Welcome You

2nd NATIONAL WORKSHOP CUM Vineet Kumar Sharma

TECHNOLOGY EXHIBITION FOR Ketan Goel
PROMOTING ENERGY EFFICIENT AND
CLEANER PRODUCTION FOR
SUSTAINABLE INDUSTRIAL GROWTH
Significant Savings in Energy through False air reduction.
We provide an Innovative & Cost-Effective Industrial
solution for the purpose of False Air arrestment. 1
Safety Thought: Safety
Should be
thought of
as an
investment,
not a cost.

2
 Energy Consumption
Impacting Production Cost
• Electrical and Thermal energy
accounts for 40 to 50% cost of
cement manufacturing.

Description UOM Value

Specific Electrical Energy Kwh/t Cement 75*
consumption
Specific Thermal Energy KCal/Kg Clinker 750*
consumption
Specific CO2 emission net Kg/t Cementitious 530 to 650*
material
Specific CO2 emission Kg/MWh 820*
for Electricity Production
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*Approximate Average Value taken for calculation purpose only
 Our contribution PAT
Our Product range help to
cope with

• Global Warming
• Environment issues
• Energy Conservation issues

We help to reduce energy consumption by decreasing false

air content in the system hence increasing efficiency of
manufacturing process in Cement Plants, Thermal Power
Plants, Green Power Plants, WHRS etc. 4
What is False air
False air is any unwanted air entering the system between two points.
The exact amount of false air is difficult to measure. An indicator of false air amount can be
the oxygen increase between two points (usable for gas
stream containing less than 21% of oxygen).

GAS

Point-1 Point-2

Disadvantages of False Air:

(1) Increase in Electrical Energy Consumption
(2) Increase in Thermal Energy Consumption
(3) Reduction in Productivity
(4) Unstable and disturbed operation
(5) Frequent human exposure to unsafe areas while arresting false air 5
 Our Product
Portfolio
• Arrest Master 1001
• Arrest Master 1002
• Arrest Master 1003
• Arrest Master 1004
• Arrest Master 2001
• Application Areas:
Cement Plants
Power Plants
Green Power Plants
WHRS & Steel Plants

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ARREST MASTER
1001
Product Highlights Two Component System
• Part A & Part B (1:1 Mix Ratio).
• Temp. Resistance: 180⁰C
• For Upper Cyclones, VRM’s &
Power plants.
• Density: 2.5 g/cm3
• Compressive Strength: 500-
525 Kg/cm2
• Non shrinkable properties &
no tools required for
application.
• Pot Life: 30 Min.
• Setting Time: 5 min at 80⁰C

FALSE AIR ARRESTING COMPOUND 7

 Before After

Cyclone Main Door

8
ARREST MASTER 1001
 Before After

Flapbox
9
ARREST MASTER 1001
 Flange Flange

Downpipe Flanges
10
ARREST MASTER 1001
 • Side View • Front View

Dispersion Plate
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ARREST MASTER 1001
 Before After

Manhole door (Pre-Calciner vessel Upcomer duct)

12
ARREST MASTER 1001
 Cleaning Application

VRM Section
13
ARREST MASTER 1001
 Before After

VRM Section- Master Roller Door

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ARREST MASTER 1001
 ARREST MASTER
1002
Product Highlights Two Component System
• Part A & Part B (1:1 Mix Ratio).
• Temp. Resistance: 150⁰C
• For Bag-house & Bag-filters of
(Raw Mill, Cement Mill, Coal
Mill).
• Density: 2.3 g/cm3
• Compressive Strength: 425-450
Kg/cm2
• Non shrinkable properties & no
tools required for application.
• Pot Life: 20 Min.
• Setting Time: 10 min at 80⁰C
FALSE AIR ARRESTING COMPOUND 15
 Full view (Bag-house 1) Full View (Bag-house 2)

CVRM Bag-house : Top Door

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ARREST MASTER 1001
 After After

CVRM Bag-house : Top Door

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ARREST MASTER 1002
 Before After

VRM- Hopper door

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ARREST MASTER 1002
ARREST MASTER
1003
Product Highlights Two Component System
• Part A & Part B (3:2 Mix Ratio)
• Temp. Resistance: 500⁰C (For
high Temperature areas)
• Application Areas: Bottom
Cyclones, Calciner, Boiler Main
Doors.
• Density: 3.0 g/cm3
• Compressive Strength: 300-
325 Kg/cm2
• Non shrinkable properties &
excellent resistance to thermal
shock.
• Inorganic Glass Ceramic
Compound.
FALSE AIR ARRESTING COMPOUND 19
 After Close-up

