.700
 Ambuja Cements Limited
Unit- Rabriyawas
BRICK LINING CHART SINCE JUNE,09 SHUT
Almag-85 60 % Al2O3- Castable ACCMON-CRC
Ferromag F1 Hassle -52A castable 50 % Al2O3-
Topmag A1 Hassle -57SC castable
Kronal 60AR Ankral R-2
ACC-Refratherm Bricks. Ankral Z-1
Cooling Zone Burning Zone
I -Tyre
4550
4150

I Man hole door

Outlet At 11.1 Mtr.

0.412 1.4

Month 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

& Year

June,09 D52A 0.412-7.012 mtrs Amag-85 7.012-23.012 mtrs Ferromag-F1

August,09

Nov,09

0.4-2.0 2-3.4mtrs Ankral-R2

Jan,10 D52A mtrs 19.4-24.6 mtrs Ankral-Z1
Almag-
85

May,10
Aug/Sept,10
D52A 0.412-7.012 mtrs Amag-85 7.012-19.012 mtrs Ferromag-F1

Remarks Location of bricks [During kiln shutdown in May '10)

9 Bricks patched in 6th ring form out let with Almag-85
12 Bricks patched at 29.0 mrs with Topmag-A1
August,09 60 Bricks patched at 39.5 mrs with Kronal-60AR
Complete Inlet sectors castable done with D57SC &
Hypercast-70
360 Bricks patched in 1-3rd ring form out let with Almag-85
Nov,09 290 Bricks patched in 5-8th ring form out let with Almag-85
240 Bricks patched at 32.0 mtrs with Topmag-A1
First ring lining done & patching done in 2nd ring with
Almag-85
May,10 445 Brick patching done from 6.8 - 13.2 mtrs with
Ferromag-F1
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr
Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs.(Installed in Jan,10 shut
down)
Ankral-R2 (Make: RHI), 2.012 to 3.412 mtrs.(Installed in Jan,10 shut down)
Almag 85 (Make: Refratechnik), 3.412 to 7.012 mtrs.
Ferromag F1 (Make: Refratechnik), 7.012 to 19.40 mtrs.
Ankral-Z1 (200 MM) (Make:RHI),19.4-22.4 mtrs(Installed in Jan,10 shut down)
Ankral-Z1 (220 MM) (Make:RHI) , 22.4 - 24.6 mtrs(Installed in Jan,10 shut down)
Ankral-R2 (Make: RHI), 26.2 to 30.2 mtrs.(Installed in May,10 shut down)
Topmag A1 (Make Refratechnik), 30.20 to 34.4 mtrs.(Installed in May,10 shut
down)
Topmag A1 (Make Refratechnik), 34.4 to 36.612 mtrs.
Kronal 60AR (Make: Refratechnik), 36.612.012 to 53.612 mtrs.
Refratherm (Make: ACE), 53.612 - 63.012 mtrs.
Al-60 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr.
ACCMON-CRC Castable at inlet sector plate (Make:ACE), 67.012 to 67.712 mtr
2.2
4.0 New Lining
4.2 New Lining
2.2
17
9.4
4
0.7
 Ambuja Cements Limited
Unit- Rabriyawas
BRICK LINING CHART SINCE JUNE,09 SHUT DOWN

Transition Zone Calcining Zone

II -Tyre

G.Gear

II Man hole door

At 42 Mtr.

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

Ferromag-F1 23.012-36.6 mtrs Topmag-A1 36.6-53.6 mtrs Kronal-60AR

19.4-24.6 mtrs Ankral-Z1

26.2-30.2 30.2-34.4
Ankral-R2 Topmag-A1
 19.0-22.2 25.0-31.6 34.6- 36.6-41.6 mtrs
mtrs Ankral- 22.2-25.0 mtrs Ankral- 31.6-34.6 36.6 Kronal-60AR
Ankral-R2 Topmag-A1
Z1 Z1 mtrs
Ankr
al-Z1

shutdown in May '10) Length(Mt Proposed Brick Lining for Sept,10 Shut Down on 17.07.2010
rs)

of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412 D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr
nik), 0.412 to 2.012 mtrs.(Installed in Jan,10 shut 1.6 Almag-85 (Make: Refratechnik), 0.412 to 7.012 mtrs.
12 to 3.412 mtrs.(Installed in Jan,10 shut down) 1.4 Ferromag F1 (Make: Refratechnik), 7.012 to 19.00 mtrs.
nik), 3.412 to 7.012 mtrs. 3.6 Ankral-Z1 (Make:RHI) , 19.0 - 22.2 mtrs

echnik), 7.012 to 19.40 mtrs. 12.4 Ankral-R2 (Make:RHI) , 22.2 - 25.0 mtrs
:RHI),19.4-22.4 mtrs(Installed in Jan,10 shut down) 3.0 Ankral-Z1 (Make:RHI) , 25.0 - 31.6 mtrs
:RHI) , 22.4 - 24.6 mtrs(Installed in Jan,10 shut down) 2.2 Topmag A1 (Make Refratechnik), 31.60 to 34.6 mtrs.
2 to 30.2 mtrs.(Installed in May,10 shut down) 4.0 Ankral-Z1 (Make:RHI) , 34.6 - 36.6 mtrs
hnik), 30.20 to 34.4 mtrs.(Installed in May,10 shut 4.2 Kronal 60AR (Make: Refratechnik), 36.6 to 41.6 mtrs.

hnik), 34.4 to 36.612 mtrs. 2.2 Al-60 % (Make: Dalmia) 62.4 mtr. to 67.00 mtr.
echnik), 36.612.012 to 53.612 mtrs. 17.0 D52A Castable at inlet sector plate (Make:ACE), 67.012 to 67.712 mtr
3.612 - 63.012 mtrs. 9.4
TOTAL LINING LENGTH
012 mtr. to 67.012 mtr. 4.0

inlet sector plate (Make:ACE), 67.012 to 67.712 mtr 0.7

Brick Lining for Sept,10 Shut Down Length(Mtrs)
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 0.412
mtr
Almag-85 (Make: Refratechnik), 0.412 to 7.012 mtrs. 6.6
Ferromag F1 (Make: Refratechnik), 7.012 to 19.00 mtrs. 12.0
Ankral-Z1 (Make:RHI) , 19.0 - 22.2 mtrs 3.2
Ankral-R2 (Make:RHI) , 22.2 - 25.0 mtrs 2.8
Ankral-Z1 (Make:RHI) , 25.0 - 31.6 mtrs 6.6
Topmag A1 (Make Refratechnik), 31.60 to 34.6 mtrs. 3.0
Ankral-Z1 (Make:RHI) , 34.6 - 36.6 mtrs 2
Kronal 60AR (Make: Refratechnik), 36.6 to 41.6 mtrs. 5.0
Al-60 % (Make: Dalmia) 62.4 mtr. to 67.00 mtr. 4.6
D52A Castable at inlet sector plate (Make:ACE), 67.012 to 67.712 mtr 0.7
TOTAL LINING LENGTH 45.8
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr
Almag-85 (Make: Refratechnik), 0.412 to 7.012 mtrs.
Ferromag F1 (Make: Refratechnik), 7.012 to 18.00 mtrs.
Ankral-Z1 (Make:RHI) , 18.0 - 26.4 mtrs
Topmag A1 (Make Refratechnik), 34.00 to 36.0 mtrs.
Kronal 60AR (Make: Refratechnik), 36.0 to 41.0 mtrs.
Refratherm (Make: ACE), 54.0 - 59.0 mtrs.
Al-50 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr.
D52A Castable at inlet sector plate (Make:ACE), 67.012 to 67.712 mtr
LINING TO BE DONE DURING SEPT,10 SHUT DOWN
LINING DECISION TO BE TAKEN AFTER INSPECTION
Proposed Brick Lining for Sept,10 Shut Down after meeting on 15.07.2010
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr
Almag-85 (Make: Refratechnik), 0.412 to 7.012 mtrs.
Ferromag F1 (Make: Refratechnik), 7.012 to 18.00 mtrs.
Ankral-Z1 (Make:RHI) , 18.0 - 26.4 mtrs
Topmag A1 (Make Refratechnik), 31.00 to 34.0 mtrs.
Kronal 60AR (Make: Refratechnik), 34.0 to 41.0 mtrs.
Refratherm (Make: ACE), 54.0 - 59.0 mtrs.
Al-50 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr.
D52A Castable at inlet sector plate (Make:ACE), 67.012 to 67.712 mtr
LINING TO BE DONE DURING SEPT,10 SHUT DOWN
LINING DECISION TO BE TAKEN AFTER INSPECTION
TOTAL LINING LENGTH
 Calcining Zone
III -Tyre
5500 600
G.Gear

