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MINES CRUSHING STACKER & RECLAIMER
RAW MILL
COAL STORAGE
COAL CRUSHER
COAL MILL
PYRO PROCESSING
BLENDING &
STORAGE
CEMENT MILL
CLINKER SILO
PACKING & DESPATCHPURCHASE
COAL
SLAG OR FLY ASH
GYPSUM
CEMENT MFG. FLOW CHART
DESIGN CRITERIA (FOR PROPOSED SYSTEM):Ambient temperature : 40 ˚CSurface Temp : 60 ̊ CMaximum heat loss : 100 kcal / m2hr.Wind Velocity : 0.0 m/sec.Finish : Aluminium-20 G (0.2 emissivity)
GI-24 G (0.3 emissivity) MATERIAL CODE :
Rockloyd Resin Bonded Rockwool Mattresses 100-120 Kg/M3
For operating temp. up to 400 ˚C
Rockloyd Resin Bonded Rockwool Mattresses 150 Kg/M3
Temperature above-400 ˚C
Preformed Pipe Sections For All Temperatures & up to 350 mm NB
144 Kg/M3
Rockloyd Rockwool Pipe Sections-144 Kg/M3 Up to 650 ˚C
THERMAL INSULATIONS IN CEMENT PLANT
SECTION SUB-SECTION OPERATING TEMP. (˚ C)
ROCKLOYD MATTRESS
DENSITY
INSULATION THICKNESS (MM)
REVERSE AIR BAG HOUSE FOR KILN / RAW MILL
200-225
300
100
100
100
280
280
100
280
240
100
90
DUCT FROM PH FAN TO MILL
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
140
DUCT FROM MILL TO CYCLONE 25
DUCT FROM CYCLONE TO MILL FAN 25
DUCT FROM MILL FAN TO RABH 25
PIPING FROM RABH TO BAGHOUSE FAN (Pipe Dia 15 mm – 600 mm)
65-140
DUCT FROM RABH FAN TO STACK 140
RECIRCULATION AIR DUCT 25
PREHEATER FAN TO RABH THROUGH BYPASS DUCT
140
BAG HOUSE FAN 140
RAW MILL FAN 100-120 Kg/m3 25
RAW MILL DEPARTMENT
THERMAL INSULATIONS IN CEMENT PLANT
Approximately Heat Loss 90-100 Kcal / Sqm. Hr. Surface Temp. = 60 ˚ C
SECTION SUB-SECTION OPERATING TEMP. (˚ C)
ROCKLOYD MATTRESS
DENSITY
INSULATION THICKNESS
(MM)
DUCT FROM PH FAN TO DEDUSTING CYCLONE
300
300
300
100
100
100
100
310
95-120
300
80-110
80-110
80-100
140
DUCT FROM CYCLONE TO BOOSTER FAN
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
140
DUCT FROM BOOSTER FAN TO MILL 140
DUCT FROM MILL TO EXPLOSION VENT & THEN TO BAG FILTER
25
DUCT FROM BAG FILTER TO MILL FAN 25
DUCT FROM FAN TO ATOMOSPHERE 25
RECIRCULATION AIR DUCT 25
COAL MILL BAG FILTER FAN 150
COAL MILL BOOSTER FAN 35
COAL MILL BAG HOUSE 140
DUST COLLECTOR 25
FINE COAL BIN 25
DEDUSTING PIPE 100-120 Kg/m3 25
COAL GRINDING DEPARTMENT
THERMAL INSULATIONS IN CEMENT PLANT
Approximately Heat Loss 90-100 Kcal / Sqm. Hr. Surface Temp. = 60 ˚ C
SECTION SUB-SECTION OPERATING TEMP. (˚ C)
ROCKLOYD MATTRESS
DENSITY
INSULATION THICKNESS
(MM)
DUCT FROM PH CYCLONE TO FAN INLET
296-450
296-450
296-450
135-275
CHUTE UNDER TOP CYCLONE
100-150 Kg/m3
100-150 Kg/m3 135-275
PH FAN 100-150 Kg/m3 135-275
CYCLONE PREHEATER DEPARTMENT
THERMAL INSULATIONS IN CEMENT PLANT
Approximately Heat Loss 90-100 Kcal / Sqm. Hr. Surface Temp. = 60 ˚ C
THERMAL INSULATIONS IN CEMENT PLANT
SECTION SUB-SECTION OPERATING TEMP. (˚ C)
ROCKLOYD MATTRESS