Hot air damper

20
ARREST MASTER 1003
 Before After

Flap valve door (K-line, 5th cyclone feed pipe connected to

pre-calciner vessel).
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ARREST MASTER 1003
ARREST MASTER
1004
Product Highlights Two Component System
• Part A & Part B (3:2 Mix Ratio).
• Temp. Resistance: 800⁰C (For high
Temperature areas).
• Density: 2.3 g/cm3
• Compressive Strength: 200-275
Kg/cm2
• Non shrinkable properties &
excellent resistance to thermal
shock.
• Inorganic Glass Ceramic
Compound.
• Pot Life: 20 Min.
• Setting Time: 5 min at 200⁰C

FALSE AIR ARRESTING COMPOUND 22

ARREST MASTER
2001
Product Highlights High Vibrations Area
• One Component system.
• Temp. Resistance: 180⁰C
• Application Areas: VRM
Section, Fans, Hammering
System of GPP.
• Density: 1.04 g/cm3 (at 25’C).
• Ultimate Elongation (S2
dumbbell): 200 %
• Excellent adhesion to most
metals & excellent durability.
• For areas having vibrations.

FALSE AIR ARRESTING COMPOUND 23

 After Close- up

Bellow of Mill roller

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ARREST MASTER 2001
 Before After

Mill inlet duct

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ARREST MASTER 2001
Packaging of Arrest Master

Part A Part B

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Advantages of Arrest master Series over
Conventional Methods and Products
Property
Life of application
Method and time required
for application
Effectiveness
Resistance to thermal
shock
Venerability to plant start-
stop
Requirement of repair and
recheck
Ability to withstand
vibrations
Working temperature
Conventional Arrest Master
Method/Products
Short As long as desired
Experienced meson easy and less time taking,
required and takes long any body can do
time application
Less and decreases with High, Remains effective till
time whole life
Less, cracks and damage High, can withstand against
occurs due to thermal thermal shock and
shock shrinkage and expansion
High, required to replace Less, remains intact even
after few start stops after many start stops
frequent Nil
Not able Can withstand up to 7mm/s
vibrations (AR-2001)
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less High up to 800 Deg C
Savings through
False air reduction

Case Studies:
1) Single String Preheater
2) Double String Preheater
3) Cement Mill VRM

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 Single String Pre Heater
1% FALSE AIR REDUCED AT PREHEATER OUTLET
Date 19th Nov,2016
Type Of plant Five stage ILC
Kiln length 65 Metrs
Kiln Dia 4.2 Metrs
Heat Consumption 750 K Cal/Kg-Clinker
Type of Cooler Grate cooler
S No Particulars Unit Values
1 Parameters
1.1 Kiln Feed TPH 315
1.2 Clinker Factor 1.62
1.3 Barometric Pressure at site mmWg 10036
1.4 Ambient Trmp Deg C 25
1.5 Power Cost Rs/Unit 3.2
1.6 Coal CV K Cal/Kg Coal 7800
1.7 Coal Cost Rs/Kg 8
1.8 PH Out let pressure mmWg 800
Pressure at PH fan Inlet mmWg 850
1.9 PH Out let temp. Deg C 300
1.1o Flow at PH Out Let m3/Hrs 731000
1.11 Flow at PH Out Let Nm3/Hrs 311333
2 False air 1%
2.1 False air Volume m3/Hrs 7310
2.2 False air Volume Nm3/Hrs 3113
3 LOSS in Power
3.1 Loss on account of PH Fan KwH 20.96
3.2 Loss in money Rs/Hr 67.06
3.3 Annual Loss due Power In Lacs 5.31
4 Loss in Heat
4.1 Loss on account of heat Kcal/hr 312500
4.2 Loss in money Rs./hr 321
Annual Loss due to Heat In Lacs 17.77
5 Total Loss (Rs) Lacs per annum 30.70
6 Arrest Master 1001 Cost Lacs 1.64
6.1 Pay-Back period In one month
Note: Considring 330 days run plant in a year
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Conclusion : Arrest Master 1001 : Cost-effective Industrial Solution
 Double String Pre Heater
S No Particulars Plant Details
1.2 Kiln length 55.8 Mtrs
1.3 Kiln Dia 3.8
1.4 Heat Consumption 815 K Cal/ Kg - Clinker
1.5 Type of Cooler Grate Cooler with IKN KIDS
1.6 Calciner Type ICL
1.7 PH Make/Stages KHD/5
S No Parameters Unit Plant Details
2.1 Kiln Feed TPH 210
2.2 Clinker Factor 1.64
2.3 Clinker production TPH 3073
2.4 Barometric Pressure at site mmWg 10017
2.5 Barometric Pressure at sea level mmWg 10336
2.6 Ambient Temperature Deg C 35
2.7 Power Cost Rs/Unit 3.2
2.8 Coal CV K Cal/Kg Coal 7800
2.9 Coal Cost Rs/Kg 8
3 Reduction in False air after using " ARREST MASTER 1001"
3.1 False air across PH (Before/After) % 9.7 7.6 2.11
Parameters Unit Kiln string Pyro string UNIT-I
4 Preheater outlet
4.1 Temperature deg c 391 395
4.2 Draft mmWG -625 -815
4.3 Flow M3/h 228000 325000
4.5 Flow Nm3/h 85179 118249 203429
5 False air = 2%
5.1 False air volume Nm3/h 1797 2495 4292
5.2 False air = 2% M3/h 4938 7043
6 LOSS
6.1 Loss on account of Power in SG fan kwh 11 20 31
6.2 Loss in money Rs./hr 35 65 101

