Bharat Heavy

Electricals Limited
Ceramic Business Unit

If wear is your problem

BHEL has the solution...

CERALIN
FOR A TROUBLE FREE TOMORROW

The Company
Bharat Heavy Electricals Limited is the largest
Engineering and Manufacturing Enterprise of its
kind in India. It ranks amongst the leading
manufacturers of power plant equipment in
the world.
BHEL has 14 manufacturing plants, 4 power
sector regional centres, 8 service centres, 18
regional offices and over 150 project sites spread
all over India and abroad. It offers a wide
spectrum of products and services for core
sectors like Power Generation, Transmission,
Distribution, Industry, Transportation, Oil & Gas,
Defence and Non-Conventional Energy Systems.
Ceramic Business Unit
The Ceramic Business Unit (CBU) of BHEL, is a
Strategic Business Unit for Ceramics and
Systems. This business unit deals with High
Tension Insulators, Ceramic Wear Resistant
liners, Industrial Ceramic Products and
associated Systems. CBU is headquartered at
Bangalore and is supported by:
Manufacturing units with “State of the Art”
technology for ceramic products, processes and
applications at
CERALIN
l
Electroporcelains Division (EPD), Bangalore
l
Insulator Plant (IP), Jagdishpur
Advanced Research and Development facilities
for Ceramic products, processes and
applications at
l
Ceramic Technological Institute (CTI),
Bangalore (A Division of Corporate Research
& Development, Hyderabad)
Products
l
High Tension Insulators for Transmission and
Distribution lines from 11kV to 800kV
l
Hollow Insulators for Instrument and Power
Transformers, Switchgear, Electro Static
Precipitators, etc.
lStation Post Insulators for Bus Bars support
and for Isolators from 11kV to 400kV
l
Composite Insulators for Railway Traction
and Transmission applications upto 400kV
l
Wear resistant Materials for Thermal Power
Plant applications, Steel, Coal Washeries,
Cement, etc.
l
Industrial Ceramic Products for various
applications
 CERALIN

CERALIN a total solution Range of Applications

against WEAR Its superior wear resistance, chemically
In steam generating units {Boilers} and inert and high thermal stability
associated pulverisers and other auxiliaries, characteristics make CERALIN suitable for
high alumina ceramic material can be used a wide range of applications:
for protection of components against wear Power Sector : Wear prone
due to abrasion and erosion. components of
Bowl / Tube Mill,
Protection Why? Fuel Piping.
Coal is one of the main source of fuel used in
Steel Sector : Sinter Plants,
power generation. Coal fired boilers adopt
Rotary Kiln, Coke
the method of pulverising raw coal in
Oven
pulverisers or mills, conveying the
pulverised coal-air mixture from the Cement Sector : Cement & Raw
pulverisers to the boiler burner for producing Mills chutes & Air
and utilising steam to generate power. Fine Separators
coal particles at high velocities cause failure
Coal Sector : Slurry Pipes,
in many components in the pulverisers and
Chutes & Launders
the coal piping system of the boiler. Ceramic
lining is provided to the components to
extend the life thereby reducing downtime.

Bowl Mill Tube Mill Fuel Piping

Components Components System
l
Classifier Inner Cone l
Connecting Duct l
Transition Piece
l
Venturi Vane l
Classifier Body l
Mill Outlet Elbows & Pipes
l
Venturi Outlet Collar l
PF outlet Box
l
Line Bends
& Vane l
Circular Duct
l
Multiple Port Outlet l
Internal Cone l
Orifices
l
Mill Discharge Valve l
PF Outlet Venturi l
Fuel Inlet Elbow
 CERALIN
Protective Lining - What?
To combat the various wear prone areas in
Coal fired Thermal Power Stations, Coal
Sector, Steel Industry, Cement Industry and
others similar applications, BHEL has
indigenously developed High Alumina
Ceramic Wear Resistant materials in its R&D.
Components fitted with CERALIN are used
all over India with a proven performance.

