WORK SHOP WORK SHOP

ON ON

KILN FURNITURE AND ENERGY SAVINGS KILN FURNITURE AND ENERGY SAVINGS

ON 23RD FEBRUARY ‘2006 AT CGCRI — ON 23RD FEBRUARY ‘2006 AT CGCRI —

KHURJA CENTERKHURJA CENTER

AGENDA

WELCOME ADDRESS WELCOME ADDRESS

CORDIERITE AND ITS APPLICATION CORDIERITE AND ITS APPLICATION

LTM CONCEPT LTM CONCEPT

DO’S AND DONTS/CONVENTIONAL WARE — DO’S AND DONTS/CONVENTIONAL WARE —

CORDIERITE CORDIERITE

PAPER PRESENTATION BY CGCRI — KHURJA PAPER PRESENTATION BY CGCRI — KHURJA

VOTE OFTHANKSVOTE OFTHANKS

CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATION

CORDIERITE A MAGNESIUM ALUMINO SILICATE WITH A CORDIERITE A MAGNESIUM ALUMINO SILICATE WITH A MOLUCULAR FORMULA 2MgO 2A1203 5 SiO2. DUE TO MOLUCULAR FORMULA 2MgO 2A1203 5 SiO2. DUE TO ITS LOW THERMAL EXPANSION CHARACTER IT HAS GOT ITS LOW THERMAL EXPANSION CHARACTER IT HAS GOT VERY GOOD THERMAL SHOCK.VERY GOOD THERMAL SHOCK.

IT IS A SYNTHETIC MATERIAL AND NATURAL IT IS A SYNTHETIC MATERIAL AND NATURAL OCCURRENCES ARE VERY MINIMAL OCCURRENCES ARE VERY MINIMAL

THE FORMATION OF CORDIERITE IN A CERAMIC THE FORMATION OF CORDIERITE IN A CERAMIC PROCESS IS VERY SENSITIVE AND MINOR VARIATION IN PROCESS IS VERY SENSITIVE AND MINOR VARIATION IN THE MATURING ZONE AFFECT THE END PRODUCT THE MATURING ZONE AFFECT THE END PRODUCT PROPERTIES.PROPERTIES.

CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATIONDUE TO VERY COMPLEX PROCESS NATURE ONLY DUE TO VERY COMPLEX PROCESS NATURE ONLY COUNTABLE NUMBER OF INDUSTRIES ARE ENGAGED IN COUNTABLE NUMBER OF INDUSTRIES ARE ENGAGED IN THE MANUFACTURE OF CORDIERITE .THE MANUFACTURE OF CORDIERITE .

UTMOST CARE IS A MUST FROM SELECTION OF RAW UTMOST CARE IS A MUST FROM SELECTION OF RAW MATERIAL TO MATURING OF THE END PRODUCT MATERIAL TO MATURING OF THE END PRODUCT OTHERWISE LOSSESS WILL BE VERY HIGH .OTHERWISE LOSSESS WILL BE VERY HIGH .

FOR COMMERCIAL KILN FURNITURE MANUFACTURING FOR COMMERCIAL KILN FURNITURE MANUFACTURING CORDIERITE IS BONDED WITH A SECONDARY MULLITE CORDIERITE IS BONDED WITH A SECONDARY MULLITE TO ENHANCE THE KILN FURNITURE LOAD BEARING TO ENHANCE THE KILN FURNITURE LOAD BEARING PROPERTIES AT HIGH TEMPERATURE PROPERTIES AT HIGH TEMPERATURE

CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATION

THE MAIN FABRICATION PROCESS OF CORDIERITE KILN THE MAIN FABRICATION PROCESS OF CORDIERITE KILN

FURNITURE ARE DRY PRESSING, SLIP CASTING & FURNITURE ARE DRY PRESSING, SLIP CASTING &

EXTRUSION EXTRUSION

CORDIERITE IS THE ONLY CHEAPER AND BEST KILN CORDIERITE IS THE ONLY CHEAPER AND BEST KILN

FURNITURE UPTO 1300*C APPLICATION ALTERNATE TO FURNITURE UPTO 1300*C APPLICATION ALTERNATE TO

SILICON CARBIDE AND OTHER TYPE OF FURNITURES SILICON CARBIDE AND OTHER TYPE OF FURNITURES

ALMOST ALL THE CERAMIC MANUFACTURING UNIT ALMOST ALL THE CERAMIC MANUFACTURING UNIT

CHANGED OVER TO THE USAGE OF CORDIERITE KILN CHANGED OVER TO THE USAGE OF CORDIERITE KILN

FURNITURE THROUGOUT THE WORLDFURNITURE THROUGOUT THE WORLD

CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATION

DUE TO CONTINUOUS INCREASE OF RAW MATERIAL AND DUE TO CONTINUOUS INCREASE OF RAW MATERIAL AND FUEL PRICE, COST REDUCTION IS THE ONLY VIABLE FUEL PRICE, COST REDUCTION IS THE ONLY VIABLE ALTLERNATE TO COMPETE THE MARKET. THEREFORE ALTLERNATE TO COMPETE THE MARKET. THEREFORE CORDIERITE KILN FURNITURE SYSTEMS SCORE OVER CORDIERITE KILN FURNITURE SYSTEMS SCORE OVER OTHER REFRACTORIES. OTHER REFRACTORIES.

CERTAIN TABLE WARE UNIT OPERATES WITH A CERTAIN TABLE WARE UNIT OPERATES WITH A SUPPORT WARE(KILN CAR, SUPER STRUCTURE) :END SUPPORT WARE(KILN CAR, SUPER STRUCTURE) :END PRODUCT RATIO OF 6:1PRODUCT RATIO OF 6:1

LOW THERMAL MASS KILN CARS & SUPER STRUCTURE LOW THERMAL MASS KILN CARS & SUPER STRUCTURE WITH THE COMBINATION OF LIGHT WEIGHT CORDIERITE WITH THE COMBINATION OF LIGHT WEIGHT CORDIERITE WITH SILICON CARBIDE BEAMS ALONG WITH CERAMIC WITH SILICON CARBIDE BEAMS ALONG WITH CERAMIC FIBER RESULTED IN UNBELIEVABLE COST REDUCTION FIBER RESULTED IN UNBELIEVABLE COST REDUCTION ZN THE CERAMIC SECTOR. ZN THE CERAMIC SECTOR.

THE TREND SET GLOBALLY THREE DECADES AGO HAS THE TREND SET GLOBALLY THREE DECADES AGO HAS GOT MOMENTUM NOW IN INDIA GOT MOMENTUM NOW IN INDIA

CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATION

THE MAJOR APPLICATION AREASTHE MAJOR APPLICATION AREAS SANITARY WARE SANITARY WARE

TABLE WARE TABLE WARE

FLOOR TILE/WALL TILE FLOOR TILE/WALL TILE

INSULATORS LT/HT INSULATORS LT/HT

GRINDING WHEEL GRINDING WHEEL

ELECTRO CERAMICS ELECTRO CERAMICS

ART WARE/STONE WARE ART WARE/STONE WARE

ROOFING TILE ROOFING TILE

FERRITE FERRITE

DYES/COLORS/PAINT DYES/COLORS/PAINT

VARIOUS PRODUCT SHAPES VARIOUS PRODUCT SHAPES

DECK SLABS DECK SLABS

PERFORATED SLABS PERFORATED SLABS

PROPS (PLAIN/STEPPED) PROPS (PLAIN/STEPPED)

BEAMS/SUPPORTS/CAPS BEAMS/SUPPORTS/CAPS

PROFILE SETTERS PROFILE SETTERS

MUG/CUP SETTERS MUG/CUP SETTERS

T-CRANK/TILE CRANK T-CRANK/TILE CRANK

FOOTREST FOOTREST

SAGGARS SAGGARS

SPECIAL SHAPES SPECIAL SHAPES

QUALITY PROBLEMQUALITY PROBLEM

DURING TRANSIT DURING TRANSIT

DURING STORAGE DURING STORAGE

ROUGH HANDLING ROUGH HANDLING

WRONG SELECTION WRONG SELECTION

WRONG LOADING WRONG LOADING

EXCEEDING THE TEMP LIMIT EXCEEDING THE TEMP LIMIT

FLAME/GLAZE/BEDDING MATERIAL ATTACK FLAME/GLAZE/BEDDING MATERIAL ATTACK

FURNITURE QUALITY PROBLEM FURNITURE QUALITY PROBLEM

LOW THERMAL MASSLOW THERMAL MASS ENERGY EFFICIENT CORDIERITE KILN ENERGY EFFICIENT CORDIERITE KILN

FURNITURE SYSTEM INTRODUCTIONFURNITURE SYSTEM INTRODUCTION

FUEL AND POWER COST IS THREATENING EVERY FUEL AND POWER COST IS THREATENING EVERY INDUSTRY IN CERAMIC SECTOR FUEL COST AMOUNTS INDUSTRY IN CERAMIC SECTOR FUEL COST AMOUNTS TO 35 TO 40% OF THE MANUFACTURING COST TO 35 TO 40% OF THE MANUFACTURING COST