6.3 Loss on account of heat Kcal/hr 231620 325157 556777

6.4 Loss in money Rs./hr 174 244 418

6.5 TotalLoss in money Lacs per annum 17 24 41

6.6 Cost of Arrest Master 1001 Lacs 4.2
6.7 Pay back period Month 1.13 30
 Glimpse of
15th NCB International Seminar on
Cement, Concrete and Building
Materials,
05-08 December 2017,
New Delhi, India

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 Some Testimonials
from NCBM Seminar
• T. Prasad (VP Project Engineering) – Thyssenkrupp
(Excellent Product. Need to be applied at Preheater, Duct
Flanges to Conserve heat.
• Rajesh Kothari (Cluster Head) – Ambuja Cements Ltd .
(Interesting Product)
• K Ganesh (President) – RV Consulting (Sagar Cement
Group)-(Good product & has future)
• Rakesh Nayak (Section In charge) – Dalmia Cement ( Very
good product for False Air Arresting)
• Devendra Sinha – JSW Cement (A good option for mind
relief for false air ingress points)
• Rabindra Singh- NCBM (Good product with future)
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Our Esteemed Customers
OCL India Ltd. Line- 1 & 2, Rajgangpur, Odisha
Dalmia Cement East Limited, Bokaro, Jharkhand
Kapilas Cement Manufacturing Works, Cuttak, Odisha
Dalmia Cement Bharat Limited, Belgaum, Karnataka
OCL India Limited, Medinipur, West Bengal

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Our Esteemed Customers
J. K. White Cement Works, Gotan,
Rajasthan

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Our Esteemed Customers
Andhra Cements Limited-
(Unit: Durga Cement Works)

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Successful trials conducted at
Ultratech Cement Ltd:
Sewagram Cement
Baga Cement
Vikram Cement
Ambuja Cements Ltd:
Rabriyawas
Bhatapara
Darlaghat
Other Groups:
My Home
Ramco Cements
Asian Cement 37
 Our Vision
“Advancement through innovation”
We are committed to the relentlessness
pursuit of innovation in compact, energy
saving, high precision technologies.

Our Values
Our values serve as a compass for our action and describe how we
behave in the world.
Leadership: The courage to shape a better future.
Collaboration: Leverage collective genius
Integrity: Be real
Passion: Committed in heart and mind
Diversity: As inclusive as our brand
Quality: What we do, we do well

Directors Message
“By using the latest technology and quality systems, we are committed to delivering a
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uniformly high-quality product which meets all our customer requirements.”
• Institute for Industrial Productivity
• Bureau of Energy Efficiency
• Knowledge Exchange Platform
• British High Commission, New Delhi

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Children's Park, Ajmer, Rajasthan -305001