Physical Properties
Volume of Material lost in cubic Bulk Density >3.2 gm/cc
centimeters per ton of ash
Water Absorption < 0.5 %
GRANITE 33.59
Hardness (MOHs Scale) > 8
FELSITE
29.64 2
QUARTZ
Cold Pulverising Strength > 3000 kg/cm
PORCELAIN 24.17
BASALT TEST CONDITIONS:
Flexural Strength
2
6.20 Particle Velocity: 50 m/sec (at room temp.) >2200 kg/cm
Erodent: Ash concentration of 0.25 kg/ Nm3
CERALIN
Period of Test: 60 min
1.44 Angle of Impingement: 450 Co-efficient of Thermal
-6
(Erosion test result) Expansion 6 to 9 x 10 /°C

The Ceramic tiles are designed with due consideration to the area of application and the type of
fixing required. Curved, flat or weld-on type tiles are designed and engineered to suit the
component configuration and the end requirement.

Operating Conditions
In coal fired steam generating units the normal operating conditions are:
Flow medium : Pulverised coal mixture
Particle size : 70% less than 75 microns
15% 75 to 90 microns
15% 90 to 150 microns.
3
Coal concentration : 0.935 to 1.545 kg/Nm
Ash content : 50% Maximum
Flow velocity : 30 mtr / Sec. Maximum
2
Pressure : 0.5 kg / cm
o
Temperature : 300 C Max
The components are designed to meet the operating parameters and life expectancy considerations.
 CERALIN
Production Facilities
Ceramic Tiles Manufacturing Ball Mill Spray Drier

RAW MATERIALS BALL MILLING

DRY PRESSING SPRAY DRYING

FIRING CERALIN TILE Hydraulic Press High Temperature Kiln

Ceralin is manufactured using Calcined Alumina

as a raw material. Spray dried powder is then
compacted in Hydraulic Presses to form tiles.
These tiles are then fired in a high temperature
kilns at around 1560-1600oC to get required wear
resistant characteristics. Ceralin tiles assembly to
the casing is done by using Mortar, Silicone
adhesives or Weld-on tiles.

Product Assembly
Fixing Method
C Mortar
E Bends
A. Fixing with
R Elbows Mortar
Fabricated Pipes
A
Component
L
I
N Adhesive
B. Fixing with
Adhesive
T Cone
I Fabricated MDV
Component Orifice
L
Venturi C. Fixing with
E Metal Plug
S Metal Plug
Customer Profile
CERALIN is having major presence in coal fired
thermal power stations, Cement sector & Steel Sector.
Major customers list includes NTPC, DVC, Jindal,
Tata Power, Nalco, Hindaco, HZL, Torrent Power,
State Electricity Boards for their Power Stations,
SAIL and Cement companies.

What our customers say?

“Ceralin Lined Orifices supplied to BTPS have given double the life as compared with
Ni-Hard.”
- Kulvinder Singh, Supdt., BMD-I, BTPS, NTPC, New Delhi, India
“Performance of Ceralin Lined Bends of Unit I & II are found very satisfactory since the
commissioning”.
- Dy Chief Engineer (GEN), 210 MW TPS, MSEB, Khaperkheda, Maharashtra, India
“The Ceralin Lined Bends supplied & erected by M/s BHEL during erection of 210 MW Unit I,
II, III, IV have performed well & lasted for 20000 to 30000 service hrs.”
- Er K Raju, Chief Engineer (GEN), MTPS, Mettur Dam, Tamil Nadu, India
“Ceralin Lined Bends installed in Unit I & II PF lines have given life of more than 25000
hours.”
- Chief Engineer (O&M), RTPS, Raichur, KPCL, Karnataka, India.

Bharat Heavy Electricals Limited

(A Government of India undertaking)

Registered and Corporate Office

BHEL House, Siri Fort, New Delhi - 110 049.
Tel: 011-2600 1010 Fax: 011-2649 3021
www.bhel.com

Efforts are constantly being made to

improve the product design and hence the
products supplied may differ in minor
details from that given in the catalogue.

For enquiries please contact:

Bharat Heavy Electricals Limited
(A Government of India Undertaking)
Ceramic Business Unit
Prof. C.N.R. Rao Circle,
Opp. Indian Institute of Science
Malleswaram, Bangalore-560 012 (India)
Ph: 080-23442988, 22182247
Fax: 080-23560741, 23344231

www.bhelceramics.com