Winchester Ringblaster, Western
Tool & Industrial Loads
Presentation for the Cement Industry
2008
1
13/04/2015
Introduction



Winchester Industrial Products is a division of Olin Corp
in the USA, listed on the US stock exchange. The company
currently employs some 6,300 personnel and has a proud
history that stretches back to 1866.
Winchester 8 gauge Industrial Products were introduced to
the cement industry 60 years ago as a means of removing ring
build-ups from rotary kilns. Since then the products have
improved and evolved into an obstruction removal system
used by many different industries like power generation,
copper smelters, ferro alloy and others.
The Winchester 8 gauge system is being used by industries
worldwide: North & South America, Europe, previous eastern
block countries, the Middle East, South Africa, the Asian rim,
Australia, New Zealand, and countries in SE Asia utilize the
system in their processes. Use of the Winchester 8 gauge
system is also rapidly expanding into many developing
nations throughout the world.
2
13/04/2015
Winchester Company Concept



Reliable global organization with localized service and
distribution facilities - Founded in 1866 and world renowned for
design and product excellence. Local presence dedicated to same
company principals.
Comprehensive knowledge of customers needs - Close
working relationship with clients to ensure the right products and
methods are utilized. Ongoing training and procedure courses etc.
Unique products and service - Continual R&D and unique
products not offered by any other company. Recent
developments include the patented frangible loads and rifled
barrel extension and western tool products.
3
13/04/2015
The Winchester Advantage



Product Value - The most cost effective way to remove all
manner of obstructive build ups in many varied applications.
Competitive up front purchase costs coupled with local
professional advisory and back up service adds up to an offer
of unmatched value.
Product Design - The 8 gauge system is designed to the
highest standards. Through years of scientific research,
development, and performance testing, Winchester is able to
offer the widest range of Industrial Products available. These
cost effective products will limit downtime, increase
production, and add increased profits to your bottom line.
Product Acceptance - The Industrial Products are designed to
meet all international standards for transport and storage. For
many years Winchester has been leading edge of 8 gauge
technology and has a superior global service network. A long
association with many different industries is reflected in
accepted, proven solutions for a range of varied applications.
4
13/04/2015
Customer Focus



Winchester Industrial Customers - The Winchester
Industrial Products customer focus includes many of world’s
coal fired power generation companies, Cement Factories,
Ferro Alloy Plants, Copper Smelters, Waste Incineration
Facilities and other industries.
Global Clients - Throughout the world there are many Cement
Plants that are valued clients of Winchester. There are many
companies in the USA, throughout Europe, areas of the
Middle East, and many other producers in other countries who
all value the 8 gauge system to enhance their production and
increase bottom line profits.
Winchester Products are currently used in many operations
throughout the world. Europe, USA, Australia, and now SE
Asia are all benefiting from the proven 8 gauge system.
5
13/04/2015
Product Applications


Industry Profile - The 4 main areas of Industrial Product use
Cement Industries
Furnace Tapping Industries
Coal Fired Power Generation Industry
Waste Incineration Industry.
Cement Industry - For many years companies have had to
rely on outdated and potentially dangerous methods to
remove build ups in kilns, preheaters, coolers and silos.
Winchester specifically designed the Western Tool,
Ringblaster and associated Industrial Loads to overcome
these issues. It is no longer necessary to have the danger of
putting people into dangerous areas to remove the build ups.
6
13/04/2015
Product Applications (Cont’d)