Inlet

55 56 57 58 59 60 61 62 63 64 65 66 67 67.70

53.6-63.0 mtrs Refratherm 63-67mtrs 60% Al2O3 D52A

 62.4-67mtrs 60% Al2O3 D52A

wn on 17.07.2010 Length(Mtrs)

te (Make: Hasle), 0 to 0.412 mtr 0.412

7.012 mtrs. 6.6
2 to 19.00 mtrs. 12.0
3.2

2.8

6.6

o 34.6 mtrs. 3.0

2

to 41.6 mtrs. 5.0

00 mtr. 4.6
e:ACE), 67.012 to 67.712 mtr 0.7

45.8
te (Make: Hasle), 0 to 0.412 mtr 0.412
7.012 mtrs. 6.6
2 to 18.00 mtrs. 11.0
8.4
o 36.0 mtrs. 2.0
to 41.0 mtrs. 5.0
rs. 5.0
7.012 mtr. 4.0
e:ACE), 67.012 to 67.712 mtr 0.7
T,10 SHUT DOWN
FTER INSPECTION
Down after meeting on 15.07.2010 Length(Mtrs)
plate (Make: Hasle), 0 to 0.412 mtr 0.412
2 to 7.012 mtrs. 6.6
7.012 to 18.00 mtrs. 11.0
mtrs 8.4
00 to 34.0 mtrs. 3.0
34.0 to 41.0 mtrs. 7.0
mtrs. 5.0
to 67.012 mtr. 4.0
Make:ACE), 67.012 to 67.712 mtr 0.7
EPT,10 SHUT DOWN
AFTER INSPECTION
45.0
 Ambuja Cements Limited
Unit- Rabriyawas
Topmag A1 70 % Al2O3 - LOF
Ankral Z1 Basic Bricks. CASTABLE LC-90 * Pacmon Hypercast - 60 castable Al60% Clog shape Accmon-CRC TC Castable
Kronal 60AR Ankral R-63 Basic Bricks. 70 % Al2O3 Kronal 50AR * Ankral R-2 Special Shape Accmon-CRC Castable Refra Rocundum 95 LCC
Ankral-ZE Ankral R-2 Basic Bricks. 60 % Al2O3- * Accmon LC-60 A castable * Accmon-70 Li Castable (0.6 Mtrs) Hasle D57SC
Kronex 87
Perilex-83 Almag-85 Hassle -52A castable Accmon LC-45 Castable 50% Alumina
Topmag-AF
ACC-Refratherm Bricks. DIAMOND SHAPE BRICK Whytheat-K Castable Ferromag F1 Rexal 2S Extra R2
Cooling Zone Burning Zone Transition Zone Calcining Zone
I -Tyre II -Tyre III -Tyre
4550 5500
G.Gear

I Man hole door II Man hole door

At 11.1 Mtr. At 42 Mtr.

Month-Year Brick lining

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 67.77
Reasons Done in (Mtrs.) (Days) (MT) (Kg/T of Clinker)
Start Date End Date
(including castable)

Lining Installed in Dec -12 Annual Kiln Shutdown

Refracorumdum

Lining Pattern
Mtrs)

Jan-13
95LCC (-0.17 - 0.0

36.0 -
18.0-25.0 Mtrs Rexal 2S Extra 39.0 mtrs
0.0 - 9.0 Mtrs Almag-85 9.0 - 18.0 Mtrs Ankral - R2
R2
25.0 - 36.0 mtrs Topmag-AF
Ankral-
39.0 - 49.0 mtrs Kronal-60AR 49-59 mtrs Kronal 50AR 59.0 - 67.77 mtrs 50% Alumina
ZE
 Ambuja Cements Limite
Unit- Rabriyawas
Topmag A1 Ankral Z1 Basic Bricks. 70 % Al2O3 - LOF CASTABLE
Kronal 60AR Ankral R-63 Basic Bricks. 70 % Al2O3 Few block casted
Ankral-Z1 Ankral R-2 Basic Bricks. 60 % Al2O3- * Accmon LC-60 A castable
Ankral-ZE Perilex-83 Almag-85 Hassle -52A castable

Kronex 87 ACC-Refratherm Bricks. DIAMOND SHAPE BRICK Whytheat-K Castable

Cooling Zone Burning Zone
I -Tyre
4550
4150

I Man hole door

Outlet At 11.1 Mtr.
Month-Year
Brick lining Reasons 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Start Date End Date

Jul-04 13.07.04 31.07.04 Planned shutdown
*160 *160 100 100 160 90 60 95 110 130 140 140 145 150 150 155 155 145 150 140 120 125

Bricks Thickness ( in mm) Ank-R2 ( Perilex-83 from 3.6 to 23.0 = 19.40 Mtrs.) ( Ank

Ankral-Z1
Mar-05 10.03.05 12.03.05 Red spot at 1.2 mtrs, Red spot appeared on
03.03.05
( Brick Thickness-60-115mm),
Apr-05 25.04.05 28.04.05 Kiln Tyre-1, Supporting Roller shaft broken
( A1-A3) ( Brick Thickness-110-140mm),
Jul-05 05.07.05 07.07.05 Red spot at 1.2 mtrs, Red spot appeared on
29.06.05
( Brick Thickness-40-190mm),
Oct-05 5.10.05 29.10.05 Planned shutdown

Mar-06 * ( Brick Thickness-75-90mm of 160mm height bricks)

Apr-06 04.04.06 08.04.06 Stopped for heavy coating & big clinker ball
breaking job * ( 1.0 Mtr. Lining from 1.2 to 2.2 mtr after retainer ring)
Jun-06 01.06.06 06.06.06 Bricks patching at 0.412 mtr.( First row) Brick patching work at 0.412 mtrs after retainer ring during plant stoppage due to Cy-5th jammed.

Aug-06 15.08.06 18.08.06 Kiln stopped due to outlet brick failure.