ENERGY CONSERVATION IS A MUST TO STAY IN THE ENERGY CONSERVATION IS A MUST TO STAY IN THE GLOBALISED MARKETGLOBALISED MARKET

LOW THERMAL MASS CONCEPT IS PROVEN EXAMPLE OF LOW THERMAL MASS CONCEPT IS PROVEN EXAMPLE OF FUEL REDUCTION TECHNIQUEFUEL REDUCTION TECHNIQUE

LOW THERMAL MASSLOW THERMAL MASS

LTM CONCEPT WILL REDUCE THE FUEL BY A MINIMUM LTM CONCEPT WILL REDUCE THE FUEL BY A MINIMUM OF 10 to 15 % AND INCREASE IN PRODUCTION OF 10 % OF 10 to 15 % AND INCREASE IN PRODUCTION OF 10 % MIN MIN

LOW MASS/LOW THERMAL EXPANSION CORDIERITE LOW MASS/LOW THERMAL EXPANSION CORDIERITE KILN FURNITURE — CERAMIC FIBER AND KILN FURNITURE — CERAMIC FIBER AND RECRYSTALLIZED BEAMS ARE THE MAIN COMPONENTS RECRYSTALLIZED BEAMS ARE THE MAIN COMPONENTS USED IN THE LTM CARS FOR ENERGY CONSERVATRION USED IN THE LTM CARS FOR ENERGY CONSERVATRION

ABREF HAS TAKEN THE TASK OF PRODUCING READY ABREF HAS TAKEN THE TASK OF PRODUCING READY MADE LTM KILN CAR OR INSTALLATION OF LTM AT MADE LTM KILN CAR OR INSTALLATION OF LTM AT CUSTOMER ENDCUSTOMER END

LOW THERMAL MASSLOW THERMAL MASS

RECENTLY ABREF HAS ISTALLED TWO LTM CARS RECENTLY ABREF HAS ISTALLED TWO LTM CARS SUCCESSFULLY IN A SANITARY WARE IN MORBI AND SUCCESSFULLY IN A SANITARY WARE IN MORBI AND AWAITING ONE EXPORT ORDER FROM A TILE INDUSTRY AWAITING ONE EXPORT ORDER FROM A TILE INDUSTRY

ALSO CONVERTED OUR OWN SHUTTLE KILNS CARS AS ALSO CONVERTED OUR OWN SHUTTLE KILNS CARS AS LTM AND ALSO PROVIDED RECUPERATION SYSTEM IN LTM AND ALSO PROVIDED RECUPERATION SYSTEM IN THE FLUE PATH AND USED THE WASTE HEAT AGAIN AS THE FLUE PATH AND USED THE WASTE HEAT AGAIN AS SECONDARY AIR SECONDARY AIR

BENEFITSBENEFITS FUEL SAVING OF 10% IS CLEARLY ACHIEVABLE FUEL SAVING OF 10% IS CLEARLY ACHIEVABLE

THE TIME TAKEN TO HEAT THE CAR AND THE LOADED THE TIME TAKEN TO HEAT THE CAR AND THE LOADED WARE IS — REDUCED, RESULTING IN INCREASED WARE IS — REDUCED, RESULTING IN INCREASED CAPACITY : LTM DESIGN ALLOWS MORE FLEXIBILITY CAPACITY : LTM DESIGN ALLOWS MORE FLEXIBILITY IN LOADING IN LOADING

PRODUCT CONTAMINATION IS ELIMINATEDPRODUCT CONTAMINATION IS ELIMINATED

BONDING CEMENT IS NOT USED IN THE ASSEMBLY BONDING CEMENT IS NOT USED IN THE ASSEMBLY HENCE VERY LESS TIME TO ASSEMBLE AND HENCE VERY LESS TIME TO ASSEMBLE AND

DISMANTLINGDISMANTLING

BENEFITSBENEFITS

LTM MATERIAL IS SUITABLE FOR ANY TYPE OF FAST LTM MATERIAL IS SUITABLE FOR ANY TYPE OF FAST OR SLOW FIRING SYSTEM — DUE TO VERY GOOD OR SLOW FIRING SYSTEM — DUE TO VERY GOOD THERMAL SHOCK & MECHANICAL STRENGTH — VERY THERMAL SHOCK & MECHANICAL STRENGTH — VERY GOOD INTERLOCKING OF BASE AND SUPER GOOD INTERLOCKING OF BASE AND SUPER STRUCTURE. STRUCTURE.

