Godawari Power & Ispat operates a major sponge iron and captive power complex at Siltara, Raipur. WHRB-14 (Waste Heat Recovery Boiler unit 14) had reached end of refractory campaign life and required full relining during the planned 2024 shutdown. M.S. Enterprises was awarded the refractory application contract.
Scope of Work
Detailed work package delivered under this contract.
- ▸Demolition and disposal of worn refractory lining
- ▸Anchor inspection, replacement and re-welding (MS + SS-310)
- ▸High-alumina castable casting — furnace walls, transition ducts
- ▸Gunning spray cement application — high-velocity wear zones
- ▸High-alumina brick lining — hot-zone arches
- ▸Insulating castable backup
- ▸Dry-out and post-cure inspection
Sponge iron WHRBs operate with high dust loading — refractory wear is faster than conventional thermal-power boilers. Previous campaign had failed at 14 months. Plant wanted improved abrasion-resistant material specs and stricter execution discipline to extend campaign life beyond 24 months.
Material specification upgraded — switched cyclone hot-zone gunning from 60% to 80% Al₂O₃ for better abrasion resistance. Anchor density increased 18% in high-wear zones. Casting consolidation verified at every 0.5 m³ batch. Dry-out ramp slowed from 35°C/hr to 25°C/hr for first 150°C to prevent thermal-shock micro-cracks.
Materials Used
Manufacturer-grade materials sourced direct, with full batch certification.
| Material | Specification | Quantity |
|---|---|---|
| High-Alumina Castable | Al₂O₃ 70%, abrasion-resistant | ~15 MT |
| Gunning Spray Cement | Al₂O₃ 80% | ~6 MT |
| High-Alumina Bricks | Al₂O₃ 70%, custom shapes | ~4 MT |
| SS-310 V-Anchors | Length 120mm, Gauge 8mm | ~1.2 MT |
Delivered & verified.
- ✓Refractory campaign completed within shutdown window
- ✓Material specifications upgraded for abrasion resistance
- ✓Hand-over QA package: batch certs, weld inspection, dry-out logs
- ✓Plant currently operating with refractory in service — campaign tracking ongoing