Brick thickness- 160-175 mm

Sep-06 ( Kiln outlet sector plate castable patch-up with CRC)

Oct-06 165 141 152 140 102 140 125 165

Nov-06 170-180 150-165 138-165 155-170 135-160 152 142 145 95 115 150 125 170
Dec-06 10.12.200 18.12.200 Kiln stopped due to red spot appeared at
6 6 23.8 Mtrs. . 151 122 145 98 150 165 135 155

Jan-07 0.412 to 0.612 very first row bricks patch-up ( 50 nos.) & 1.22 to 1.62 Mtrs Bricks patch-up ( 50 Nos.) ( Ankral-Z1-

3.4-3.6 mtrs Ankral-R2 last row of conical portion & from 3.6-22.4 mtrs Perilex-83)

( 25 nos. Kiln outlet sector plate castable patch-up with D 52A out of 30 nos. )
Feb-07 01.02.200704.02.200 04 Bricks from the first row & 06 nos. Brick tickness- ( Brick lining done from 0.412 to 3.4 Mtrs with Ankral-R2 Bricks)

bricks from 4th row ( R.Ring) fallen 80- 100- 130- 50- ( Remaining 05 nos. Kiln outlet sector plate castable patch-up with D 52A out of 30 nos. )

180 168 168 160

May-07 15.05.07 17.05.07 04-06 Bricks from the first & second row.
( Ankral-Z1-0.412 to 2.212 Mtrs)

150-165 155-165
Planned Annual Kiln shutdown.Up-
Jul-07 gradation to 6000 TPD.
Aug-07 26.07.07 20.08.07 0.412 0.60 1.0 1.4

Kiln Outlet brick lining failure followed by PM

Jan-08 23.01.08 29.01.08 @' patch-up of Kiln outlet sector plate castable with Hasle D-52A , 0.412 to 2.012 = 1.60 mtrs Kronex-87 ( Make Refratechnik), 2.012-3.412 = 1.4 Mtrs Ankral-R2 and 3.412 -6.212 = 2.80 mtrs
Brick thickness- Ist row= 90-160 mm, 2nd row 95-145 mm ( 03 bricks missing), 3rd row -all bricks missing, 4th row-80-160 ( 03 rows missing),5th row 90-160mm, 6th row-100-170mm, 7th r
Coating profiles Nil 100/1150-200 120-200 250-400 400-550 50-150 50-1
Red spot at 16.5 mtrs, Red spot appeared Red spot was obseved at 16.5 Mtrs on 28.02.08. During
Feb-08 29.02.08 01.03.08 on 28.02.08 at 18.05 hrs. @ @' First Row spalling was observed at 02 portion of approx. 54 nos. bricks same re-patchup with new bricks.
Brick thickness- 200-210 180-200
Coating profiles 0-2.4 No coating 2.4-7.4: 150-250mm 7.4-16.8 ( up to bricks patchup):250-550mm 16.8-20.4 ( up to bricks pa 20.4-24.8 :350-400mm

Kiln stopped due to very first row bricks

Apr-08 10.04.08 12.04.08 found missing from the ring. Brick lining patchup with Almag-85 on first two rows i.e. 0.412 to 0.812 mtrs.
Brick thickness- Ist row= 50-200 mm ( 13 bricks missing), 2nd row 110-200 mm , 3rd to 8th row - 190-200 mm , 9th to 15 th rows 188-203 from 6th to kiln inlet measuremnt not carried out , h
Coating profiles Ist row= Nil , 2nd row - Nil , 3rd to 8th row - thin coating collapsed during rotation, 9th to 15 th rows - thin coating, from 6th-13 mtrs 100-140-200 13 to 18 200-450 mm , 18
Jun-08 08.06.08 10.06.08 Kiln stopped due to red spot at 33 Mtrs.
Brick thickness-
Coating profiles
Red sopt at 28.2 mtrs followed by
16.06.08 27.06.08 prepone of Kiln Annual Shutdown
22.012-

Jun-08 0.412 HASL 0.4-2.0 ANKRAL-R2 2.0-3.4 ALMAG-85 3.412 - 22.012Mts. = 18.6 Mtrs ANKRAL-ZE

01.11.08 09.11.08
Red sopt at 7.5 mtrs area. Total stoppage
Nov-08 at 19.25 at 10.50
183.25 Hours. 8.0 to 11.0 mtrs
hrs hrs 3.4 to 8.0 mtrs ALMAG-85 FERROMAF-
F1

Red spot appeared at 45.8 to 46.2 mtrs

area.(Refratherm Bricks)
16.02.09 20.02.09
Feb-09 at 2.15 at 20.30 Tip
Hrs Hrs casting
Total Kiln stoppage 114.15 Hrs repaired Kronex-87 used
with from 0.412 to 1.6 Almag-85 cone shape used
D52A mtrs. from 1.6 to 3.0 mtrs.
Tip
Red spot appeared at 25.4 mtrs area. casting
(Ankral Z1 area) repaired
with
14.04.09 19.04.09 D52A
Apr-09 at 15.15 at 11.30 (04
Hrs Hrs. Sectors)
 with
14.04.09 19.04.09 D52A
Apr-09 at 15.15 at 11.30 (04
Hrs Hrs. Sectors)
Patching
Total kiln stoppage 116.15 Hrs done with
Kronex-87 in 24.4 to 29
very first row mtrs) linin
(45 Bricks) Topm

Red spot appeared at 61 mtrs (3rd

Tyre)

21.06.09 15.07.09
June,09 at 17.40 at 10.25 Out let
hrs hrs tip
Total kiln stoppage 568.45 Hrs casting
done
with
Hasle
D52A 0.412 to 7.012 mtrs Almag-85 7.012 to 23.012 mtrs Ferromag F1
Aug-09 25.08.09 28.08.09
at 03.45 at 12.20 Material spillage from kiln inlet because of 6th ring
Hrs hrs inlet sector plate damaged from out let
patching job
with Almag-
85
Total kiln stoppage 80.35 Hrs
Nov-09 16.11.09 19.11.09
at 8.00 at 18.25
hrs hrs
Red spot appeared at 32 mtrs area 0-0.412
5th-
First 1-3 8th
Out let ring lining ring
tip done with lining
casting Almag-85 patc
repairing h up
done work
with with
ACCMO Alma
Total kiln stoppage 82.25 hrs N-CRC g-85
Jan,10 26.01.10 01.02.10
at 16.00 at 23.35 Kiln stopped due to low productivity because
hrs hrs 22.4-24.6 mtrs
of inlet jamming,material spillage from inlet &
Thick coating in Burning zone area. 0- 0.412 0.412 - 2.0 12 2.012- 3.412 19.4- 22.4 mtrs
Complete brick Complete brick lining Ankral-Z1 (200mm) lining Ankral-
Complet lining done with done with cone shape done Z1(220mm)
e out let Almag-85 Ankral-R2 lining done
tip
casting
done
with
Hasle
Total kiln stoppage 151.35 hrs D52A
May,10 17.05.201 24.05.201 0.412-0.612
0 at 12.00 0 at 15.30 Kiln stopped due to red spot appeared at
hrs hrs 27.5 Mtrs. 6.8- 13.2 mtrs
First ring
lining done
Total kiln stoppage 171.30 Hrs with Almag- 445 Brick patching job done with Ferromag-F1
85 &
Aug/Sept,1 25.08.201 12.09.201
Patching
0 0 at 20.00 0 at 10.35 Kiln stopped due to red spot appeared at 36
done in 2nd
Hrs hrs mtrs area. Followed by Annual shut down. ring
 Hrs hrs Complet
e out let
tip 19.012-22.2 mtrs 22.2-25.012
casting Ankral-Z1 mtrs Ankral-R2
30
blocks
done
with
Hasle
Total kiln stoppage 422.35 Hrs D52A 0.412 to 7.012 mtrs Almag-85 7.012 to 19.012 mtrs Ferromag F1
Dec,10 01.12.201 04.12.201 Kiln stopped due to red spot appeared at 19
0 at 7.40 0 at 11.00 mtrs area at the junction of Ferromag &
hrs hrs Ankral-Z1
Total kiln stoppage 75.20 Hrs First 3 ring 3 2 rings
bricks rings patchin
patching patc g job
done with hing done at
Almag-85 job 19 mts
don area
e at with
18 Ankral-
mts Z1
area
with
Ferr
oma
g-F1
Location of bricks [During major kiln shutdown in June '09) Length (mtr.)

