The refractory industry primarily produces bricks and castables that are highly fire-resistant. These products are essential for steel industries, cement industries, and other related sectors, serving as linings for kilns where high temperatures are required to produce molten metals for steel and alloy materials. High-temperature industrial processes are critical for industries such as steel, cement, lime, non-ferrous metals, glass, environment, and chemicals. These industries require refractory bricks, castables, moulds, and similar products, each in varying sizes and shapes. These refractory bricks can endure temperatures exceeding 1200 °C.
These materials act as linings to facilitate processes like burning, melting, blasting, firing, fusing, and shaping steel and alloy materials. The product range includes bricks, lining mixes, and flow control products such as slide gates, nozzles, and plugs.
The raw materials for these products, including magnesium and dolomite, are processed in kilns operating at temperatures as high as 2800 °C. Designing such intricate processes demands a comprehensive understanding of the industry’s specific requirements.
V Sridhar Reddy, Managing Director of Sri Harsha Consulting Engineers Pvt Ltd (SHPL), shares insights into various refractory projects as case studies.
RHI Magnesita
RHI Magnesita (formerly RHI-Classil) was designed by SHPL in 2003. The company began in India as Classil Refractories, founded by its promoter, Dr RV Raju.
The project marked a major milestone for SHPL in designing such a significant factory. Dr Raju’s passion for establishing the factory in Anakapally near Visakhapatnam was evident in his commitment to strict budget control and timelines. He set an ambitious target of 270 days for the project’s completion. Key inputs for the design were provided by the employees, who helped the SHPL team understand the challenges involved.
In 2003, pre-engineered buildings (PEBs) were not yet popular, so the entire structure was designed using trusses and lattices made of circular hollow sections (CHS). All the purlins were custom-designed as built-up members using CHS. At the time, steel hoppers and silos were not the norm, so SHPL designed reinforced cement concrete (RCC) silos and hoppers, which were complex to both design and execute but were completed successfully.
The mill house was designed with RCC floors, while the roof was constructed using CHS trusses. The presses were engineered to accommodate static and dynamic loads, making this part of the design particularly intricate. Other sections, such as the raw material area, kiln, engineering stores, lab, and finished goods godown, were designed with ‘A’-type trusses made of CHS, featuring multiple bays supported by RCC columns and gutters.
The project was completed within the stipulated 270 days, meeting both budget and timeline requirements. The collaboration established a long-term relationship, with RHI Magnesita continuing to engage SHPL for their projects. Today, the factory premises are enveloped in greenery, giving the impression of a factory nestled within a garden—a testament to thoughtful planning and design.
Refratechnic (India) Pvt Ltd
We designed the entire premises of Refratechnic Refractory at Parawada near Visakhapatnam from start to finish, covering architectural 3D views, structural design, plumbing, firefighting, and electrical design. The architectural and structural designs, along with the 3D views, were done in-house. For plumbing and firefighting, we collaborated with Techno Engineering Services, and for electrical design, we partnered with HCE Engineering. Both consultants are Hyderabad-based.
This German-based company established its factory on 20 acres of land. Mr Uday Shankar, the Managing Director of the Indian division, entrusted us with the project, demonstrating strong confidence in our abilities.
The main challenge at this site was the significant ground level variations, with a depth of 9 m below the existing ground level. When we first visited, the site resembled a large lake filled with water and slush. Levels were recorded only after dewatering the entire premises. Following this, soil testing revealed a soil bearing capacity (SBC) of just 8 tonne per sq m at a depth of 3–4 m below the existing ground level. At the site centre, the foundation depth reached 12 m below the existing ground level, resulting in high costs for the foundation.
To manage costs, we adopted an alternate approach. The contractor, Ratna Constructions, dewatered the site entirely, dried it, and filled the area with good morrum soil in layers, compacting it until reaching 3 m below the proposed ground level. After the area was well compacted, the shed foundation plan was marked on the ground.
