Case Studies
Each case study below is anonymised at the customer's request — but the equipment, the failure pattern, the spec we proposed and the outcome are all real. Read these for the engineering reasoning more than the names.
Customer identity withheld in published materials per standard NDA practice. Plant location, equipment specification and engagement scope are reported accurately. Performance figures reflect customer-reported outcomes after one full operating campaign.
A 60-tonne steel ladle was failing the slag-line at 75 heats. Post-mortem revealed under-spec carbon (8% vs. recommended 14%) at the slag-zone. Re-spec to MC-14 with anti-oxidant package took the campaign to 104 heats.
Magnesia-chrome bricks in the upper transition zone of a 2,500 tpd kiln were spalling at 6 months — a known limit with chrome-bearing brick under high alkali load. Switch to chrome-free magnesia-spinel extended the zone to 11 months and removed the chrome-disposal headache at relining.
A 5-tonne reverberatory melting furnace was building corundum at the metal-line every 3 months — forcing chip-out shutdowns. Switching the metal-line castable to a low-cement bauxite formulation with BaSO4 + SiC anti-corundum additives moved the chip-out cycle from quarterly to annual.
A 35 MW CFBC boiler cyclone was needing patch repair every 4 months from bed-material abrasion. A coordinated package of nitride-bonded SiC tiles for the inlet target and high-density chemically-bonded LCC for the cone moved planned cyclone refractory work from quarterly to during the annual major shutdown only.
Project Gallery
A visual gallery of refractory installations and lining inspections from across our Pune-belt and pan-India engagements. Photographs published with customer permission; identifiable plant features have been cropped or anonymised where requested.
Customer features that could identify a specific plant are cropped or blurred per published-permission policy. Original photographs available to qualified customers under NDA.
Engineering
Each engagement runs through our 5-phase total refractory solution. Read the services page for the methodology.
Quality
Plant-level quality system independently audited. Test certificate accompanies every despatch.
Heritage
Originally Chaney & Co; relaunched as Chaneyco Refratech Pvt. Ltd. in 2011 with the Chakan, Pune plant.
Tell us the equipment and the failure pattern. We'll share which of our case studies matches most closely and propose a starting-point spec within one working day.