Bharat Heavy

Electricals Limited
Ceramic Business Unit

If wear is your problem

BHEL has the solution...

CERALIN
FOR A TROUBLE FREE TOMORROW

CERALIN
The Company
Bharat Heavy Electricals Limited is the largest
Engineering and Manufacturing Enterprise of its
kind in India. It ranks amongst the leading
manufacturers of power plant equipment in
the world.
BHEL has 14 manufacturing plants, 4 power
sector regional centres, 8 service centres, 18
regional offices and over 150 project sites spread
all over India and abroad. It offers a wide
spectrum of products and services for core
sectors like Power Generation, Transmission,
Distribution, Industry, Transportation, Oil & Gas,
Defence and Non-Conventional Energy Systems.

Ceramic Business Unit

The Ceramic Business Unit (CBU) of BHEL, is a
Strategic Business Unit for Ceramics and
Systems. This business unit deals with High
Tension Insulators, Ceramic Wear Resistant
liners, Industrial Ceramic Products and
associated Systems. CBU is headquartered at
Bangalore and is supported by:
Manufacturing units with State of the Art
technology for ceramic products, processes and
applications at

Electroporcelains Division (EPD), Bangalore

l
Insulator Plant (IP), Jagdishpur
l
Advanced Research and Development facilities
for Ceramic products, processes and
applications at
Ceramic Technological Institute (CTI),
l
Bangalore (A Division of Corporate Research
& Development, Hyderabad)

Products
High Tension Insulators for Transmission and
l
Distribution lines from 11kV to 800kV
Hollow Insulators for Instrument and Power
l
Transformers, Switchgear, Electro Static
Precipitators, etc.
Station Post Insulators for Bus Bars support
l
and for Isolators from 11kV to 400kV
Composite Insulators for Railway Traction
l
and Transmission applications upto 400kV
Wear resistant Materials for Thermal Power
l
Plant applications, Steel, Coal Washeries,
Cement, etc.
Industrial Ceramic Products for various
l
applications

CERALIN
CERALIN a total solution
against WEAR
In steam generating units {Boilers} and
associated pulverisers and other auxiliaries,
high alumina ceramic material can be used
for protection of components against wear
due to abrasion and erosion.

Range of Applications
Its superior wear resistance, chemically
inert and high thermal stability
characteristics make CERALIN suitable for
a wide range of applications:
Power Sector

: Wear prone
components of
Bowl / Tube Mill,
Fuel Piping.

Steel Sector

: Sinter Plants,
Rotary Kiln, Coke
Oven

Cement Sector

: Cement & Raw

Mills chutes & Air
Separators

Coal Sector

: Slurry Pipes,
Chutes & Launders

Protection Why?
Coal is one of the main source of fuel used in
power generation. Coal fired boilers adopt
the method of pulverising raw coal in
pulverisers or mills, conveying the
pulverised coal-air mixture from the
pulverisers to the boiler burner for producing
and utilising steam to generate power. Fine
coal particles at high velocities cause failure
in many components in the pulverisers and
the coal piping system of the boiler. Ceramic
lining is provided to the components to
extend the life thereby reducing downtime.

Bowl Mill

Tube Mill

Fuel Piping

Components

Components

System

l
Classifier Inner Cone
l
Venturi Vane
l
Venturi Outlet Collar
& Vane
l
Multiple Port Outlet
l
Mill Discharge Valve

l
Connecting Duct
l
Classifier Body
l
PF outlet Box
l
Circular Duct
l
Internal Cone
l
PF Outlet Venturi

l
Transition Piece
l
Mill Outlet Elbows & Pipes
l
Line Bends
l
Orifices
l
Fuel Inlet Elbow

CERALIN
Protective Lining - What?
To combat the various wear prone areas in
Coal fired Thermal Power Stations, Coal
Sector, Steel Industry, Cement Industry and
others similar applications, BHEL has
indigenously developed High Alumina
Ceramic Wear Resistant materials in its R&D.
Components fitted with CERALIN are used
all over India with a proven performance.

