Keltech

Introduction

KELTECH ENERGIES LIMITED [KEL] is a company of the renowned Chowgule Group of companies.

KEL manufactures industrial explosives under technical know-how from M/s. Du Pont of USA and expanded perlite under technical collaboration from M/s. Silibrico Crop USA.

KEL operates two expanders for Perlite production One is South India and other in Central India. KEL manufacture Perlite products for construction, low temperature insulation, horticulture, refractory, fillers, foundry, as carrier for poultry medicine, thermoplastic and other applications.

KEL also undertakes turnkey Perlite insulations services for cryogenic storage tanks, Air Separation units etc.,

KEL is an active member of the Perlite Institute Inc., USA and an ISO 9001 - 2000 Company.

KEL’s current annual business turnover is 23 million USD

Introduction

From modest beginning in 1916, the Chowgule Group has today activities in the areas as diverse as

Iron Ore mining and ExportsIron Ore PelletizationShipbuildingInternational shipping with integrated logistics managementShip owners (international tramp trading)ExplosivesIndustrial saltIndustrial gasesAutomobile DealershipConstruction Chemicals and EquipmentMarketing AgenciesEducation A diversification that has only been possible and successful because of the role played by the people at Chowgules, their shareholders and the natural resources of the land.The Group's turnover is over Rs.l300crores ($ 300 Million)

Iron Ore mining and Exports

Industrial salt and Shipping

Shipbuilding

Pelletization of iron ore

Explosives

Automobile Dealership

Perlite Activities

Stationary Expanders – Bagged Perlite Products

Portable Expanders – Site Expansion and Filling

Perlite Concrete Block – Factory made / Site Cast

Perlite Removal and Refilling

Perlite Expanders

KEL has an Licensed capacity to produce 9000 Tons per annum of Expanded perlite for varied application at Two Locations

Bagged Products

KEL Manufactures Bagged Expanded Perlite and Exfoliated VermiculiteProducts for Horticulture, Construction, Refractory, Foundry, Fillers, Animal feed, Cryogenic and Low Temperature Insulation Applications

Perlite Insulation services

• Installation of expanded perlite in the annular space between concentric Vertical cylindrical tanks – LNG, Ethylene & Propylene.

• Perlite concrete blocks manufacture and installation

• Leveling concrete over bottom late for placing perlite concrete blocks

• Installation of expanded perlite in to air separation units ( cold boxes) and small storage tanks- LOX, LIN & LAR tanks

Portable Site Expanders

Portable Site Expanders - Total 4 Nos.Capacity - 800 KGs Per Hour

Perlite Concrete Blocks

KEL is also involved in manufacturing and installation of Perlite Concrete Blocks for LNG, LPG, Ethylene, Propylene & Ammonia Tanks.

Perlite Filling of ASU, cold boxes and small cryogenic tanks

Perlite Removal and Refilling

Removal of Expanded Perlite from cold boxes, and refilling the same.

Resources

Each of these units have well equipped laboratory to test raw materials and finished products with qualified laboratory technicians.

Organization Chart

Perlite expansion is managed and supervised by qualified Engineers and technicians.

Manpower

Permanent Company Personnel

Management - 19

Engineers - 35

Procurement - 3

QA / QC - 10

Clerical - 12

Craftsman - 50( By Trade )

TOTAL - 129

Resources– KEL has its own 20 ft Containers for mobilizing portable expanders to any project site

Quality Standards

"WE AT KELTECH ENERGIES COMMIT TO ACHIEVE TOTAL CUSTOMER SATISFATION AND GROWTH BY MANUFACTURE & SUPPLY OF PRODUCTS MEETING CUSTOMER REQUIREMENTS".

WE COMMIT THIS BY OPTIMUM UTILISATION OF RESOURCES AND CONTINUAL IMPROVEMENT.

Quality Objectives

TO ACHIEVE CUSTOMER SATISFATION.TO GROW BY WAY OF PRODUCT IMPROVEMENT AND DEVELOPMENT.

TO OPTIMISE UTILISATION OF RESOURCES.TO ACHIEVE CONTINUAL IMPROVEMENT.

