Reduction pots, Other Thermal Process Equipment
Furnace, Recuperators, Annealing Lehrs, etc.
Various types of furnaces as refractory back-up
Boilers, Steam Lines, Recuperators, etc.
Steam lines, Furnaces
Incinerators, Hot gas lines,etc.
Tunnel Kilns & Trolleys
Boilers, Turbines, Steam lines, Flue gas, Ducts etc
Boilers, High Temperature reactors, Flue gas
Steam/Thermic Fluid lines, Dryers, Furnaces, etc.
Significant fuel savings can be obtained in Ceramics,
Rolling Mills, Foundries and various industries,
use thermal equipments at high temperature.
a thumb rule, wherever refractory bricks are being used,
Calcium Silicate Insulation should be used as a back-up
is un-matched in places where a backup insulation is
needed or where there is likely possibility of
insulation being subject to accidental exposure to water
or impact loads or foot traffic.
Silicate has given excellent cost - benefit performance
in cement plants. All new cement plants in India have used CSI instead
of traditional Vermiculite & Mica
insulation bricks for additional thermal energy savings. We have
most reputed corporate clients
cement plant manufacturing 1 million tons of cement consumes
about 2 lacs tons of steam coal per year. By using CSI -
about 265 tons - it is possible to save 30,000 tons of steam
coal value Rs.60 million per year.
M/s. Saurashtra Cement Ltd.,
Ranavav (SCL), has insulated their plant equipments using
our Calcium Silicate insulation materials and has saved fuel
and electrical energy value Rs.110 million per annum. They
presented national award for best improvements in thermal energy
performance for the year 1998-99 at the 7th NCB international
seminar on Cement & Building Materials held on 20.11.2000 at
New Delhi. (Please contact us for a copy of this
M/s. IDBI & M/s. USAID have carried out energy surveys
in cement plants through M/s. Holtec Engineers, Cement
Consultants, New Delhi, India and M/s. Resource Management Association, Wisconsin, USA. Their report
thermal energy conservation saving of 15% is available in the
Indian Cement Sector and therefore investing in energy
efficiency can be as profitable as investing in increased
production capacity. (Please contact us for a copy of this
& Steel Plants:
over the world aluminum plants have started using CSI.
We have been able to successfully demonstrate cost
performance of our product at M/s. Hindalco, Renukoot, reducing
electrical energy consumption from 18,000 KWH to about 13,000
KWH saving 5000 KWH value Rs. 0.20 lac per ton of aluminum metal
has started using our product extensively in their electrolytic
cells and we are currently executing their order for supply of
300 tons CSI. Their expanded capacity will be 3 lacs tons of aluminium
metal per year and M/s. Hindalco will save about 1,500 million KWH
cost Rs. 6000 millions per year.
M/s. Bhilai Steel
Plant and M/s.
Bokaro Steel Plant have used SONASIL for thermal energy. We are currently
executing substantial orders for M/s.
Bokaro Steel Plant.
Trouillard, Sr. construction Manager - Saint-Gobain (France), a
Fortune 100 company, has assessed our factory and the product
and we have executed their order for CSI for their green-field
venture, M/s. Saint-Gobain Glass (India) Ltd. near Chennai.
Alembic Glass, M/s. Shreno Ltd., M/s. Maharashtra Glass, M/s.
Krishnaa Glass and others have already used CSI in their furnaces and
We have designed a new rolling mill furnace with our
Calsium Silicate Insulation Material and have been able to achieve significant reduction in fuel cost along
with increase in production. Our CSI
has given a payback period of less than 3 months in a furnace with equivalent
Insulation brick lining. CSI has
benefited the users in various ways.
Case : M/s. Kalpana Steel at GIDC, Chitra,
Bhavnagar-364004 has 22' long furnace producing 6 mm. & 8 mm. round bar.
Previous design :
18” thick refractory wall
liters per ton of rolled steel
Starting heat-up time :
90 minutes during summer
120 minutes during winter
Production per day of 10 hours: 8 tons
New design :
9” thick refractory wall in pre-heating zone
13.5” thick refractory wall in burning zone
+ 1.5” CSI
in bottom &
2” CSI at top & 4 sides of
: 45-50 liters per ton of rolled steel
Starting heat-up time: 20-30 minutes during summer
35-45 minutes during winter.
per day of 10 hours: 11
Saving 40 liters of oil per ton of rolled steel
Decrease in starting heat-up time by 65%
Increase in daily production by 40%
Lower temperature around the furnace resulting in
b) Less burning loss
c) Better quality of rolled steel.
d) Less maintenance and
burner start-up without the need of pre-burning a cloth dipped in
Industries, Kiran Ispat, Laxmi Steel, Maruti
Ispat, Ragaria Steel, Vedant, etc. are some rolling mills in Bhavnagar
Dist. who have benefited significantly by the use of CSI in
Ketan A. Shah has made a presentation on “ Thermal Energy
Conservation” at a seminar on Energy Management- the New
Imperative organized by the Confederation of Indian Industry at
Ahmedabad and Rajkot. (Please
contact the company for a copy of this paper)