Physical Properties
Volume of Material lost in cubic
centimeters per ton of ash
GRANITE

33.59

FELSITE

29.64

QUARTZ
PORCELAIN

24.17
TEST CONDITIONS:

BASALT

6.20
CERALIN

Particle Velocity: 50 m/sec

Erodent: Ash concentration of 0.25 kg/ Nm3
Period of Test: 60 min

1.44

Angle of Impingement: 450

(Erosion test result)

Bulk Density

>3.2 gm/cc

Water Absorption

< 0.5 %

Hardness (MOHs Scale) > 8

2

Cold Pulverising Strength > 3000 kg/cm

Flexural Strength
(at room temp.)

>2200 kg/cm

Co-efficient of Thermal
Expansion

6 to 9 x 10 /C

-6

The Ceramic tiles are designed with due consideration to the area of application and the type of
fixing required. Curved, flat or weld-on type tiles are designed and engineered to suit the
component configuration and the end requirement.

Operating Conditions
In coal fired steam generating units the normal operating conditions are:
Flow medium

: Pulverised coal mixture

Particle size

: 70% less than 75 microns

15% 75 to 90 microns
15% 90 to 150 microns.

Coal concentration

: 0.935 to 1.545 kg/Nm

Ash content

: 50% Maximum

Flow velocity

: 30 mtr / Sec. Maximum

Pressure

: 0.5 kg / cm

Temperature

: 300 C Max

The components are designed to meet the operating parameters and life expectancy considerations.

CERALIN
Production Facilities
Ceramic Tiles Manufacturing
RAW MATERIALS

BALL MILLING

DRY PRESSING

SPRAY DRYING

FIRING

CERALIN TILE

Ball Mill

Spray Drier

Hydraulic Press

High Temperature Kiln

Ceralin is manufactured using Calcined Alumina

as a raw material. Spray dried powder is then
compacted in Hydraulic Presses to form tiles.
These tiles are then fired in a high temperature
kilns at around 1560-1600oC to get required wear
resistant characteristics. Ceralin tiles assembly to
the casing is done by using Mortar, Silicone
adhesives or Weld-on tiles.

Product Assembly
C
E
R
A
L
I
N
T
I
L
E
S

Mortar
Fabricated
Component

Fixing Method
Bends
Elbows
Pipes

Adhesive
Fabricated
Component
Metal Plug

Cone
MDV
Orifice
Venturi

A. Fixing with
Mortar

B. Fixing with
Adhesive

C. Fixing with
Metal Plug

Customer Profile
CERALIN is having major presence in coal fired
thermal power stations, Cement sector & Steel Sector.
Major customers list includes NTPC, DVC, Jindal,
Tata Power, Nalco, Hindaco, HZL, Torrent Power,
State Electricity Boards for their Power Stations,
SAIL and Cement companies.

What our customers say?

Ceralin Lined Orifices supplied to BTPS have given double the life as compared with
Ni-Hard.
- Kulvinder Singh, Supdt., BMD-I, BTPS, NTPC, New Delhi, India
Performance of Ceralin Lined Bends of Unit I & II are found very satisfactory since the
commissioning.
- Dy Chief Engineer (GEN), 210 MW TPS, MSEB, Khaperkheda, Maharashtra, India
The Ceralin Lined Bends supplied & erected by M/s BHEL during erection of 210 MW Unit I,
II, III, IV have performed well & lasted for 20000 to 30000 service hrs.
- Er K Raju, Chief Engineer (GEN), MTPS, Mettur Dam, Tamil Nadu, India
Ceralin Lined Bends installed in Unit I & II PF lines have given life of more than 25000
hours.
- Chief Engineer (O&M), RTPS, Raichur, KPCL, Karnataka, India.

Bharat Heavy Electricals Limited

(A Government of India undertaking)

Registered and Corporate Office

BHEL House, Siri Fort, New Delhi - 110 049.
Tel: 011-2600 1010 Fax: 011-2649 3021

www.bhel.com
Efforts are constantly being made to
improve the product design and hence the
products supplied may differ in minor
details from that given in the catalogue.
For enquiries please contact:

Bharat Heavy Electricals Limited

(A Government of India Undertaking)

Ceramic Business Unit

Prof. C.N.R. Rao Circle,
Opp. Indian Institute of Science
Malleswaram, Bangalore-560 012 (India)
Ph: 080-23442988, 22182247
Fax: 080-23560741, 23344231

www.bhelceramics.com