Company ISO Certification

Credentials

Site Expansion and Filling

Perlite Ore


Perlite Ore

Perlite Mining

Perlite Crushing and Grading

Bagging and Shipment


Perlite Mining


Perlite Crushing and Grading


Bagging and Transportation


Shipment

Perlite ore bags are shipped in containers or as break bulk cargo to the port nearest to the project site and transported to the site in trailer trucks

Plant & Machinery

Required nos of Portable expanders with essential spares

Vibration Equipments

Control panels an all accessories

Testing laboratory with equipments

All the above will be shipped in ISO 20 feet containers

Conveying hose pipes

Site Organization Chart

Manpower – 2 Expanders

Project Manager - 1

Supervisors - 2

Operators - 2

QC / QAD - 2

Casual Labour - 12

Maintenance Assistant - 1

Safety Supervisor - 1

Flow Diagram of - Portable Perlite Expander

Perlite is a type of volcanic glass rock containing combined water. When heated above 850 0C, the crude perlite particles expand approximately 20 times its size. The combined water vaporizes to form microscopic cells or voids in the heat-softened glass. The resulting honeycomb structureaccounts for its lightweight and excellent thermal insulation properties. Because of its granular form,expanded perlite will conform to and fill irregular shapes easily and completely.

ADVANTAGES OF USING EXPANDED PERLITE AS CRYOGENIC INSULATOR.

• Low thermal conductivity at very low temperature [-1730 C]• The low density of expanded perlite• Inorganic - No deterioration• Free Flowing• Easy availability• Chemically inert• Free from organics

Hence Perlite has been recognized as the most efficient insulation material for low temperature storage vessels and process equipments.

Expanded Perlite for Cryogenic Insulation

APPLICATIONS OF EXPANDED PERLITE IN CRYOGENIC INSULATION

• Insulation of double wall storage tanks for liquid gases like Oxygen, Nitrogen, Ethylene, Propylene Ammonia, LNG

• Insulation of double wall liquid gas tankers LNG/LPG tankers (ships) upto 10,000 M 3

• Insulation of cold box and Air Separation units.

Perlite Ore

Principal Manufacturers of cryogenic grade Perlite ore.

• Greece - Silver & Barytes• USA - World minerals, Redco• New Zealand - Inpro • Philippines - Induplex / Asian Perlite• Turkey - D-Perlite

Perlite Ore

Grades

Size Basis Size in mm Application Basis

Coarse 1mm - 4mm Horticulture/Construction

Medium Coarse 0.8mm - 2.5mm Construction

Medium 0.3mm - 1.4mm Construction

Medium Fine 0.6mm - 0.15mm Cryogenic, Fine Aggregates

Fine 0.4mm - 0.15mm Cryogenic, Fine Aggregates

Extra Fine 0.075mm - 0.30mm Fillers, Fine Aggregates

Perlite Ore

Typical Chemical Composition of Crude Perlite Ore

REDCO - USA INPRO-NEWZEALAND

S&B-GREECE

Silica 75% 75% 74%

Aluminium oxide 13.2% 14% 12.7.%

Ferric Oxide 0.7% 1.0% 0.7%

Calcium Oxide 0.5% 1.3% 0.7%

Magnesium Oxide Trace 0.3% 0.2%

Sodium Oxide 4.3% 3.0% 3.3%

Potassium Oxide 4.6% 4.0% 4.0%

Trace 0.2% 0.3% 0.2%

Loss of Ignition 3.2% 3.2% 2.8%

Perlite Ore

Other Properties

Colour - Pale to dark grey, brown, green and blackHardness - 5.5 to 7.0 on Mohr’s scaleSG - 2.0 to 2.8SP - 760 o C - 1000 0 CRI - 1.490 to 1.610

Cryogenic Grade Ore

Size - 0.6 - 0.15 mm, or 0.400 - 0.150 mmCrushability - Not easily crushableExpandability - GoodUnexpandable material - Minimum

Material Delivery & Storage

The Perlite ore is packed in 1 M.T Jumbo bags. The shipment of ore is done either incontainers or as hold cargo (open). After clearing, the shipment / consignment the perlite ore bags are loadedinto the trucks and transported to the site. The ore must be stored only in covered space and kept in dryconditions. Storing of perlite ore outside under plastic cover should be avoided.

Perlite ore will be conveyed to the surge hopper of the expander using pick & carry / forklifts.

Perlite Ore

Why Site Expansion?

Insulation of double walled storage tanks for liquid gas

Insulation of double walled liquid gas tankers

Insulation of oxygen plants, cold box / ASU

For large sized jobs above 1500 M 3 volume.

Advantages

Reduced transportation cost - Ore / Expanded Perlite

Less handling problem of bulky Expanded Perlite

Controlled insulation procedures

Maximum thermal efficiency (low moisture)

Installation Procedure

Preparation of annular space to receive expanded Perlite to be arranged by the Client:

All debris and foreign material has to be removed from the annular space completely.

Installation of required material in the annular space must be completed.

All structural proof tests and leak tests have to be completed as specified before expanded Perlite is installed.