DENSITY
100 100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100-120 Kg/m3
100
90
95
95
95
INSULATION THICKNESS (MM)
CEMENT MILL FAN 25
CEMENT MILL BAG HOUSE 25
DUCT FROM CEMENT MILL TO BAG HOUSE
25
DUCT FROM BAG HOUSE TO FAN
25
RECIRCULATION AIR DUCT TO STACK
25
RECIRCULATION DUCT 25
CLINKER GRINDING PLANT-CEMENT MILL
Approximately Heat Loss 90-100 Kcal / Sqm. Hr. Surface Temp. = 60 ˚ C
THERMAL INSULATION THERMAL INSULATION
Thermal Insulation is the system which is provided to retard flow of heat and is used as a barrier between two bodies of different temperatures to Either a) reduce the heat loss from a hot body or b) reduce the heat ingress into a cold body.
INSULATION AUDIT SERVICES
Lloyd insulation audit is the only scientific
methodology available indigenously for quantified
analysis of performance of existing insulation
systems in a plant. Observations and recordings
assist in developing a database for existing
performance levels and for determining techno-
economic feasibility for upgradation of insulation.
• ROCKLOYD ROCKWOOL MATTRESS / BLANKET faced with one side GI or SS wire netting.
LLOYD RANGE OF PRODUCTS
SPECIFICATION CONFORMANCE
IS : 8183 – 1993
BS : 3958 Part-3
ASTM : C 592-80
APPROVED FOR A-60 CLASS INSULATION .*
*The only product in India.
ROCKLOYD ROCKWOOL MATTRESS
TECHNICAL SPECIFICATIONS
1 Standard Densities 100, 120, 150 Kg/m3
2 Application Temperatures
-1000C to +8000C
3 Standard Thickness* 25, 40, 50, 65, 75mm
4 Standard Size 1520 x 1220mm
* Other thickness from 20 to 100mm insteps of 5mm can also be made available.
ROCKLOYD ROCKWOOL MATTRESS
TECHNICAL PROPERTIES OF ROCKLOYD LRB MATTRESS
LLOYD RANGE OF PRODUCTS
TEST RESULTS1 Bulk Density (Kg/m3)
Shot ContentOver 500 MicronsOver 250 Microns
Moisture Content
4 Moisture Absorption 0.127% 0.120%
5 Sulphur Content 0.159% 0.156%
100.34 to 104.68
121.15 to 125.72
22.88%7.16%
2.47%6.98%
3 0.118% 0.115%
LLOYD RANGE OF PRODUCTS
TEST RESULTSThe material is Incombustible6 Incombustibility
% Loss in Weight
Chloride Content
8 Alkalinity 8.2 8.2
9 Average Fibre Dia 3.86 Microns 3.86 Microns
10 Compressibility and Resilience
97.4% 96.7%
1.41% 1.35%
7 0.0018% 0.0017%
TECHNICAL PROPERTIES OF ROCKLOYD LRB MATTRESS
LLOYD RANGE OF PRODUCTS
TEST RESULTS11 Heat Resistance Test at
6500C for 96 Hrs.O.K. No fusion of fibres observed
12 Remarks The material conforms to IS : 8183-1993
TECHNICAL PROPERTIES OF ROCKLOYD LRB MATTRESS
LLOYD RANGE OF PRODUCTS
• ROCKLOYD PIPE SECTIONS - pre-formed pipe section of pipe dia upto 350mm NB
TECHNICAL SPECIFICATIONS
1 Standard Densities 144, 150 & 160 Kg/m3
2 Application Temperatures -1000C to +8000C
3 Standard Thickness* 25, 40, 50, 65, 75mm4 Diameter Range** 12.5mm to 350mm
Nominal Bore5 Standard Length 0.5, 0.75, 1.0 mtrs.
