Applications of HYSIL Blocks


By virtue of being a highly energy-intensive as an industry, energy-efficiency is a key focus area with cement manufacturers in India. Clinker Production accounts for much of the energy consumption by cement companies, and efficient Insulation is often sought to bring down operational costs and increase competitiveness.

HYSIL has helped turn around operational efficiencies for many leading cement companies by providing thermal insulation and reducing energy usage in:

  • Precalciner Cyclones and Riser Ducts
  • Precalciner
  • Tertiary Air-Ducts
  • Firing Hood and Clinker Cooler
  • Flue Gas Heat-Recovery to CPP HRSG Unit

HYSIL is reputed to be the ideal insulating material due to its lower thermal conductivity and superior strength characteristics and meets a whopping 80% of industrial requirements in India.Some of our clients include:

  • Associated Cement Companies (ACC)
  • GRASIM Cement
  • Jaypee Cement
  • Ambuja Cement
  • India Cement
  • Chettinad Cement
  • Madras Cements
  • Dalmia Cements
  • Lafarge Cement
  • Birla Cement
  • Zuari Agro Cement

    As a key strategy, the Power Industry often looks to harness internal energy while generating power. Therefore, lower energy consumption through insulation is an important method of reducing operational costs.

    Hysil Insulation, being Rigid Preformed, has lower thermal conductivity at higher temperatures and offers consistent thermal performance for decades together, which also means lower maintenance costs. HYSIL blocks are an ideal solution to reduce energy costs when it comes to:

    • Fluidised Bed Boilers
    • Flue Gas Heat Recovery System
    • Steam Pipe Lines
    • Air Preheaters

    Some of Our customers include:

    • Hidalco Renusagar Power Co.
    • NTPC –Simahdri, Singrauli, Dabhol
    • Jindal Power-Raigarh
    • Tata Power
    • Bandel TPS
    • Patratuu TPS
    • MPEB Korba
    • Neyveli Lignite Barsingsar, Neyveli
    • DVC Bokaro
    • NALCO Angul
    • GIPCL-Mangrol
    • And many more captive power plants

    The petro-chemical industry has extensive pipelines carrying hot gases, steam and oil. These are often poorly insulated and therefore can potentially conserve huge amounts of energy with better, long-lasting insulation.

    HYSIL products meet the need of this industry because of their:

    • Good structural strength
    • Lower thermal conductivity
    • Longer service life, exceeding 20 years

    Some of our customers include:

    • Indian Oil Corporation – Refineries
    • Hindustan Petroleum
    • Numaligarh Refinery
    • Kribhco, RCF, NFL and Iffco Fertiliser Plants
    • Reliance Hazira and Dahej
    • Jindal Polyester
    • Indian Acrylics
    • MCC PTA- Haldia
    • Sudarshan Chemicals

    In the Aluminium industry, insulation solutions are critical for melting pots and holding Furnaces.
    HYSIL, with its structural strength, low thermal conductivity and long life, works as an ideal insulation in such applications. Hysil Products have been tested and approved by KAISER ALM -USA.

    Some of our clients include:

    • Hindalco–Renukoot
    • Hindalco– Sambhalpur
    • Balco – Korba

    To conserve energy and reduce manufacturing costs, the fertilizer industry uses HYSIL Blocks extensively as back-up applications in Hydrogen Reformers. HYSIL Pipe Coverings are also used to insulate Steam Pipe Lines. In India, HYSIL pipe coverings have been used in gas-based fertilizer plants on steam pipe lines operating above 250 0C, as per HALDOR-TOPSOE-DENMARK specifications.

    HYSIL blocks have fast gained popularity with the fertilizer industry for their perfect insulation, structural strength, high load-bearing capacity and long life.

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