Any nozzle / penetration into the annular space not to be used for installing the insulation or purging the insulation space shall be closed to prevent water or air entering the insulation space.

Weather condition during installation

Expanded perlite can be installed from on site expanders even during rainy season. It will ensured that the nozzles through which the tank is being filled are properly protected from any infiltration of moisture into theexpanded perlite or insulation space. Rain shelters will be provided wherever necessary.

Portable Expansion and Filling

The perlite ore is transferred from the go down and fed into the feed hopper. The variable speed ore feeder continuously meters the perlite ore into the bucket elevator, which discharges the same into the expander. The ore falls from the elevator into the expanding tube. The expanding tube is heated from the bottom and has a constant upward air flow created by the main exhaust fan. The expanded perlite and hot gas are discharged into a cyclone and conveyed to the baghouse collector. The product discharges from the bottom of the collector into the perlite conveying system. Samples are drawn from the sample port for periodical testing of bulk density, moisture content, size filtered gas is then discharged into the atmosphere by the exhaust fan. The product is discharged from the Perlite-conveying system through a flexible pipeline to the tank being insulated.

Filling is started from the top of the annular space with flexible hose. The expanded perlite falls down gravimetrically and the perlite column starts building naturally. Perlite level shall be monitored regularly and the filling nozzle changed whenever necessary. When the annular space is filled to the required level the perlite filling will be stopped to allow settlement of the perlite. Filling is then continued till refusal to further settlement of perlite is achieved at the reservoir top.

Vibration

The tank manufacturer sometimes insists for additional vibration of the expanded perlite after filling. For this operation electromagnetic pneumatic vibrators are used.

These vibrators are equally divided along the whole periphery of the tank at almost 3M from the bottom. After 6 hours of vibration (without adding expanded perlite all the vibrators are raised by 3M. This operation is repeated till we reach the level of 3M beneath the top of the space to be insulated.

However vibration is possible only in smaller tanks where the outer shell is of steel construction. In larger tanks with outer shell of pre-stressed concrete wall vibration is carried using plate vibratos

External Vibration

Vibration

Internal Vibration

The following inspection shall be performed in accordance to client’s requirement.

Compacted Density

The material shall be measured at least every eight hours of production.

Moisture content shall be checked once in 24 hours.

Thermal conductivity shall be measured at the bottom and top section of the tank and will be tested as per IS – 3346 / 1980 at 0 C. (Four sample consisting of 3 specimens will be sent to CBRI, Roorkee for test. Test report will be submitted after one month).

Grading:

Inspection may be performed by the inspector representing the IHI, Owner and / or the nominated third party. The inspector has the right to witness the inspection and testing of the ordered material. (Once in 12 Hours - 2 samples / day.)

Inspection:

Health, Safety, Environment

KELTECH is keen to use the best health and safety practices from its operation around the world and where appropriate to replicate them through out its business. In addition to wearing safety helmets, safety boots, goggles, gloves and masks, all personnel will wear full safety harness at all times while working off the ground. Safety ropes and runners will be used as necessary. Some of the KELTECH project team members are specially trained to raise skill levels in site safety & first aid. HSE plan will be submitted for site specific project and KEL will ensure that this is complied to.

Clientele for Cryogenic applications

CUSTOMER LOCATION QTY. EQUIPMENT | YEAR JOB

Reliance Petro Chemical Industries, Hazira

Gujarat 90 MTs Nitrogen Tank 1990 Filling and supervision

S M Dyechem Ltd Pune 80 MTs ASU 1992 Supply

National Ferlilizers Ltd. Vijayapuri MP 08 MTs Liquid Oxygen Tank

1992 Supply

Rourkela Steel Plant Orissa 125 Cu M ASU 1991 Supply

Bhilai Steel Plant, Bhilai M.P 200 Cu M ASU 1990 Supply

Industrial Oxygen Co.Ltd., Pune 24 MTs ASU 1994 Supply

Indian Oxygen Ltd. Jamshedpur

Jamshedpur 70 MTs ASU 1989 Supply

Industrial Oxygen Ltd., Pune (Sterlite Industries Ltd.)

Tuticorin 44 MTs ASU 1998 Supply

Toyo Engineering Corporation Ltd.,

Haldia 57 MTs ASU 1998-99 Supply and supervision of filling

Ispat Industries Ltd. Raigad 35 MTs ASU 1999 Supply

Industrial Oxygen Co. Pondicherry

Pondicherry 32 MTs ASU 2000 Supply

Linde India Baroda 13MT ASU 2005 Supply

Petronet LNG Tank Dahej, Gujarat 1100 MTs LNG Tank 2002 Site expansion & Filling.

