04 Lloyd Insulation s

UPGRADED THERMAL INSULATION FOR

MINIMIZING HEAT LOSSES

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


Approximately Heat Loss 90-100 Kcal / Sqm. Hr. Surface Temp. = 60 ˚ 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




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





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


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


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%


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%



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



• ROCKLOYD PIPE SECTIONS - pre-formed pipe section of pipe dia upto 350mm NB

ROCKLOYD AL. FOIL LAMINATED PIPESECTION


SPECIFICATION CONFORMANCE

IS : 9842

BS : 3958 Part-4

ASTM : C 547-95

ROCKLOYD PIPE SECTION

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


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%


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%




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.


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


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


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


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


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.



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.


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’.


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.


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).


THANK YOU !!THANK YOU !!

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04 Lloyd Insulation s