Manufacture of an indirect-fired hot-air heater

Customer: Vápenka Čertovy schody a.s. – a member of the Lhoist Group
Project: Manufacture of an indirect-fired hot-air heater
Lead time: 10 weeks from order placement

Project Scope and Key Challenge

For a production line manufacturing SORBACAL® speciality hydrated lime, we were commissioned to manufacture the main sections of an indirect-fired hot-air heater.

The customer provided the basic engineering documentation. PME was subsequently responsible for developing it into complete manufacturing documentation, finalising the detailed design and manufacturing the equipment.

The greatest challenge was the combination of technical complexity and an extremely tight schedule. The delivery was directly linked to a planned shutdown and the fixed commissioning date of the new production line. We had just 10 weeks from order placement to complete the entire project – during the peak summer holiday period.

From Engineering to Completed Equipment

PME’s engineering department first prepared the complete manufacturing documentation and made the necessary design modifications to ensure that the equipment could be manufactured at our facilities and subsequently integrated seamlessly with the customer-supplied components.

The result was a complex, predominantly stainless-steel welded assembly measuring approximately 6.5 × 2 × 4.5 metres and weighing 4.5 tonnes. It was designed for operating temperatures of 400–450 °C and a maximum temperature of up to 650 °C.

Our scope of supply included:

• the supporting frame,
• the recirculation and reversing chambers,
• the process-air flanges,
• the insulation support frames,
• all required fasteners, anchoring components and sealing materials.

Manufacturing and Quality Control

The entire manufacturing process was carried out at PME – from material cutting, bending and welding through assembly to the final surface treatment.

The stainless-steel components underwent pickling and passivation, while the carbon-steel supporting frame received a special coating suitable for high operating temperatures.

The quality of the welded joints was verified using, among other methods, penetrant testing (PT). The final handover documentation included dimensional inspection reports, coating inspection reports, the declaration of conformity, and documentation covering the pickling and passivation processes.

Trial Assembly Before Shipment

A key part of the project was the complete trial assembly carried out at PME’s facility.

Before shipment, this allowed us to verify not only the fit and alignment of all components manufactured by PME, but also their precise interface with the Honeywell heat exchanger supplied separately by the customer.

This step significantly reduced the risk of complications during final installation. Any interference or dimensional discrepancy can be resolved far more efficiently in a fully equipped manufacturing facility than during a scheduled shutdown at the customer’s site.

Following the successful trial assembly and customer acceptance inspection, the equipment was dismantled into transportable sections and delivered to Vápenka Čertovy schody as an oversized load.

10 Weeks – From Initial Documentation to Shipment

We completed the entire project within 10 weeks of order placement – from detailed engineering and manufacturing through quality control and trial assembly to final shipment.

For the customer, PME was therefore more than a manufacturer of individual components. We assumed responsibility for the entire manufacturing process and delivered a complete technical solution ready for installation and commissioning as part of the new production line.

#engineering #manufacturing #qualitycontrol #assembly #shipping #allunderoneroof

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