KELTECH ENERGIES LIMITED manufactures expanded perlite and provides perlite insulation services using equipment from the US. It operates two expanders in South and Central India. KEL provides bagged perlite products and performs on-site expansion and filling. It is part of the large Chowgule Group and has over 100 employees working in perlite expansion and services. KEL aims to achieve total customer satisfaction through quality products and services.

2. 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

3. Introduction
From modest beginning in 1916, the Chowgule Group has today activities in the areas as
diverse as
Iron Ore mining and Exports
Iron Ore Pelletization
Shipbuilding
International shipping with integrated logistics management
Ship owners (international tramp trading)
Explosives
Industrial salt
Industrial gases
Automobile Dealership
Construction Chemicals and Equipment
Marketing Agencies
Education
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)

4. Iron Ore mining and Exports

5. Industrial salt and Shipping

6. Shipbuilding

7. Pelletization of iron ore

8. Explosives

9. Automobile Dealership

10. Perlite Activities
Stationary Expanders – Bagged Perlite Products
Portable Expanders – Site Expansion and Filling
Perlite Concrete Block – Factory made / Site Cast
Perlite Removal and Refilling

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

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

13. 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

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

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

16. Perlite Filling of ASU, cold boxes and small cryogenic tanks

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

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

19. Organization Chart
Perlite expansion is managed and supervised by qualified Engineers and technicians.

20. Manpower
Permanent Company Personnel
Management - 19
Engineers - 35
Procurement - 3
QA / QC - 10
Clerical - 12
Craftsman - 50
( By Trade )
TOTAL - 129

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

22. 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.

23. Company ISO Certification

24. Credentials

25. Credentials

26. Credentials

27. Credentials

28. Credentials

29. Site Expansion and Filling
Perlite Ore

30. Site Expansion and Filling
Perlite Ore
Perlite Mining
Perlite Crushing and Grading
Bagging and Shipment

31. Site Expansion and Filling
Perlite Mining

32. Site Expansion and Filling
Perlite Crushing and Grading

33. Site Expansion and Filling
Bagging and Transportation

34. Site Expansion and Filling
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

35. Plant & Machinery
Required nos of Portable expanders with essential spares
Conveying hose pipes
Vibration Equipments
Control panels an all accessories
Testing laboratory with equipments
All the above will be shipped in ISO 20 feet containers

36. Site Organization Chart

37. Manpower – 2 Expanders
Project Manager - 1
Supervisors - 2
Operators - 2
QC / QAD - 2
Safety Supervisor - 1
Maintenance Assistant - 1
Casual Labour - 12

38. Flow Diagram of - Portable Perlite Expander

39. Expanded Perlite for Cryogenic Insulation
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 structure
accounts 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 [-173 0 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.

40. 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.

41. 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

42. 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

43. Perlite Ore
Typical Chemical Composition of Crude Perlite Ore
REDCO - USA INPRO- S&B-GREECE
NEWZEALAND
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%

44. Perlite Ore
Other Properties
Colour - Pale to dark grey, brown, green and black
Hardness - 5.5 to 7.0 on Mohr’s scale
SG - 2.0 to 2.8
SP - 760 o C - 1000 0 C
RI - 1.490 to 1.610
Cryogenic Grade Ore
Size - 0.6 - 0.15 mm, or 0.400 - 0.150 mm
Crushability - Not easily crushable
Expandability - Good
Unexpandable material - Minimum
Material Delivery & Storage
The Perlite ore is packed in 1 M.T Jumbo bags. The shipment of ore is done either in
containers or as hold cargo (open). After clearing, the shipment / consignment the perlite ore bags are
loaded
into the trucks and transported to the site. The ore must be stored only in covered space and kept in dry
conditions. 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.

45. Perlite Ore
Why Site Expansion?
For large sized jobs above 1500 M 3 volume.
 Insulation of double walled storage tanks for liquid gas
 Insulation of double walled liquid gas tankers
 Insulation of oxygen plants, cold box / ASU
Advantages
 Reduced transportation cost - Ore / Expanded Perlite
 Less handling problem of bulky Expanded Perlite
 Controlled insulation procedures
 Maximum thermal efficiency (low moisture)

46. 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 the
expanded perlite or insulation space. Rain shelters will be provided wherever necessary.