Inox Air products., Pune Pune and Tadapatri [AP]

35 MTs Oxygen plant 2005 supply

Clientele for Cryogenic applications

CUSTOMER LOCATION QTY. EQUIPMENT | YEAR JOB

Inox Air products., Pune Pune and Tadapatri [AP]

35 MTs Oxygen plant 2005 supply

Goyal MG Gases Burnpur 121 MTs ASU 2006 Supply & Filling

Chemplast, [Through VTV]. Karaikal 80 MTs Ethylene tank 2006 Site expansion, Filling & Vibration

Praxair India Ltd Kalyani steel-Hospet project

160 MTs ASU 2006 Supply & Filling

Goyal MG Gases Durgapur W.B 119 MTs ASU 2007 Supply & Filling

Praxair India Ltd Durgapur 205MTs ASU 2007 Supply & Filling

Goyal MG Gases Burnpur 40 MTs ASU 2008 Removal & Filling

Whessoe Al Rushaid Co. Ltd Petro Rabigh- KSA 1160 MTs Ethylene &Propylenetanks

2008 Site Expansion,Filling & Vibration

Goyal MG Gases Raipur 137 MTs ASU 2008 Supply

Pull B.V. Rhenen Bahrain 20 MT LPG Tankers 2008 Supply

Plant & Machinery

a. Portable Expander complete with ore bin, screw type ore feeder, bucket elevator, pipe lines, cyclone, expansion tube, blower, exhaust fan, burner, compressor, bag house type collector assembly, ducting, hoppers, conveying pump & pipe line for connecting conveying pump to the Vessel being insulated, Structural frame and mounting.....2 sets

b. All Essential Spares for expander Assembly

Following are the Essential spares :

1. Fuel Pumps. 2. Burner Assembly. 3. Blowers. 4. Compressor. 5. Filter bags. 6. Hose coupling. 7. Conveying hose pipes. 8. Exhaust fans.

c. Control panels and all accessories for Electrical connections

d. Testing equipment and site laboratory

Supply and installation of expanded perlite in to Ethylene/ propylene tanks- Yansab Project At Yanbu – Kingdom of Saudi Arabia

FACILITIES REQUIRED AT SITE

Following facilities are required at site.

A. 10 X 30 M leveled space for erecting 2 portable Expanders close to the both the tanks to be filled.B. Space for bulk storage of HSD Tank and drums.C. Unloading and storage of Perlite ore under cover at Site.D. 3 ton capacity crane with 15 M boom for 7 days to offload and install 3 nos perlite expanders.E. Fork lift/mobile crane with driver for feeding ore to the hopper and handling of equipments.F. Supply of HSDG. Providing Fuel tank age 10 KL capacity and about 5 KL replenishment perday.H. Providing and permitting access inside tanks.I. Uninterrupted power supply 150 KVA 440 50 has frequency either through DG sets or Power mains at one point near the expander,J. Required illumination at site to facilitate day and night working,K. Illumination inside the tank. L. Toilet and bath facilities.M. Scaffolding along the tank periphery if required,N. Boarding, Lodging, entry permits (Visas) for KEL personnel and local conveyance for the Site TeamO. Casual Laborers - 12 Nos.P. Advance payments at site in local currency and payment of bills at site as authorized by us, which is to be deducte from the

total amount payable tous. Q. Safety gadgets, First Aid and sanitary facility at site for the site personnel and staff.R. Clearing of equipment and to and fro transportation from Jeddah to site and backS. Customs Duty payment for the equipment.T. Crane for fixing external vibrators.

Shift A General Shift Shift B

7 AM to 7 PM 9 AM to 5 PM 7 PM to 7 AM

1 –Supervisor 1 – Project Manager 1 –Supervisor

1 –Operator 1- Maintenance Assistant 1 –Operator

1 –Lab Assistant 3- Safety Supervisor 1 – Lab Assistant

6 –Casual Labour 6 –Casual Labour

Supervisors / Operators - 12 hours / shift

Perlite ore Required for Ethylene tank TK 7501 – 520 MT Perlite ore Required for Propylene tank TK 7502 – 360 MT Total Perlite ore Required - 880 MT

Job Execution

The Job will be carried out using 2 perlite expanders each having a capacity of 12 MT / Day ie 24 MT /Day running Continuously 24 hours / day 7 days a week

Schedule for Filling and vibration

For Ethylene tank – TK 7501 – 520 MT of Perlite ore

Filling – 22 Days

Vibration – 3 Days

Total – 25 Days

Quantity of Supply

For Propylene tank – TK 7502 – 360 MT of Perlite ore

Filling – 15 Days Vibration – 3 Days

Total - 18 Days

Shifting of Equipments

The equipments will be shifted from port by trucks to the project site for erection.