Ring Removal - The Kiln is usually stopped for few minutes
to remove a ring, ball or log. Unlike other methods like high
pressure water or CO2 , you don’t need to drill holes in your
kiln at a predetermined location or expose your workers to
dangerous blow backs from using high pressure water, the
Ringblaster will remove any ring or ball at any location
whether it is 3 meters or 60 meters.
Brick shooting
Snowmen Removal - Winchester designed the Western Tool
especially for this purpose. You can remove a snowman very
easily without stopping production.
Preheater and Silos - The Western Tool is also used with
specific loads to completely clean your preheater and silos
without risking your workers by inserting them into a silo or
exposing them to material blow back from the use of high
pressure water.
7
13/04/2015
Removal of Ring Buildups in Cement Kilns.
Place the gun at the front end of the kiln, this enables you to aim
at any target inside the kiln.
The Winchester Ringblaster provides fast and economical way to
remove ring buildups in cement kilns.
You get best results if you start to use the gun as soon as the ring
starts to form and not after it has closed the kiln completely.
8
13/04/2015
Removal of Ring Buildups in Cement Kilns
With the gun in place and aimed at the obstruction, you can
shoot very easily.
While the gun is in use, the kiln is stopped from rotating to
enable the shooter create a keyway into the ring.
Shooting multi keyways will make the ring collapse.
9
13/04/2015
Removal Ring Buildups in Cement kilns
Alternatively while kiln is rotating you can aim at a fixed
point and shoot at a ring until it is trimmed.
10
13/04/2015
Rhino Horn on the Burner
When using secondary fuel, such as petcoke, buildups on the
burner tube is very common. Winchester's low velocity and
buck shot ammunition are ideal in removing such buildups.
11
13/04/2015
Other Applications
The Industrial gun can also be used to clean silos if you
experience such blockage.
The Winchester Western Tool due to its lighter weight &
flexibility can be used with great advantage in such
applications.
12
13/04/2015
Other Applications
Christmas trees or snowmen can easily be removed with either
the Ringblaster or Western Tool while production is still
running. Though, in some instances the fan is stopped to be
able to see the build-up.
13
13/04/2015
Brick shooting
JACK HAMMER VS. WINCHESTER
RINGBLASTER INDUSTRIAL TOOL
(Three hundred metric ton per day valued at $70.00 per metric ton.)
(Total production = $21,000 per day and $875.00 per hour.)
JACK HAMMER
-Cool down time – 36 hours x $875 = $31,500.00 production loss.
-Fifteen laborers.
-Jack hammer time:
15 laborers x 8 hours x 3 shifts x 10 days = 3,600 labor hours and
$210,000.00 production loss. ($21,000.00 x 10 days)
-Roll time (turning kiln to remove brick):
5 laborers x 10 hours = 50 labor hours and $8,750.00 production
14
13/04/2015
loss. ($875.00 x 10 hours)
Brick Shooting
Re-brick time:
15 laborers x 8 hours x 3 shifts x 10 days = 3600 labor hours and
$210,000.00 production loss. (10 days x $21,000.00)
Re-heating kiln takes 20 hours which equals $17,500.00
production loss. (20 hours x $875.00 per hour)
Total Labor hours = 7,250
Total Production Loss = $477,750.00
WINCHESTER RINGBLASTER INDUSTRIAL Tool
Cool down time – 8.0 hours x $875.00 = $7,000.00 production
loss.
-Shoot time:
3 laborers x 3 hours = 9 labor hours and $2,625.00 production
15
loss. ($875.00 x 3 hours.)
13/04/2015
Brick Shooting
Cool Time: 8.0 hours and production loss $7,000 ($875.00 x
8.0 hours)
- Roll time (turning kiln to remove brick):
5 laborers x 10.0 hours = 50.00 labor hours and $8,750.00
production loss. ($875.00 x 10 days)
- Re-brick time:
15 laborers x 8.0 hours x 3 shifts x 10 days = 3600 labor
hours and $210,000.00 production loss. (10 days x
$21,000.00)
- Re-heating kiln takes 20 hours which equals $17,500.00
production loss.(20 hours x $875.00 per hour)
- Loads used – CE8SPW lead slug magnum x 15 cases =
$6,000.00.
- Total Labor hours: 3662
- Total Production Loss $252,875.00
- Load Cost $6,000.00
- Total Cost $258,875.00
-
16
13/04/2015
Brick shooting
JACK HAMMER
Total Labor hours = 7,250
Total Production Loss = $477,750.00
WINCHETSER INDUSTRIAL GUN
Total Labor hours = 3662
Total Production Loss = $252,875.00
Ammunition Cost =
$6,000.00
-----------------------------------------------$258,875.00
Total Savings $218,875.00
Total Labor Hours Saved 3,558 Hours
17
13/04/2015
Build Up Removal Method
CONTINUED NEXT SLIDE
18
13/04/2015
Summary
Winchester 8 Gauge Industrial Equipment and Loads.
Through years of scientific research, development, and
performance testing, Winchester is now able to offer the widest
variety of Industrial Equipment and Loads for use in abroad
range of applications. These industry specific products offer
advanced design and construction forming a highly effective
system. This safe, versatile, cost effective, and proven system is
designed to remove build-ups and add increased profits to your
bottom line.
**Don’t let production build-ups slow down your
operation. Blast them away with Winchester
Industrial Products.**
19
13/04/2015
Where to Get More Information
All information can be accessed directly from the
Winchester web site at www.winchester.com. This
includes MSDS sheets, maintenance, and product
information.
D.K. ENGINEERING
4TH FLOOR AALY PLAZA BLUE AREA
ISLAMABAD PAKISTAN
PHONE: 051 282 9800 FAX 051 2827600

Email: SALES@DKENGG.COM
20
13/04/2015