A complete kiln line and preheater tower removed to make way for a modern replacement on the same footprint.
- Client
- Cement Manufacturer
- Location
- Rajasthan, India
- Duration
- 6 months
- Material handled
- 7,300 t
Removal of an obsolete kiln line including a 78-metre preheater tower, rotary kiln, clinker cooler and associated ductwork, clearing the footprint for a replacement line while the plant's second line continued production.
Scope of works
- Preheater tower demolition (78 m)
- Rotary kiln shell sectioning and removal
- Clinker cooler and ductwork dismantling
- Refractory removal and disposal
- Foundation removal to new line requirement
- Footprint preparation for replacement line
The plant's second kiln line stayed in production 30 metres away, with a shared electrical substation and a common raw material conveyor crossing the demolition footprint.
The preheater tower structure had been extended twice, and the drawings for the second extension could not be located anywhere in the plant's records.
Refractory volumes were substantial and required characterisation before disposal routing could be confirmed.
The shared conveyor was re-routed on a temporary structure designed and built by our team, keeping the operating line supplied throughout. The substation was hard-protected and monitored for vibration.
The undocumented tower extension was surveyed and structurally modelled from scratch — a two-week investment that identified a transfer arrangement whose failure mode would have been serious had the demolition proceeded on assumed load paths.
Refractory was sampled by zone, characterised and routed to appropriate licensed outlets, with the reusable basic brick fraction recovered and returned to the client for their operating line.
The footprint was handed over surveyed and prepared to the replacement line's foundation requirement, allowing the new works contractor to start without a preparation period.
7,300 t
Material recovered
100%
Production line uptime
340 t
Refractory recovered for reuse
Foundation-ready
Footprint handed over
Delivered on schedule
Programme
Equipment mobilised against the engineered method for this programme. Where the correct machine was not in our own fleet, it was brought in rather than substituted.
- 65 m high-reach excavator
- 350 t crawler crane
- Kiln shell cutting systems
- Material handlers
- Temporary conveyor structure
If this looks like your asset, we should talk.
Send us the structure, the environment around it and the date you need it gone. We will come back with a method.