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 ₹28.6 Lakh 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