6 Facings (if specified) Kraft Paper, Scrim Cloth, Canvas or Aluminium Foil
*Other thickness from 20 to 100mm insteps of 5mm can also be made available.
** Outer diameter of pipe to be specified.
ROCKLOYD PIPE SECTION
TECHNICAL PROPERTIES OF ROCKLOYDPREFORMED PIPE SECTION
LLOYD RANGE OF PRODUCTS
TEST RESULTS1 Bulk Density (Kg/m3)
Shot ContentOver 500 MicronsOver 250 Microns
Moisture Content
4 Moisture Absorption 0.119%
5 Sulphur Content 0.128%
144.62 to 148.25
22.67%6.76%
3 0.110%
LLOYD RANGE OF PRODUCTS
TEST RESULTSThe material is Incombustible6 Incombustibility
% Loss in Weight
Chloride Content
8 Alkalinity 8.1
9 Average Fibre Dia 3.85 Microns
10 Compressibility and Resilience
96.9%
0.97%
7 0.0018%
TECHNICAL PROPERTIES OF ROCKLOYDPREFORMED PIPE SECTION
TECHNICAL PROPERTIES OF ROCKLOYDPREFORMED PIPE SECTION
LLOYD RANGE OF PRODUCTS
TEST RESULTS11 Heat Resistance Test at
6500C for 96 Hrs.O.K. No fusion of fibres observed
12 Remarks The material conforms to IS : 9842-1994
HOT PIPELINE INSULATION
APPLICATION SPECIFICATIONS FOR HORIZONTAL / VERTICAL PIPELINES
For single layer insulation up to maximum thickness of 75mm
1. Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease.
2. Providing and fixing MS flat ring of size 25x3mm, over pipe having diameter more than 150mm NB, at every 1150 mm distance having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt.
THERMAL INSULATION
3. Providing and fixing the recommended insulation thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G .
4. Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface .
5. Providing and applying aluminium sheet as cladding over the MS flat ring already provided at 1150mm distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94.
6. Providing and applying 22G aluminium band at every 450mm C/C over the cladding to secure it firmly to its place.
THERMAL INSULATION
7. Providing and applying 22G aluminium band at every 450mm c/c over the final layer of insulation to secure it firmly to its place.
8. Providing and applying Aluminium sheet as cladding screw over the MS flat ring already provided at 1150mm distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94.
9. Providing and applying 22G Aluminium band at every 450mm c/c over the cladding to secure it firmly to its
THERMAL INSULATION
HOT PIPELINE INSULATION
APPLICATION SPECIFICATIONS FOR VERTICAL & HORIZONTAL PIPELINES
For multiple layer insulation above 75mm thickness.
1. Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease.
2. Providing and fixing MS flat ring of size 25x3mm over pipes having diameter more than 150mm NB at every 1150mm distance having L shaped lugs with a packing of ceramic paper duly riveted and tightening it over the surface with nut and bolt.
THERMAL INSULATION
3. Providing and fixing the first layer of insulation in recommended thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G.
4. Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface.
5. Providing and fixing the second / subsequent layer of insulation in recommended thickness of RockloydResin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G.
6. Butting each joints and stitching the mattress properly with GI Wire of 20G to secure it firmly to the surface.
THERMAL INSULATION
7. Providing and applying 22G aluminium band at every 450mm c/c over the final layer of insulation to secure it firmly to its place.
8. Providing and applying Aluminium sheet as cladding screw over the MS flat ring already provided at 1150mm distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94.
9. Providing and applying 22G Aluminium band at every 450mm c/c over the cladding to secure it firmly to its
THERMAL INSULATION
APPLICATION SPECIFICATION FOR EQUIPMENTS
1. Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease.
