The main goal of this case study is to show how Glassline Repair Putty (a special repair material) helped Aarti Industries Limited (AIL) fix damaged glass linings in their chemical factory equipment. Glass linings are like a protective layer inside big metal tanks used to make chemicals. When this layer cracks or breaks, it can cause leaks, safety problems, and stop production. AIL needed a quick, cheap, and long-lasting solution. SR-Glassline, which works like “cold welding” (sticking materials together without heat), solved this problem. This case study explains how it worked and why it’s better than old repair methods.
Aarti Industries Limited(AIL) is a leading Indian manufacturer of specialty chemicals with a global footprint. The company excels in process chemistry (recipe focus) and scale-up engineering (asset utilization) to create a sustainable future. Over the last decade, AIL has transformed from an Indian company catering to global markets into a global entity with state-of-the-art manufacturing facilities in India. Their products play a crucial role in the downstream manufacturing of agrochemicals, polymers, additives, surfactants, pigments, and dyes.
In factories that make chemicals, medicines, or paints, big metal tanks are used to mix ingredients. These tanks are coated with a glass layer inside (like a ceramic cup) to protect the metal from getting corroded (eaten away) by harsh chemicals. This glass lining is very important because: It stops chemicals from reacting with the metal. It keeps the products pure and safe. It makes the tanks last longer.
AIL’s(Aarti Industries Limited) glass-lined tanks were getting damaged because of:
- Thermal shocks: Sudden temperature changes (like pouring hot liquid into a cold tank) causing cracks.
- Physical damage: Tools or hard materials hitting the glass lining during cleaning or mixing.
- Chemical corrosion: Over time, strong acids or alkalis wearing down the glass.
Even small cracks could lead to big issues:
- Chemicals leaking out, risking worker safety.
- Contaminated products (like medicines or pesticides) becoming unusable.
- Stopping production for days, costing money.
Earlier, AIL tried fixing cracks by:
- Welding: Using heat to melt metal patches over cracks. But this often damaged the glass further.
- Epoxy glue: Sticking temporary patches that peeled off quickly.
These methods were slow, costly, and didn’t last. AIL needed a better fix.
How We Fixed the Problem
AIL worked with engineers to test SR-Glassline Repair Putty, a cold welding material. Here’s how they did it:
Industrial Applications
Step 1: Finding the Damage
First, they checked the damaged tank using ultrasonic testing (like using sound waves to find hidden cracks). They found tiny holes and cracks in a 10,000-liter reactor tank.
Step 2: Preparing the Surface
- Cleaning: They used sandblasting (spraying sand at high speed) to remove rust and dirt from the damaged area.
- Drying: The area was washed with solvents (strong cleaners) to make sure it was completely dry.
Step 3: Applying the Putty
- Mixing: The SR-Glassline putty comes in two parts (like glue and hardener). They mixed equal amounts to activate it.
- Applying: Workers spread the putty over cracks using a spatula, like icing a cake. They made sure the layer was smooth and even.
- Drying: The putty dried at room temperature (25°C) for 24 hours. No heaters or special tools were needed.
Step 4: Testing the Repair
After drying, they checked the repair by:
- Spark testing: Using electric sparks to find air bubbles or weak spots.
- Chemical testing: Pouring strong acids (like hydrochloric acid) on the repaired area for 2 days.
- Pressure testing: Filling the tank with water and pressurizing it to 6 bar (like pumping air into a balloon) to check for leaks.
What We Discovered
1. It Worked Faster
- Old welding repairs took 5–7 days. SR-Glassline dried in 1 day, cutting repair time by 70%.
- This saved AIL(Aarti Industries Limited) cost per repair because production could restart faster.
2. It Lasted Longer
- Repaired areas stayed intact even after long term of use with harsh chemicals.
- No leaks were found, even when the tank was heated to 180°C or cooled to 20°C.
3. It Saved Money
- SR-Glassline cost 40% less than welding or buying new tanks.
- The tanks’ lifespan increased by 3–5 years, saving replacement costs.
4. It Was Safer
- No fire risks (unlike welding).
- Workers didn’t need heavy safety gear to apply the putty.
Cold welding (SR-Glassline) works like glue but stronger. Here’s why it’s better than old methods:
- No Heat Needed: Welding uses fire or electricity, which can melt the glass. Cold welding doesn’t need heat, so the glass stays safe.
- Strong Bond: The putty sticks to glass like super glue, forming a waterproof, acid-proof layer.
- Easy to Use: Anyone can learn to apply it, unlike welding, which needs experts.
This method is perfect for factories that can’t afford long shutdowns. It’s also eco-friendly because it reduces waste (no throwing away old tanks).
Through expert intervention and the use of SR-Glassline Repair Putty, Aarti Industries was able to resolve their glass lining issue efficiently. This case study demonstrates how innovative repair solutions can significantly enhance equipment longevity and operational efficiency in the chemical industry. For industries facing similar challenges, Shree Ram Sealing Engineers offers reliable and cost-effective repair solutions to keep operations running smoothly.
