A Partnership to build on

EagleBurgmann designs custom-made fabric expansion joints for cement plants 

KeyVisual_CaseStudy_RamcoCement.jpg
SITUATION

Cement is the binding agent that gives strength to common building materials such as concrete and mortar. By adding different kinds of rock, it can be processed to various materials with distinct properties. Mixing cement with water and sand produces mortar, further adding gravel makes for concrete.

CHALLENGE

Cement production is a heat-intensive process and causes thermal expansion in duct systems. To compensate this, Indian cement producer Ramco Cement needed fabric expansion joints with a diameter of several meters for two of their plants. 

SOLUTION

On the basis of a close collaboration, EagleBurgmann was able to design components that increase the efficiency of the plant in the long run. EagleBurgmann supplied Ramco Cement’s plants with isolation joints as well as duct expansion joints. Isolation joints are mainly used to isolate vibrations in the ducts and machinery, while duct expansion joints compensate for the thermal expansion of the duct system. 

Our modern civilization is quite literally built upon cement. Binding agents made from burnt lime are not a new invention however: In ancient Rome, “caementum” (“quarry stone”, “stone chips”) was used to build structures like the Pantheon. Today, building materials made from cement are used in buildings, roads, bridges, dams etc. Cement production is a heat-intensive process and causes thermal expansion in duct systems. To compensate this, Indian cement producer Ramco Cement needed fabric expansion joints with a diameter of several meters for two of their plants. On the basis of a close collaboration, EagleBurgmann was able to design components that increase the efficiency of the plant in the long run. 

In 2019, India was the world’s second biggest cement producer with an annual production of 320 million tonnes. As in every cement plant, the approximately 250 facilities in India rely on expansion joints to cancel out the thermal expansion of the duct system. In a plant with a production capacity of 3.000 tonnes per day (tpd), some 150 expansion joints are needed. 

Cement is the binding agent that gives strength to common building materials such as concrete and mortar. By adding different kinds of rock, it can be processed to various materials with distinct properties. Mixing cement with water and sand produces mortar, further adding gravel makes for concrete.

In 2020, Ramco Cement, one of the biggest cement manufacturers in South India, needed fabric expansion joints for two of their plants. Instead of obtaining them from an OEM, they ordered the 132 expansion joints directly from EagleBurgmann. “The area from rotary kiln to clinker cooler and heat recovery to the admixture of the gypsum is a highly critical section of the plant”, explains Bhaskar Chatterjee, assistant sales manager for expansion joints at EagleBurgmann. “For this crucial area, EagleBurgmann has equipped almost every large cement plant in India with expansion joints.” This also includes facilities of Ramco Cement, where EagleBurgmann expansion joints are in service reliably since years. 

EagleBurgmann supplied Ramco Cement’s plants with isolation joints as well as duct expansion joints. Isolation joints are mainly used to isolate vibrations in the ducts and machinery, while duct expansion joints compensate for the thermal expansion of the duct system. Duct expansion joints can have diameters of up to 4,5 m. When choosing the right products and materials, all relevant factors such as flow media, dust content, flow direction, pressure and temperature had to be taken into account. The experts from EagleBurgmann can rely on extensive experience and know-how in the fields of process, materials and manufacturing and hence ensure that the expansion joints can reliably withstand all stresses and loads that may occur during operation.

“Apart from successful collaborations in the past, our fast response was key in convincing the customer to work with us”, says Shankar Gopalan, business development manager at EagleBurgmann. Within only two days, EagleBurgmann’s design team submitted the technical drawings to the customer. This gave Ramco Cement enough time to thoroughly evaluate the proposed solutions, even though the project timeline was tight. The quick response also assured the customer of EagleBurgmann’s high agility – which was especially important with this project due to a delivery period of only eight weeks.

Constant communication between the EagleBurgmann team and the stakeholders at Ramco Cement was a decisive factor in the project’s success. “We not only communicated and coordinated with the technical project team, but also with their management and finance department”, says Daniel Vijaykumar, deputy general manager sales at EagleBurgmann. At project launch, EagleBurgmann and Ramco Cement agreed on a quality plan to assure the project’s success. As the project progressed, this quality plan was constantly checked. Every delivered product had to meet the defined checkpoints – from raw materials to the characteristics of the final product. 