47. 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.

48. 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

49. Vibration
Internal Vibration

50. Inspection:
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.)

51. 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.

52. Clientele for Cryogenic applications
CUSTOMER LOCATION QTY. EQUIPMENT | YEAR JOB
Reliance Petro Chemical Gujarat 90 MTs Nitrogen Tank 1990 Filling and supervision
Industries, Hazira
S M Dyechem Ltd Pune 80 MTs ASU 1992 Supply
National Ferlilizers Ltd. Vijayapuri MP 08 MTs Liquid Oxygen 1992 Supply
Tank
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 70 MTs ASU 1989 Supply
Jamshedpur
Industrial Oxygen Ltd., Pune Tuticorin 44 MTs ASU 1998 Supply
(Sterlite Industries Ltd.)
Toyo Engineering Corporation Haldia 57 MTs ASU 1998-99 Supply and supervision
Ltd., of filling
Ispat Industries Ltd. Raigad 35 MTs ASU 1999 Supply
Industrial Oxygen Co. Pondicherry 32 MTs ASU 2000 Supply
Pondicherry
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 35 MTs Oxygen plant 2005 supply
[AP]

53. Clientele for Cryogenic applications
CUSTOMER LOCATION QTY. EQUIPMENT | YEAR JOB
Inox Air products., Pune Pune and Tadapatri 35 MTs Oxygen plant 2005 supply
[AP]
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- 160 MTs ASU 2006 Supply & Filling
Hospet project
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 & 2008 Site Expansion,Filling &
Propylene Vibration
tanks
Goyal MG Gases Raipur 137 MTs ASU 2008 Supply
Pull B.V. Rhenen Bahrain 20 MT LPG Tankers 2008 Supply

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

55. 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 HSD
G. 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 Team
O. 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 back
S. Customs Duty payment for the equipment.
T. Crane for fixing external vibrators.

56. Supervisors / Operators - 12 hours / shift
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

57. Quantity of Supply
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

58. For Propylene tank – TK 7502 – 360 MT of Perlite ore
Filling – 15 Days
Vibration – 3 Days
Total - 18 Days

59. 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.

60. Site expansion, Filling and internal vibration
1. Preliminary Operations
2. Transportation
3. Expansion and filling
4. Vibration

61. 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.

62. 2. Storage and Transportation of Perlite ore
Ore Stored in covered shed Ore transferred by Forklift Ore Fed for expansion

63. 3. Expansion
Expansion Under Progress Perlite Collector With Pot Blower

64. Filling of Expanded Perlite

65. PNEUMATIC CONVEYING SYSTEM FOR PERLITE POWDER

66. 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

67. 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.

68. 3. Filling
Perlite Conveying Pipes ( Collector to Tank ) Location of Perlite Conveying
Pipe on Tank

69. 3. Filling
Vent Socks Conveying Hoses to Nozzle ( Tank Roof )

70. 3. Filling
Measuring Level of Perlite Filled

71. 4. External Vibration
Vibration equipment consists of pneumatic hammers, eductors and Vacuum cups

72. 4. External Vibration

73. 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

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

75. 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.

76. Expanded Perlite Test Report: Compact density

77. Expanded Perlite Test Report: Sieve Analysis

78. Expanded Perlite Test Report: Moisture Content

79. Expanded Perlite Test Report: Vibration Report

80. Project Execution Schedule

81. Project Execution Details
1. Petronet Dahej LNG tank filling
2. Chemplast Ethylene tank filling
3. Petronet Dahej LNG Perlite concrete blocks for bottom
insulation – cast at site
4. Perlite concrete blocks Fedo – Cast at factory
5. Praxair ASU and Tank filling
6. Simulation of Vibration

82. KELTECH ENERGIES LIMITED.
Thank you for your
attention