Wooden piles were placed every 450 mm at designated locations, followed by a 200 mm layer of compacted river sand. Plate load testing was conducted, yielding SBC values between 24-28 tonne per sq m across the premises. Based on this, we designed all the foundations for 20 tonne per sq m at 3 m below the existing ground level. Press foundations were designed using friction piles of 16–20 m in depth.
The Raw Material (RM) Store is located at the southwest corner of the site. This 12 m high building was designed in a PEB format. Adjacent to the RM store is the mill house, a 20 m high structure with multiple mezzanine floors to accommodate machinery like hoppers, silos, mixers, and blenders. The mill house was entirely designed using Jindal UB sections.
Additionally, the press section, kiln, and finished goods warehouse were all designed in PEB, incorporating different crane capacities as required. Mezzanine floors were included in some sections to serve as offices for plant staff, enabling them to monitor and manage production. Additional plant structures include the castable plant, also designed in PEB, while the administration building and electrical panel rooms were designed in RCC.
IFGL Refractories
IFGL Refractories, a Kolkata-based Indian company, operates plants in Bengal, Odisha, Andhra Pradesh, China, and the UK.
We designed their factory at Atchyuthapuram near Visakhapatnam in three phases, spanning 20 acres of land. The site, located near the sea coast, is prone to cyclones and rainwater inundation. To address these challenges, we conducted a thorough study of the ground contours and provided soil filling levels and road levels with gentle slopes to mitigate the risk of flooding.
The structural design was relatively straightforward, executed in three phases. Some portions of the shed were designed as high bays to accommodate mixing and batching operations. The administrative office was strategically located within the shed area, allowing oversight of production activities.
All steel structures were designed as PEBs, with execution carried out by Kirby. They adhered to the specifications we provided, ensuring quality and precision. For each phase, we created 3D views, which IFGL followed precisely during execution. The resulting color combination, complemented by well-designed porticos at all loading and unloading bays, added aesthetic value to the facility.
Vesuvius Refractories
Vesuvius Refractories, a UK-based firm, has established a new plant on 26 acres of land at Parawada, near Visakhapatnam.
The client initially requested that we reuse the existing structures on the site. After evaluating the site, we determined that the old structures would not align with the master layout. With significant persuasion, the client agreed to dismantle all the old structures except for the administrative building, which was located in a corner and did not interfere with the master plan. We further optimised the administrative building by adding an additional floor to accommodate more office staff.
The mill house was incorporated within a large shed, featuring spans of up to 40 m and high bay areas reaching nearly 28 m. The shed design included numerous variations to accommodate different crane capacities in various orientations.
For one specific section, where the crane requirement covered only a small portion of the shed span, we designed a suspender system from the roof rafter to support the crane girder. To address ventilation and natural lighting in this expansive structure, we integrated continuous rooftop strips, effectively illuminating the interior.
The pre-engineered building was supplied and erected by Zamil, adhering to our design specifications.
The client was highly satisfied with the final outcome, appreciating the functional and aesthetic aspects of the project. Consequently, they have entrusted us with the design of Phase II of their facility.
Conclusion
With the success stories of working with leading refractory giants, we have been fortunate to secure opportunities to design facilities for several other refractory industries. Currently, we are designing projects for TRL (Tata) Krosaki Refractory at Belpahar, Sarvesh Refractory, Romco Refractory, Chosun Refractory Industries at Rourkela, Reframin Refractory, and Avanee Refsol Refractory near Visakhapatnam.
Contributed by
V Sridhar Reddy, Managing Director of Sri Harsha Consulting Engineers Pvt Ltd (SHPL)
Quote
“Having collaborated with the top global refractory companies brings us immense satisfaction. Each project is a testament to SHPL’s innovative design approach, tailored to meet unique industry requirements.”
– V Sridhar Reddy, Managing Director of Sri Harsha Consulting Engineers Pvt Ltd (SHPL)