D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412

Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs. 1.600

Almag 85 (Make: Refratechnik), 2.012 to 3.412 mtrs. (Cone shape) 1.400

Almag 85 (Make: Refratechnik), 3.412 to 7.012 mtrs. 3.600

Ferromag F1 (Make: Refratechnik), 7.012 to 23.012 mtrs. 16.000

Topmag A1 (Make Refratechnik), 23.012 to 36.612 mtrs. 13.600

Kronal 60AR (Make: Refratechnik), 36.612.012 to 53.612 mtrs. 17.000

Refratherm (Make: ACE), 53.612 - 63.012 mtrs. 9.400

Al-60 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4.000

D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.700

Location of bricks [During kiln shutdown in Jan '10) Length(Mtrs)

D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412

Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs. 1.6

Ankral-R2 (Make: RHI), 2.012 to 3.412 mtrs. (Cone shape) 1.4
Almag 85 (Make: Refratechnik), 3.412 to 7.012 mtrs. 3.6
Ferromag F1 (Make: Refratechnik), 7.012 to 19.40 mtrs. 12.4
Ankral-Z1 (200 MM) (Make:RHI) , 19.4 - 22.4 mtrs 3
Ankral-Z1 (220 MM) (Make:RHI) , 22.4 - 24.6 mtrs 2.2
Topmag A1 (Make Refratechnik), 24.60 to 36.612 mtrs. 12
Kronal 60AR (Make: Refratechnik), 36.612.012 to 53.612 mtrs. 17
Refratherm (Make: ACE), 53.612 - 63.012 mtrs. 9.4
Al-60 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.7

Location of bricks [During kiln shutdown in May '10) Length(Mtrs)

D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412
Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs. 1.6
Ankral-R2 (Make: RHI), 2.012 to 3.412 mtrs. (Cone shape) 1.4
Almag 85 (Make: Refratechnik), 3.412 to 7.012 mtrs. 3.6
Ferromag F1 (Make: Refratechnik), 7.012 to 19.40 mtrs. 12.4
Ankral-Z1 (200 MM) (Make:RHI) , 19.4 - 22.4 mtrs 3
Ankral-Z1 (220 MM) (Make:RHI) , 22.4 - 24.6 mtrs 2.2
Ankral-R2 (Make: RHI), 26.2 to 30.2 mtrs. 4.0 New Lining
Topmag A1 (Make Refratechnik), 30.20 to 34.4 mtrs. 4.2 New Lining
Topmag A1 (Make Refratechnik), 34.4 to 36.612 mtrs. 2.2
Kronal 60AR (Make: Refratechnik), 36.612.012 to 53.612 mtrs. 17
Refratherm (Make: ACE), 53.612 - 63.012 mtrs. 9.4
Al-60 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.7
ted
* Pacmon Hypercast - 60 castable ACCOMON 70M

* Ankral R-2 Special Shape

* Accmon-70 Li Castable (0.6 Mtrs)
Accmon LC-45 Castable

Ferromag F1
Transition Zone Calcining Zone
II -Tyre III -Tyre
5500 600
G.Gear

II Man hole door

At 42 Mtr.

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 67.66Done in (Mtrs.) (Days) (MT)

(including castable)

70 70 85 115 100 140 155 160 162 160 140 145 140 135 105 150 95 160 135 145 100 * 68.00 139 645864

nkral-Z1 from 23 to 35=12.0 Mtrs.) (Ankral-ZE, 35 to 45 = 10.0 Mtrs.) ( Refratherm from 45 to 59.4 = 14.4 Mtrs.) Al-60 % from 59.4-67.4=08.0 Mtrs.

1.00 217 1088932

2.4 38 186493

1.00 65 329721

68.00 86 414524

1.00 147 713943

0.2 52 249143

3.2 69 326760

107 491243

Z1-22.4 to 24.8 Mtrs) ( Al-60% Clog shape -from 45 to 47 Mtrs.)

 120 554000

97.28 477078

( 08 Rows Al-60% patch-up of arround 160-165nos. bricks at 61 Mtrs)

67.77 63.82 297521

5.8 147.64 848458

mtrs Ankral-ZE soild shape )
h row-90-165 mm , 8th row-120-160 mm
0-100 mud ring
ng the inside Kiln inspection cavities noticed from 16.0 to 16.8 mtrs in 04 rows, same repaired with Bricks patch-up of total 130 bricks.
29.96 181141

0.4 38.10 230773

, however overall bricks condition found satisfactory
18 to 21.5 - 400-500 mm , from 21.5 mtrs onwards no caoting through out the kiln. ( Two soft mud ring observed at 48 & 57 mtrs. )
( Total 358 Nos bricks where patchup in 08 rings ) 0.6 54.84 340945
( 20-80 mm) -11 nos bricks fallen.
200-350 mm ( Mud ring at kiln tyre area )

D52A
Refratherm bricks lining could not be carried out due to good physical condition during inspection. 48 5.27 31604
2- 35.012 Mtrs. = 13 Mtrs.ANKRAL-Z1 35.012- 42.812 Mtrs. = 7.8 42.8 62.17 - 66.97 Mtrs. = 4.8 Mtrs
Mtrs.ANKRAL-ZEI - 70% ALUMINA
43.6
ANK
RAL
-Z1

60% Alumina Clog bricks

used from 43.6 to 47.8 mtrs
(4.2 mtrs)
 33.4 to
34.4
mtrs (1.0
mtrs
lining

29.4 mtrs (5.0

1 done
with
ning done with
pmag A1
2 Topmag
A1)
ri
n
g
p
at
Kiln inlet
Pat
chi
c sector
63.012 to 67.012 mtrs 60% Hasle
23.012 to
ng
h
job36.6 mtrs Topmag A1
Patc
hing 36.6 to 53.6 mtrs Kronal 60AR 53.6 to 63.012 mtrs Refratherm Alumina All
D52A
sector
at
29.
u job
at
plate
castable
mtr
0
p 39.5
mtrs
done
with
s
wit
w with
Kron
D52A &
Hyperca
h
To
or al-
60A
st-70
pm
ag-
k R

A1 d
o
n
e
w
it
h 34.0-36.0
T
o Patching done
at 03 locatons
p offrom Topmag-A1
34-36
m mtrs.

a
g-
26.2-30.2 mtrs A34.2 mtrs
30.2-

Complete brick
1
Complete brick
lining done with
Ankral-R2.
atdone with
lining
Topamg-A1.
3
2
m
tr
s.
 25.012-31.6 mtrs 31.6-34.6 34.6- 36.6-41.6 mtrs Kronal- Lining not done 62.4-67.0 mtrs 60% Alumina Brick Hasle
Ankral-Z1 mtrs Topmag- 36.6 60AR D52A
A1 mtrs
Ankral-
Z1