2. Providing and fixing MS flat ring of size 25x3mm at every 1150mm distance c/c having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt.
3. Providing and welding GI wire pins of 8 to 10G diameter having length 20mm more than the thickness of insulation at every 300mmc/c(incase of equipments having diameter more than 1000 mm).
THERMAL INSULATION
APPLICATION SPECIFICATION FOR EQUIPMENTS
4. Providing and fixing the recommended insulation thickness of Rockloyd Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm x 24G and piercing it through the GI wire pins.
5. Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface.
6. Bending the pins over the insulation surface.
THERMAL INSULATION
APPLICATION SPECIFICATION FOR EQUIPMENTS
7. Providing and applying 22G AL band at every 450MM C/C over the insulation to secure it firmly to its place.
8. Providing and fixing 22G Aluminium sheet cladding over the MS flat ring already provided at 1150mm C/c duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 40mm. Sealing all the joints with mastic MAS-94.
THERMAL INSULATION
ESP INSULATIONTHE CASINGS ARE INSULATED WITH ROCKWOOL
INSULATION OF EQUIPMENTSINSULATION OF EQUIPMENTS
Pipelines at ground level exposed to Atmosphere and prone to foot traffic
1. Cleaning the pipe surface properly.2. Providing and applying metal ring wherever pipe dia is more
than 150mm NB.3. Providing & applying required thickness of Rockloyd Water
Repellent Grade Rockwool Pipesections (max. 75mm and upto 350mm nb) of density 144 kg/m3 conforming to IS : 9842 and held in position by 25mm wide Aluminium bands at 450mm Centre to Centre.
OR4. Providing and applying required thickness of Rockloyd
Water Repellent Grade Rockwool slabs of density 100 or 150 Kg/m3 conforming to IS : 8183 and held in position by 25mm wide Aluminium bands at 450mm Centre to Centre.
THERMAL INSULATION OF STEAM LINESTHERMAL INSULATION OF STEAM LINES
Pipelines at ground level exposed to Atmosphere and prone to foot traffic
5. Providing and applying 2nd layer of Rockloyd Water Repellent Grade Rockwool slabs 100 or 150 kg/m3 and holding the same with 25mm Aluminium band. Second layer of insulation to be applied where total thickness is more than 75mm.
6. Providing and applying 0.01mm Aluminium Foil over the insulation surface and joints sealed with 75mm wide Aluminium Tape.
7. Providing and applying 20mm hard setting plaster over the insulation surface and coated with a waterproof paint.
THERMAL INSULATION OF STEAM LINESTHERMAL INSULATION OF STEAM LINES
Pipelines at ground level exposed to Atmosphere and prone to foot traffic
8. Providing and applying 22G Aluminium Sheet or Colour Coated Steel Sheet cladding.
9. Providing and applying 25mm Aluminium Band or Steel Band at 450mm Centre to Centre.
THERMAL INSULATION OF STEAM LINESTHERMAL INSULATION OF STEAM LINES
Effect of Wind Velocity
Presence of Wind in surrounding takes away heat generated from cladding surface.
A strong wind will carry away heat and ensure a lower surface temperature.
Windage has effect on insulation thickness –reduces with increase in windage.
For energy conservation, windage is taken as ‘Zero’.
THERMAL INSULATION OF STEAM LINESTHERMAL INSULATION OF STEAM LINES
Effect of Emissivity
Heat coming on top of insulation is emitted out.
Polished surface will emit maximum heat (Aluminium)
Aluminium calls for higher thickness & GI, Plaster lower thickness
Old aluminium will emit lower heat as compared to new sheet.
THERMAL INSULATION OF STEAM LINESTHERMAL INSULATION OF STEAM LINES
Cladding
Cladding corrosion due to condensation on inner side
Moisture present on inner side condenses & lower corrosion to cladding sheet.
Polysurlyn coated aluminium sheet is now available(earlier bitumen coating underneath).
THERMAL INSULATION OF STEAM LINESTHERMAL INSULATION OF STEAM LINES