Implementation Case Study

Improvement in Kiln Insulation

Improvement in Kiln Insulation using PCPF Wall Blocks

Optimization of Combustion Efficiency of Spray Dryer Furnace

Walls and Floor Tiles Manufacturing Industry, having three spray dryers with fluidized bed coal fired furnaces (Fuel: Coal)

Removing the moisture contents of coal using solar drying

Modifying Kiln Cars for Efficient Use of Heat (Low Thermal Mass)

Modifying Kiln Cars for Efficient Use of Heat (Low Thermal Mass)

Modification in kiln car furniture by replacing ‘Solid Cordierite Kiln Car Shelves (Saggers)’ with ‘Oxide Bonded Silicon Carbide (SiC) Shelve’

Tableware Industry – Replacing high weight HFK refractories with light weight low density UltraliteTM filling material for kiln cars

Table ware Industry: Modification in kiln car furniture by modifying the shape of cups and saucers holding shelves (Fuel: Natural Gas)

Reuse of Water & Sludge in the Process

Wall and Floor tile manufacturing industry, having a Waste Water treatment plant designed to reuse 100% of water back to the process in wet grinding

Low Tension Ceramic Insulators manufacturing industry

Low Tension Ceramic Insulators manufacturing industry

Wall and Floor tile manufacturing industry, reusing 100% of sludge generated in wet grinding operation for tiles body

Optimization of combustion efficiency Kilns and Dryers

Wall and Floor Tiles manufacturing industry with roller kilns and horizontal and vertical roller dryers (Fuel: Natural Gas)

Low Tension Ceramic Insulators manufacturing industry having tunnel kiln (Fuel: Natural Gas)

Low Tension Ceramic Insulators manufacturing industry having tunnel kiln (Fuel: Natural Gas)

Low tension porcelain ware and industrial and technical ceramics manufacturing industry having tunnel kiln (Fuel: Natural Gas)

Tableware manufacturing industry having tunnel kiln (Fuel: Natural Gas)

Options for Saving Electricity

Power factor improvement to unity through installation of capacitors

Installation of Variable Frequency Drive (VFD) In Ball Mill Motor

Optimize Power Consumption at Ball Mill Motor by Installing Timer Based ON-OFF Controller

Optimize Power Consumption at Ball Mill Motor by Installing Timer Based ON-OFF Controller

Implementation of ON - OFF Controller (10 minutes ON and 5 minutes OFF) for Agitation Motors

Avoid Compressed air usage for cleaning purposes from direct open hose pipe