12 5
rin ring
gs s
pat pat
chi chi
ng ng
job job
do don
ne e at
at 34
2n
d
mts
are
Lining Installed in June -08 Annual Kiln Shutdown
tyr
e
a
with
0 -0.412 Mtrs. = 0.412
HasleMtr
- D52A Imported Castable (0.412 Mtrs)
) are
a
Ank
ral- 0.412 -2. Kronex-87 (1.6 Mtrs) Installed in FEB,09
wit Z1
h 2.012 - 3 Almag-85 (Special shape) , for conical portion ( 1.4 Mtrs) Ins
To
pm
ag-
3.412 - 8 Almag-85 (Installed in NOV,08)
A1
8.012 - 1 Ferromag-F1(Installed in NOV,08)
11.012 - Ankral ZE ( Solid Shape)
22.012- 2Ankral Z1
24.412- 2Topmag A1(Installed in April,09)
29.412- 3Ankral Z1
33.412- 3Topmag A1(Installed in April,09)
35.012- 4Ankral ZEi
42.812 - Ankral Z1
43.60 - 4 60% Alumina Clog shape, Installed in FEB,09
62.17 - 6 70 % Alumina Bricks
* 66.97- 67Hasle D52 A Castable (0.8 Mtrs)
(Kg/T of Clinker)

0.74

0.01

0.09

0.02

1.15

0.01

0.01

0.07

0.00
0.00

0.00

1.59

0.05

0.00

0.01

0.01

10.63
) Installed in FEB,09
 Ambuja Cements Limit
Unit- Rabriyawas
Topmag A1 70 % Al2O3 - LOF
Ankral Z1 Basic Bricks. CASTABLE LC-90 * Pacmon Hypercast - 60 castable
Kronal 60AR Ankral R-63 Basic Bricks. 70 % Al2O3 * Ankral R-2 Special Shape
Ankral-ZE Ankral R-2 Basic Bricks. 60 % Al2O3- * Accmon LC-60 A castable * Accmon-70 Li Castable (0.6 Mtrs)
Kronex 87
Perilex-83 Almag-85 Hassle -52A castable Accmon LC-45 Castable

ACC-Refratherm Bricks. DIAMOND SHAPE BRICK Whytheat-K Castable Ferromag F1

Cooling Zone Burning Zone
I -Tyre
4550
4150

I Man hole door

Outlet At 11.1 Mtr.
Month- Brick lining
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Year Reasons
Start Date End Date
2-3.4m-AL70% Diamond
May-96 0.4-1.2 m-castable shape 3.4- 44.0 M- Al70%

Nov-96
9.0 - 20.0 M- AL70%
Dec-96
10-11 M- AL70%
Jul-97 2-3.4m-AL70% Diamond
0.4-1.2 m-castable 3.4- 45.0 M- Al70%
shape
Apr-98 04.04.98 22.04.98 Kiln has been stopped for CMA restriction.
Total stoppage 432 Hrs. 0.4-1.2 m-castable 9.0-12.0 M-AL70%