Erection

The equipments will be erected at site by using cranes / chain pulley blocks and assembled on the platform as required.

Commissioning

The plant will be commissioned at site and all the systems are thoroughly checked at all stages. Corrections will be done if any failure is noticed.

Trial Run

A trial run is conducted to check for all the parameters required for inspection. Samples are drawn for testing.

Site expansion, Filling and internal vibration

1. Preliminary Operations

2. Transportation

3. Expansion and filling

4. Vibration

1. Preliminary Operations

Preparation of annular space to receive expanded Perlite to be arranged by the Client:

All debris and foreign material has to be removed from the annular space completely.

Installation of required material in the annular space must be completed.

All structural proof tests and leak tests have to be completed as specified before expanded Perlite is installed.

Any nozzle / penetration into the annular space not to be used for installing the insulation or purging the insulation space shall be closed to prevent water or air entering the insulation space.

2. Storage and Transportation of Perlite ore

Ore Stored in covered shed Ore transferred by Forklift Ore Fed for expansion

3. Expansion

Expansion Under Progress Perlite Collector With Pot Blower

Filling of Expanded Perlite

PNEUMATIC CONVEYING SYSTEM FOR PERLITE POWDER

Nozzle Orientation - Ethylene Tank

Conveying pipe from each Expander 1 and 2 will fill the sectors 1and 2 respectively and the dia of each nozzle and conveying pipe is 6 inch. Total 32 Nozzles - each sector will have 16 nozzles, 8 filling, 8 vent

Nozzle Orientation - Propylene Tank

Conveying pipe from each Expander 1 and 2 will fill the sectors 1and 2 respectively and the dia of each nozzle and conveying pipe is 6 inch. Total 25 Nozzles - each sector will have 12 and 13 nozzles

respectively.

3. Filling

Perlite Conveying Pipes ( Collector to Tank ) Location of Perlite Conveying Pipe on Tank

3. Filling

Conveying Hoses to Nozzle ( Tank Roof )Vent Socks

3. Filling

Measuring Level of Perlite Filled

4. External Vibration

Vibration equipment consists of pneumatic hammers, eductors and Vacuum cups

Vibration Procedure

• Fill Perlite to level A• Vibrate each shell• Perlite settles to level B after first vibration • Refill back to level A• Vibrate again for every 2.4m between level A and B• Perlite settles to level C after 2nd vibration • Final filling to be completed to the top roof of the outer tank


19 Vibrators will be used at a distance of 8 M between each other for Ethylene tank and 15 Vibrators for the Propylene tank.

Process Control

Sieve analysis, loose & compact density and moisture content will be tested during process.

Qualification

Prior to start of actual expansion & filling the perlite ore and expanders will be qualified at site to ensure that the required specification of expanded perlite is met.

Fuel & Storage

It is proposed to install a bulk storage tank for HSD, and then transfer to smaller feed tanks for supply to the expanders.Filling Procedure

The perlite ore is transferred from the go down and fed into the feed hopper. The variable speed ore feeder continuously meters the perlite ore into the bucket elevator, which discharges the same into the expander. The ore falls from the elevator into the expanding tube. The expanding tube is heated from the bottom and has a constant upward air flow created by the main exhaust fan. The expanded perlite and hot gas are discharged into a cyclone and conveyed to the baghouse collector. The product discharges from the bottom of the collector into the perlite conveying system. Samples are drawn from the sample port for periodical testing of bulk density, moisture content, size analysis etc. The hot gas exit from the top of the baghouse collector. The filtered gas is then discharged into the atmosphere by the exhaust fan. The product is discharged from the Perlite-conveying system through a flexible pipeline to the tank being insulated.

Expanded Perlite Test Report: Compact density

Expanded Perlite Test Report: Sieve Analysis

Expanded Perlite Test Report: Moisture Content

Expanded Perlite Test Report: Vibration Report

Project Execution Schedule

Project Execution Details

1. 1. Petronet Dahej LNG tank filling

2. 2. Chemplast Ethylene tank filling

3. 3. Petronet Dahej LNG Perlite concrete blocks for bottom insulation – cast at site

4. 4. Perlite concrete blocks Fedo – Cast at factory

5. 5. Praxair ASU and Tank filling

6. 6. Simulation of Vibration

KELTECH ENERGIES LIMITED.KELTECH ENERGIES LIMITED.

Thank you for your

attention

Keltech

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