As the global demand for cement increases, so do cement plant’s production capacities. Whereas a single plant used to produce up to 2.500 tpd cement clinker per day, this number has increased to 8.000 tpd in modern facilities. To handle these throughput volumes, duct systems and expansion joints of bigger diameters are needed. “With this project, the size of the expansion joints was particularly challenging. We’re talking about diameters of three meters and more”, says Gopalan. “Steel frames of this size are produced in segments. Welding them requires highly skilled and experienced employees.” EagleBurgmann has the infrastructure and personnel to manufacture, store and handle expansion joints of this size.

Cost-effective solutions with the end customer in mind

At its place of destination in the cement plant, the expansion joints were installed in heights of up to 40 m. During the development stage EagleBurgmann realized that future replacements of the entire fabric expansion joints in these places may turn out to be time-consuming and costly for Ramco Cement. “When working with the customer, we always have the long-term operating costs in mind. That’s why we proposed a steel frame design that doesn’t require the whole expansion joint to be exchanged”, Gopalan explains the customer-specific modifications to the design. “Instead, all it takes to exchange the fabric is loosening the nuts and bolts.”

Solution: EagleBurgmann designs custom-made fabric expansion joints for cement plants

Further reference projects

KeyVisual_CaseStudy_Hengli.jpg
China

10 years ahead

Between June 2017 and March 2019 the Hengli Group constructed an integrated refining and chemical complex in the Chinese harbor town Dalian where 20 million tons of crude oil are processed every year. EagleBurgmann advised the company Hengli concerning the selection of mechanical seals and supply systems for the whole plant and supplied more than 95 % of the components in use. 

Read the complete case study
Feuer und Flamme_DRO_Head3
Germany

100 percent performance at 300 degrees

Things get hot in rotary kilns, very hot in fact. In the production of cement, for example, the thermometer measures more than 1,000 degrees Celsius. Sealing systems from EagleBurgmann, a company of the Freudenberg Group and EKK, make sustainable contributions to environmental protection, energy efficiency and process reliability under these "fiery" high-temperature conditions.

Read the complete case study
KeyVisual_CaseStudy_RamcoCement.jpg
India

A Partnership to build on

Our modern civilization is quite literally built upon cement. Today, building materials made from cement are used in buildings, roads, bridges, dams etc. Cement production is a heat-intensive process and causes thermal expansion in duct systems. To compensate this, Indian cement producer Ramco Cement needed fabric expansion joints with a diameter of several meters for two of their plants. On the basis of a close collaboration, EagleBurgmann was able to design components that increase the efficiency of the plant in the long run.

Read the complete case study
KeyVisual_RoTechBooster_Dock_Sud
Argentina

Clean gas despite fluctuating operating conditions

Frequent starts and stops are a severe test for gas-lubricated compressor seals. Installed in an Argentinean combined cycle power plant is an EagleBurgmann supply system that provides a continuous gas flow rate for the seals and adapts it to changing conditions. Since then, the operational reliability of the compressors has increased significantly.

Read on for the entire case study
KeyVisual_CaseStudy_AGSR_Schaufeltrockner.jpg
Germany

Clean sealing solution for demanding crystal production

Seals are a risk factor in the production of liquid crystals. If there is even the slightest contamination of the liquid crystals, this will later affect the image quality of the display. Read on to see which sealing solution Merck KGaA uses in paddle dryers for the production of liquid crystals.

Read on for the entire case study
KeyVisual_CaseStudy_SHVI-CGSH_USA.jpg
United States

Convincing high pressure seals for pipeline pumps

Reduce maintenance costs for seal supply systems and extend MTBR intervals - EagleBurgmann's task was to significantly improve the availability of unmanned pump stations in a gas pipeline in Texas with single seals for multifluid pumps.

Read on for the entire case study
Show all references
Newsletter

Excellence in Practice

With our free e-mail newsletter „Excellence in Practice“, you will receive first-hand information about current products, services, references and worthwhile industry insights.

True