Apr-98 11.40 - 26.40 M- AL70%

Jul-98 23.07.98 28.07.98 Kiln has been stopped for CMA restriction. 2-3.4m-AL70% Diamond
0.4-1.2 m-castable 3.4 - 10.0 M- AL70%
Total stoppage 120 Hrs. shape
Jan-99 05.01.99 at 20.01.99 at Kiln has been stopped due to red spot
5.20 hrs 17.50 hrs. followed by annual brick lining job. Total 0.4-1.2 m-castable 5.0 - 11.0 M- AL70%
stoppage 372.30 hrs.
Apr-99 2-3.4m-AL70% Diamond
0.4-1.2 m-castable shape
Jul-99 0.4-1.2 m-castable
Sep-99 0.4-1.2 m-castable 2-3.4m-AL70% Diamond 3.4- 41.0 M- Al70%
shape
Jun-00 2-3.4m-AL70% Diamond
0.4-1.2 M-Hasle D-52A 3.4 - 15.0 M -AL70%
shape
Sep-00
6.2-7.0 M-AL70% 10.0-13.2 M- AL70%
Jan-01 1.2-
1.6 M
Apr-01
May-01 6.4-17.3 M-AL70%-LF
Aug-01 1.2- 16.55-21.55 M-AL70%-LF
2.2
Oct-01 2.2-3.6m-AL70%
0.4-1.2 M- LC-60A M- 3.6 - 11.4 M -AL70% 16.5-21.5 M-AL70%
AL7 Diamond shape
Apr-02
0.4-1.2 M- LC-60A 0%- 24.0
Sep-02 LF
Feb-03 11.2.2003 15.02.03
Red spot at 25 Mtrs. 21.57-27.57 M-
6.4.2003 24.4.2003 2-3.4m-AL70% Diamond
Apr-03 Planned shutdown 0.4-1.2 M-Hasle D-52A 3.6 - 23.0 M -AL70%
shape
8.12.2003 10.12.2003
Dec-03 Red spot at 1.4 mtrs.
1.02.2004 11.02.2004 2.2-2.8 M-AL70%
3.6-14.0 M- AL70%
Feb-04 1.2-2.2 Diamond shape
17.06.04 20.06.04
Jun-04 Red spot at 1.2 mtrs.
Jul-04 13.07.04 31.07.04 Planned shutdown 0.4-1.2 M-Hasle D-
52A 1.2-3.6 M- Ankral-R2 3.6-23.0 M- Perilex-83
Mar-05 10.03.05 12.03.05 Red spot at 1.2 mtrs, Red spot appeared on 1.2-
03.03.05 2.2
M-
Apr-05 25.04.05 28.04.05 Kiln Tyre-1, Supporting Roller shaft broken 1.2-
Ankr 2.2-2.8 M-AL70%
2.2 Diamond shape
al-Z1
M-
Jul-05 05.07.05 07.07.05 Red spot at 1.2 mtrs, Red spot appeared on 1.2-
AL7
29.06.05 2.2
0%
M- ( Brick Thickness-40-190mm),
Oct-05 5.10.05 29.10.05 Planned shutdown 0.0.412 AL7
M- 0%
1.22 M- Ankral-R2
0.412-3.4 3.4-23.0 M- Perilex-83
Hasle- to
Apr-06 04.04.06 08.04.06 Stopped for heavy coating & big clinker ball 1.2-
D52A 1.62
breaking job * 2.2
Mtrs
M-
Jun-06 01.06.06 06.06.06 Cyclone 5th KS-2 Jammed Brick Brick Brick patching work at 0.412 mtrs after retainer ring during plant stoppage due to Cy-5th jammed.
AL7
patching job s
0%
Aug-06 15.08.06 18.08.06 Kiln stopped due to outlet brick failure. done patc
h-up
Sectors p 0.412-3.4 M- Ankral-R2
( 50
Dec-06 10.12.2006 18.12.2006 Kiln stopped due to red spot appeared at ( 25 nos. 0.412 to Nos. 3.4-3.6 mtrs Ankral-R2 22.4-
23.8 Mtrs. . Kiln 0.612 very ) last row of conical 3.6-22.4 M- Perilex-83 24.8 M
outlet first row portion Ankral
Feb-07 01.02.2007 04.02.2007 04 Bricks from the first row & 06 nos.bricks
sector bricks Z1
from 4th row ( R.Ring) fallen 05 sectorpatch-up 0.412-3.4 M- Ankral-R2
plate
May-07 15.05.07 17.05.07 04-06 Bricks from the first & second row. castable (0.4-2.2
50 nos.)M-Ankral-
patch-up Z1
with D
Jul-07 26.07.07 20.08.07 Planned Annual Kiln shutdown.Up- 0-0.4-
52A out
gradation to 6000 TPD. D52A
of 30 0.412-3.4 M- Ankral-R2 3.4 - 22.4 M- Ankral-ZE
Jan-08 23.01.08 29.01.08 Kiln Outlet brick lining failure followed by PM nos. ) 0.4-2.0 M-Kronex- 3.4-6.2 M-Ankral-
87 2.0-3.4 M-Ankral-R2 ZE
Feb-08 29.02.08 01.03.08 Red spot at 16.5 mtrs, Red spot appeared @' First Red
on 28.02.08 at 18.05 hrs. Row spot
spalling was was
Apr-08 10.04.08 12.04.08 Kiln stopped due to very first row bricks 0.4-0.8
observedM-at obse
found missing from the ring. Almag-85
02 portion ved
of approx. at
Jun-08 08.06.08 10.06.08 Kiln stopped due to red spot at 33 Mtrs. 1st ring
54 nos. 16.5
patched up
bricks same Mtrs
16.06.08 27.06.08 with
0-0.4 M- re-patchup on
Red sopt at 28.2 mtrs followed by Almag-85
with new 28.0
D52A
Jun-08 prepone of Kiln Annual Shutdown 0.4-2.0M-Ankral-R2
bricks. 2.0-3.4M-Almag-85 3.4-22.0 M- Ankral-ZE
2.08.
Nov-08 01.11.08 at 09.11.08 at Red sopt at 7.5 mtrs area. Total stoppage 8.0-11.0M- Durin
19.25 hrs 10.50 hrs 183.25 Hours. Tip 3.4-8.0M-Almag-85 g the
Ferromag- insid
16.02.09 at 20.02.09 at casting 0.4-1.6M-Kronex- 1.6-3.0M-Almag-85
Red spot appeared at 45.8 to 46.2 mtrs repaired F1 e
Feb-09 2.15 Hrs 20.30 Hrs area.(Refratherm Bricks)Total Kiln stoppage with 87
Kiln
114.15 Hrs D52A inspe
14.04.09 at 19.04.09 at Red spot appeared at 25.4 mtrs area. Tip Patching ction
caviti
Apr-09 15.15 Hrs 11.30 Hrs. (Ankral Z1 area) Total kiln stoppage 116.15 casting done with
es
Hrs repaired Kronex-87
with in very first notic 24.4-29
21.06.09 at 15.07.09 at Red spot appeared at 61 mtrs (3rd D-52A
D52A row (45 ed
June,09 17.40 hrs 10.25 hrs (04 Bricks) 0.4-7.0 M- Almag-85 7.0-23.0 M-from
Ferromag-F1
Tyre)Total kiln stoppage 568.45 Hrs 16.0
Sectors) 6th ring
Aug-09 25.08.09 at 28.08.09 at Material spillage from kiln inlet because of to
from out let
03.45 Hrs 12.20 hrs inlet sector plate damaged. Total kiln 16.8
patching job
stoppage 80.35 Hrs mtrs
with Almag-
in 04
85
rows,
same
repai
Nov-09 16.11.09 at 19.11.09 at Red spot appeared at 32 mtrs area. Total 0-0.412 First 1-3 5th-
8.00 hrs 18.25 hrs kiln stoppage 82.25 hrs Out let ring lining 8th
tip done with ring
Jan,10 26.01.10 at 01.02.10 at 0- 0.412 0.412
casting Almag-85- 2.0 12lining 2.012- 3.412 Complete 19.4- 22.4 mtrs Ankral-Z1 22.4-24.6 mtrs
16.00 hrs 23.35 hrs Kiln stopped due to low productivity because Complet
repairing Complete brick patc brick lining done with (200mm) lining done Ankral-
of inlet jamming,material spillage from inlet & e out let lining done with
done h up cone shape Ankral-R2 Z1(220mm)
Thick coating in Burning zone area.Total kiln tip
with Almag-85 work lining done
stoppage 151.35 hrs casting
ACCMO with
May,10 17.05.2010 24.05.2010 Kiln stopped due to red spot appeared at N-CRC 0.412-
done Alma 6.8- 13.2 mtrs-445 Brick patching job done with
at 12.00 at 15.30 hrs 27.5 Mtrs. Total kiln stoppage 171.30 Hrs with 0.612-First g-85 Ferromag-F1
hrs Hasle ring lining
D52A done with
Aug/Sept 25.08.2010 12.09.2010 Kiln stopped due to red spot appeared at 36 Complete 19.012-22.2 mtrs 22.2-25.012
Almag-85 &
,10 at 20.00 at 10.35 hrs mtrs area. Followed by Annual shut out let tip 0.412 to 7.012 mtrs Almag-85 7.012 to 19.012 mtrs Ferromag F1 Ankral-Z1 mtrs Ankral-
Hrs down.Total kiln stoppage 422.35 Hrs casting Patching R2
30 blocks done in 2nd
Dec,10 01.12.2010 04.12.2010 Kiln stopped due to red spot appeared at 19 First
ring 3 ring 3 2 rings
done
at 7.40 hrs at 11.00 hrs mtrs area at the junction of Ferromag & bricks rings patchin
with
Ankral-Z. Total kiln stoppage 75.20 Hrs patching patc g job
Hasle
done with hing done at
Jan,11 26.01.2011 29.01.2011 Kiln stopped due to low productivity because D52A Complete At 16
Almag-85 job 19 mts
at 17.00hrs at 22.40 hrs of thick coating in burning zone.Total kiln first and few mtrs.
don area
stoppage 77.40 hrs bricks in 25
e at with
2nd and 3rd nos.
18 Ankral-
row (6 nos. Ferro
mts Z1
each) mag
area
replaced. F1
with
brick
Ferr
s
oma
repla
g-F1
ced

Location of bricks [During major kiln shutdown in June '09) Length (mt
D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412

Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs. 1.600

Almag 85 (Make: Refratechnik), 2.012 to 3.412 mtrs. (Cone shape) 1.400

Almag 85 (Make: Refratechnik), 3.412 to 7.012 mtrs. 3.600

Ferromag F1 (Make: Refratechnik), 7.012 to 23.012 mtrs. 16.000

Topmag A1 (Make Refratechnik), 23.012 to 36.612 mtrs. 13.600

Kronal 60AR (Make: Refratechnik), 36.612.012 to 53.612 mtrs. 17.000

Refratherm (Make: ACE), 53.612 - 63.012 mtrs. 9.400

Al-60 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4.000

D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.700

Location of bricks [During kiln shutdown in Jan '10) Length(Mtrs)

D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412

Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs. 1.6

Ankral-R2 (Make: RHI), 2.012 to 3.412 mtrs. (Cone shape) 1.4
Almag 85 (Make: Refratechnik), 3.412 to 7.012 mtrs. 3.6
Ferromag F1 (Make: Refratechnik), 7.012 to 19.40 mtrs. 12.4
Ankral-Z1 (200 MM) (Make:RHI) , 19.4 - 22.4 mtrs 3
Ankral-Z1 (220 MM) (Make:RHI) , 22.4 - 24.6 mtrs 2.2
Topmag A1 (Make Refratechnik), 24.60 to 36.612 mtrs. 12
Kronal 60AR (Make: Refratechnik), 36.612.012 to 53.612 mtrs. 17
Refratherm (Make: ACE), 53.612 - 63.012 mtrs. 9.4
Al-60 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.7

