Essar Power, Surat, Gujarat
A chimney aluminized in place at the power plant, without dismantling it.
Thermal Spray Coating in Kalaburagi
Mythri Metallizing arc sprays zinc and aluminium onto blasted steel at cement and power plants around Kalaburagi.
- Zinc and aluminium, 175–200 µm
- Aluminizing for preheaters and TA ducts
- Site teams with their own equipment
Metal Spray for Hot Cement Plant Steel
Thermal spray means zinc or aluminium wire melted in an electric arc or a flame and sprayed onto freshly blasted steel. At a Kalaburagi plant it is applied to structures in place, with nothing dismantled.
In a cement plant, the main use is aluminizing hot steel. Aluminium resists oxidation at temperatures where paint softens and peels. Aluminizing on preheater structures, rotary kilns and TA ducts can also reduce heat radiation to a certain extent.
Metal spray requires no curing, so the full thickness can be applied in one shift, which suits a shutdown window. Mythri has worked at the Vicat Sagar cement plant near Kalaburagi.
What Is Metal Sprayed, and Where
Preheaters, kilns and TA ducts
Aluminium arc sprayed over blasted steel and sealed, to resist heat and to reduce radiation to a certain extent.
Chimneys at cement and power plants
Boiler, DG and RABH chimneys aluminized in situ from scaffolding during a shutdown.
Structural steel and handling
Thermal spray zinc on conveyor galleries, silos, supports and pipe racks, with a sealer and paint where required.
Site Spraying and Peenya Wear Coatings
Zinc and aluminium are sprayed at your site by arc spray, with flame spray for repairs and tight spaces. The team brings arc spray sets, compressors and blasting equipment from Bengaluru, about 570 km away, and requires only power and access at site.
- Arc rectifier and gun sets
- 15 sets
- Wire purity
- Zinc 99.95%, aluminium 99.5%
- Alloy
- Zinc-aluminium 85/15
- Thickness
- 175–200 µm standard, up to 500 µm possible
- Tests
- Thickness to IS 3203, adhesion to ASTM D4541
Chimneys and Power Plant Steel
JKPL, Tamil Nadu
Thermal spray aluminium on a boiler chimney.
Essar Projects, Hazira, Gujarat
Essar recorded that the metallizing was completed within schedule and that the quality of workmanship was excellent.
Frequently Asked Questions
Can you aluminize a preheater or kiln while the plant is down?
Yes, during a planned shutdown once the plant has made the equipment safe to work on. The team blasts and sprays in shifts so that the window is used fully, and the full coating thickness can be applied in one shift.
How much heat loss does aluminizing save on kilns and ducts?
Aluminizing on preheater structures, rotary kilns and TA ducts can reduce heat radiation to a certain extent. We do not quote a saving, because it depends on the surface and the operating conditions.
Is zinc or aluminium preferable for galleries and silos?
Zinc suits most structural steel and gives strong sacrificial protection, and it can be sealed and painted. Aluminium is the better choice for hot surfaces and chimneys. We recommend one from the operating conditions.
Send a Drawing for a Metallizing Quote
Please share the structure, its dimensions and location, and your planned shutdown window. Our engineers will respond with a recommended method, schedule and quotation.
- Reply within one working day
- Drawings kept confidential
- Email acknowledgement
Thank you. Your enquiry has been received.
One of our engineers will contact you to discuss the requirement. A confirmation has been sent to your email address.