LONGER SERVICE LIFE LONGER SERVICE LIFE

CONCLUSIONCONCLUSION

CERAMIC INDUSTRIES ARE IMPORTANT SEGMENT CERAMIC INDUSTRIES ARE IMPORTANT SEGMENT CONTRIBUTING TO THE NATIONS’S ECONOMYCONTRIBUTING TO THE NATIONS’S ECONOMY

COMPETITIVNESS IN THE CERAMIC INDUSTRY CAN BE COMPETITIVNESS IN THE CERAMIC INDUSTRY CAN BE TREMENDOUSLY IMPROVED BY REDUCTION IN ENERGY TREMENDOUSLY IMPROVED BY REDUCTION IN ENERGY COST COST

THE LTM CARS AND SUPER STRUCTURE WILL HAVE A THE LTM CARS AND SUPER STRUCTURE WILL HAVE A MAJOR ROLE IN ENERGY COST REDUCTION IN THE MAJOR ROLE IN ENERGY COST REDUCTION IN THE CERAMIC INDUSTRY CERAMIC INDUSTRY

BOTH SMALL & LARGE CERAMIC PRODUCT BOTH SMALL & LARGE CERAMIC PRODUCT MANUFACTURERS SHOULD CAPITALISE ON THE MANUFACTURERS SHOULD CAPITALISE ON THE LATEST DEVELOPMENTS IN LTM MATERIALS FOR LATEST DEVELOPMENTS IN LTM MATERIALS FOR BOTH BASE AND SUPER STRUCTURE AND REAP BOTH BASE AND SUPER STRUCTURE AND REAP THE BENEFIT OF ENERGY CONSERVATION THE BENEFIT OF ENERGY CONSERVATION

CONCLUSIONCONCLUSION

CONVENTIONAL WARE/CORDIERITECONVENTIONAL WARE/CORDIERITE

Conventional wares are made of fire clay grog, Conventional wares are made of fire clay grog, aluminosilicate grog or recycled material grog with aluminosilicate grog or recycled material grog with unknown chemistry unknown chemistry

The above mentioned grogs are mixed with enormous The above mentioned grogs are mixed with enormous amount of clay and temporary binders to make it a plastic amount of clay and temporary binders to make it a plastic mass. mass.

Pressed manually in the mould and fired at a very low Pressed manually in the mould and fired at a very low temperature temperature

Introducing all sorts of flaws and end up with a product Introducing all sorts of flaws and end up with a product having all undesirable quality having all undesirable quality

CONVENTIONAL WARE/CORDIERITECONVENTIONAL WARE/CORDIERITE

These type of products are heavy and do not withstand These type of products are heavy and do not withstand load at higher temperature and also due to higher thermal load at higher temperature and also due to higher thermal expansion, wares breaks off within a few cycle expansion, wares breaks off within a few cycle

The situation is now becoming too worse due to The situation is now becoming too worse due to introduction of shorter firing cycle being introduced in the introduction of shorter firing cycle being introduced in the ceramic industry ceramic industry

Totally the above practice is too bad and no one bother to Totally the above practice is too bad and no one bother to estimate the cost of money/manpower/time involved estimate the cost of money/manpower/time involved

Almost 90% of the ceramic manufacturers have switched Almost 90% of the ceramic manufacturers have switched over to usage of cordierite over to usage of cordierite

Conventional waresConventional wares Cordierite waresCordierite waresMature at a lower Mature at a lower temperature with temperature with undesirable silica phaseundesirable silica phase

Mature at high temp with Mature at high temp with controlled cordierite/mullitecontrolled cordierite/mullite

Profile mismatch of setter Profile mismatch of setter affects the end product affects the end product qualityquality

Product density is high Product density is high B.D.2.lto 2.5g/ccB.D.2.lto 2.5g/cc

Product density is low 8.0.1.8 Product density is low 8.0.1.8 to24g/ccto24g/cc

Conventional waresConventional wares Cordierite waresCordierite waresHigh TE& poor TSHigh TE& poor TS

Cracks within 4 or 5 cyclesCracks within 4 or 5 cycles

Reaction with end ware is Reaction with end ware is moremore

Actual cost is moreActual cost is more