Location of bricks [During kiln shutdown in May '10) Length(Mtrs)

D52A Castable at outer part of sector plate (Make: Hasle), 0 to 0.412 mtr 0.412
Almag-85 (Make: Refratechnik), 0.412 to 2.012 mtrs. 1.6
Ankral-R2 (Make: RHI), 2.012 to 3.412 mtrs. (Cone shape) 1.4
Almag 85 (Make: Refratechnik), 3.412 to 7.012 mtrs. 3.6
Ferromag F1 (Make: Refratechnik), 7.012 to 19.40 mtrs. 12.4
Ankral-Z1 (200 MM) (Make:RHI) , 19.4 - 22.4 mtrs 3
Ankral-Z1 (220 MM) (Make:RHI) , 22.4 - 24.6 mtrs 2.2
Ankral-R2 (Make: RHI), 26.2 to 30.2 mtrs. 4.0 New Lining
Topmag A1 (Make Refratechnik), 30.20 to 34.4 mtrs. 4.2 New Lining
Topmag A1 (Make Refratechnik), 34.4 to 36.612 mtrs. 2.2
Kronal 60AR (Make: Refratechnik), 36.612.012 to 53.612 mtrs. 17
Refratherm (Make: ACE), 53.612 - 63.012 mtrs. 9.4
Al-60 % (Make: Dalmia) 63.012 mtr. to 67.012 mtr. 4
D52A Castable at inlet sector plate (Make: Hasle), 67.012 to 67.712 mtr 0.7
mited
Al60% Clog shape

Accmon-CRC Castable

Transition Zone Calcining Zone

II -Tyre III -Tyre
5500 600
G.Gear

II Man hole door

At 42 Mtr.
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 67.66
Done in (Mtrs.)(Days) (MT)
(including castable)

45.0 - 67.0 m- AL60%

21.0 - 37.0 M- AL70%

37.0 - 42.0 M- Al70% 43.0 - 53.0 M- Al60%

23.0 - 37.0 M- Al70%

61.0- 67.0 M- Al70%

42.0-47.0 M- AL60% 52.0 - 62.0 M- AL60%

20.0 - 43.0 M- AL70% 47.0-53.0 M - AL70%

5.4-30.4 M-AL70%-LF 30.4-47.2 M- Al70% 61.0-67.0 M- AL70%

52.0- 60.8 M-AL60%
31.2-37.4 M-AL70%
21.55-33.2 M-AL70% 37.2-51.7 M-AL70%
32.0-39.6 M-AL70%
4.0-31.2 M-AL70% 36.2-45.9 M-AL70% 55.8-63 M-AL70%
26.4-36.78 M-AL70% 49.85-56.0 M-AL70% WH-K
 44-
M-AL70% 45
M-
24.0-36.0 M- Ankral-Z1 37.0-44.0- Ankral-R63(clog shape) AL 46.0-59.0 M- Refratherm 60-61 M-AL60% 62-65 M-Refratherm 66-67 M- AL60%
Hyper cast-60
70
%

ACCMON-70LI
23.0-35.0 M- Ankral-Z1 35.0-45.0 M- Ankral-R63(clog shape) 45.0-59.4 M- Refratherm 59.4-67.4 M- AL60% 68.00 139 645864

1.00 217 1088932

2.4 38 186493

1.00 65 329721

LC-45
23.0-35.0 M- Ankral-Z1 35.0-45.0 M- Ankral-R63(clog shape) 46.0-61.0 M- Refratherm 62.067.0 M-AL60% 68.00 86 414524

1.00 147 713943

0.2 52 249143

3.2 69 326760
.4- 45-47 06
8 M- M- sectors 107 491243
ral- casted
1
AL60% 05
with
(clog sectors
CRC 2.8 120 554000
shape) ( 08 repaired
Rows with 97.28 477078
Al- WH-K
60% 70LI
22.4-34.4 M- Ankral-Z1 34.4-44.4 M- Ankral-R63(clog shape) 44.4-64.4 M- Refratherm 64.4-66.9M-AL60% 67.77 63.82 297521
patch-
up of
5.8 147.64 848458
arroun
d 160-
165no 29.96 181141
s.
bricks 0.4 38.10 230773
Total at 61
358 Nos Mtrs)
bricks 0.6 54.84 340945
where 42.8
patchup - D52A
22.0-35.0 M- Ankral-Z1 in 08 35-42.8M-Ankral-R63(clog Shape)43.6 Refratherm bricks lining could not be carried out due to good physical condition during inspection. 62.17-66.97M-AL70% 48 5.27 31604
rings M-
Ankr
al-
Z1

33.4
Pat -
chi 34.4
-29.4M-Topmag-A1 All sector
ng M- Patc plate
job Top hing
23.0-36.6 M- Topmag-A1 36.6-56.3 M- Kronal-60AR 53.6-63.0 M- Refratherm 63.0-67.0 M-AL60% castable
D-52A
at mag job done
29. -A1 at with
0 39.5 D52A &
mtr mtrs Hyperca
s with st-70
wit Kron
h al-
To 60A
 12
rin
mtrs g 34.0-36.0-
pat Patching done
) ch at 03 locatons
up of Topmag-A1
wo from 34-36
26.2-30.2 mtrs- 30.2- 34.2 mtrs- mtrs.
Complete brick rk
Complete brick
lining done with do done with
lining
25.012-31.6 mtrs ne31.6-34.6
Ankral-R2 Topamg-A1.
012 34.6- 36.6-41.6 mtrs Lining not done due to brick conditions were OK 62.4-67.0 mtrs 60% Alumina Brick Hasle
ral- Ankral-Z1 wit mtrs 36.6 D52A
Kronal-60AR
hTopmag-A1 mtrs
To 12 Ankral-
5
pm rin Z1
ring
ag- gs s
A1 pat pat
Fro At
chi
at 33. chi
m
ng ng
30 32 0job- job
to mtr 33.
30. do don
6
6
s ne
mtr
e at
mtr at 34
s.
. in 2n mts
12
d are
3
ro
no
tyr
s.
a Lining Installed in June -08 Annual Kiln Shutdown
ws e with
To
42 are
pm
a
Ank
ral-
0 -0.412 Mtrs. = 0.412
HasleMtr
- D52A Imported Castable (0.412 Mtrs)
nos ag
mtr.) .
bri
wit
A1
h
bri
Z1
0.412 -2. Kronex-87 (1.6 Mtrs) Installed in FEB,09
2 To
cks
of
cks
pm
rep
2.012 - 3 Almag-85 (Special shape) , for conical portion ( 1.4 Mtrs)
An ag-
0 lac
kra A1
ed 3.412 - 8 Almag-85 (Installed in NOV,08)
l
0 Z1
rep
8.012 - 1 Ferromag-F1(Installed in NOV,08)
0 lac
ed 11.012 - Ankral ZE ( Solid Shape)
0
22.012- 2Ankral Z1
0
24.412- 2Topmag A1(Installed in April,09)
0
29.412- 3Ankral Z1
0
33.412- 3Topmag A1(Installed in April,09)
0
35.012- 4Ankral ZEi
0
42.812 - Ankral Z1
43.60 - 4 60% Alumina Clog shape, Installed in FEB,09
62.17 - 6 70 % Alumina Bricks
* 66.97- 67Hasle D52 A Castable (0.8 Mtrs)
(Kg/T of Clinker)
0.74

0.01

0.09

0.02

1.15

0.01

0.01

0.07

0.00

0.04

0.00

1.59

0.05

0.00

0.01

0.01

10.63
) Installed in FEB,09
Basic Brick (VDZ) required per ring
3K-322= 220*198*76.5/66.5
3K-622= 220*198*74/69

3K-322 bricks required 3K-622 bricks required Total Nos 3K-322 bricks required 3K-622 bricks required Total Nos
of Bricks Kiln dia No. of Bricks Kiln dia No. of Bricks of Bricks
required required
Kiln dia No. of Bricks Kiln dia No. of Bricks per ring per ring
MM Nos. MM Nos. Nos. MM Nos. MM Nos. Nos.
4150 103.665 4150 68.93 173 4550 86.078 4550 104.08 190

Equations
Let x nos of 3K-322 bricks required in a ring
Let y nos of 3K-622 bricks required in a ring
Let dia of kiln is D

76.5*x+74*y=D*3.14 ------------------------------------------1
66.5*x+69*y=(D-440)*3.14 ---------------------------------2

Basic Brick (ISO) required per ring

3K-322= 220*198*103/88
3K-622= 220*198*103/95.5
Total Nos Total Nos
3K-322 bricks required 3K-622 bricks required of Bricks 3K-322 bricks required 3K-622 bricks required of Bricks
required required
Kiln dia No. of Bricks Kiln dia No. of Bricks per ring Kiln dia No. of Bricks Kiln dia No. of Bricks per ring
MM Nos. MM Nos. Nos. MM Nos. MM Nos. Nos.
4150 57.640 4150 68.87 127 4550 45.393 4550 93.31 139

Equations
Let x nos of 3K-322 bricks required in a ring
Let y nos of 3K-622 bricks required in a ring
Let dia of kiln is D

103*x+103*y=D*3.14 ------------------------------------------1
88*x+95.5*y=(D-440)*3.14 ---------------------------------2

Basic Brick (ISO) required per ring

3K-320= 200*198*103/89
3K-620= 200*198*103/96.2
of Bricks
3K-320 bricks required 3K-620 bricks required required
Kiln dia No. of Bricks Kiln dia No. of Bricks per ring
MM Nos. MM Nos. Nos.
4550 43.458 4550 95.25 139

Equations
Let x nos of 3K-320 bricks required in a ring
Let y nos of 3K-620 bricks required in a ring
Let dia of kiln is D

103*x+103*y=D*3.14 ------------------------------------------1
x+y= 138.71
89*x+96.2*y=(D-400)*3.14 ---------------------------------2

Basic Brick (ISO) required per ring

3K-320= 200*198*103/89
3K-820= 200*198*103/97.8
of Bricks
3K-320 bricks required 3K-820 bricks required required
Kiln dia No. of Bricks Kiln dia No. of Bricks per ring
MM Nos. MM Nos. Nos.
5200 49.05 5200 109.47 159

Equations
Let x nos of 3K-320 bricks required in a ring
Let y nos of 3K-820 bricks required in a ring
Let dia of kiln is D

103*x+103*y=D*3.14 ------------------------------------------1
x+y= 158.52
89*x+97.8*y=(D-400)*3.14 ---------------------------------2

Basic Brick (ISO) required per ring Basic Brick (VDZ) required per ring
3K-318= 180*198*103/90.5 3K-318= 180*198*76.5/66.5
3K-618= 180*198*103/97 3K-618= 180*198*74/69
Total Nos
3K-318 bricks required 3K-618 bricks required of Bricks 3K-318 bricks required 3K-618 bricks required Total Nos
required Kiln dia No. of Kiln dia No. of of Bricks
Kiln dia No. of Bricks Kiln dia No. of Bricks per ring Bricks Bricks required
MM Nos. MM Nos. Nos. MM Nos. MM Nos. per ring
Nos.
4450 48.677 4550 86.98 136 4450 40 4450 148 187

Equations Equations
Let x nos of 3K-318 bricks required in a ring Let x nos of 3K-318 bricks required in a ring
Let y nos of 3K-618 bricks required in a ring Let y nos of 3K-618 bricks required in a ring
Let dia of kiln is D Let dia of kiln is D

103*x+103*y=D*3.14 ------------------------------------------1 76.5*x+74*y=4450*3.14 ------------------------------------------1

x+y= 135.66 76.5*x+74*y=13973
90.5*x+97*y=(D-360)*3.14 ---------------------------------2 66.5*x+69*y=(D-360)*3.14 ---------------------------------2
66.5*x+69*y=(4450-360)*3.14
66.5*x+69*y=12842
Basic Brick (VDZ) required per ring
B320= 200*198*76.5/66.5
B620= 200*198*74/69
of Bricks
B320 bricks required B620 bricks required required
Kiln dia No. of Bricks Kiln dia No. of Bricks per ring
MM Nos. MM Nos. Nos.
4550 60.178 4550 130.86 191

Equations
Let x nos of B320 bricks required in a ring
Let y nos of B620 bricks required in a ring
Let dia of kiln is D

76.5*x+74*y=D*3.14 ------------------------------------------1

66.5*x+69*y=(D-400)*3.14 ---------------------------------2

Basic Brick (ISO) required per ring

3K-320= 200*198*103/89
3K-620= 200*198*103/96.2
of Bricks
3K-320 bricks required 3K-620 bricks required required
Kiln dia No. of Bricks Kiln dia No. of Bricks per ring
MM Nos. MM Nos. Nos.
4550 43.46 4550 95.24 139

Equations
Let x nos of 3K-320 bricks required in a ring
Let y nos of 3K-620 bricks required in a ring
Let dia of kiln is D

103*x+103*y=D*3.14 ------------------------------------------1
x+y= 138.71
89*x+96.2*y=(D-400)*3.14 ---------------------------------2

Basic required per ring for ILC TA Duct

IH-16= 230*114*84/68 mm
IH-10= 230*114*81/71 mm
of Bricks
IH-16 bricks required IH-10 bricks required required
TAD Dia No. of Bricks Kiln dia No. of Bricks per ring
MM Nos. MM Nos. Nos.
1600 17.01 1600 44.39 61

Equations
Let x nos of IH-16 bricks required in a ring
Let y nos of IH-10 bricks required in a ring
Let dia of TA duct is D

84*x+81*y=1600*3.14 ------------------------------------------1
84*x+81*y=5024 ------------------------------------------1
68*x+71*y=(1600-228)*3.14 ---------------------------------2
68*x+71*y=4308.08 ---------------------------------2
 0.412 -2.012 Mtrs. = 1.6 Mtrs
* 2.012 - 3.412 Mtrs.= 1.4 Mtrs.
3.412 - 22.012Mts. = 18.6 Mtrs
22.012- 35.012 Mtrs. = 13 Mtrs.
35.012- 42.812 Mtrs. = 7.8 Mtrs.
42.812 - 43.612 Mtrs. = 0.8 Mtrs
62.17 - 66.97 Mtrs. = 4.8 Mtrs
Ankral-R2 (1.6 Mtrs)
Ankral-R2 (Special shape) , fo
Ankral ZE ( Solid Shape)
Ankral Z1
Ankral ZEi
Ankral Z1
70 % Alumina Bricks
 (1.6 Mtrs)
(Special shape) , for conical portion ( 1.4 Mtrs)
( Solid Shape)

mina Bricks