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Disa and Wheelabrator. Global Trends in Furnace Fume Extraction And Filtration. VI National Foundry Conclave 2013 Coimbatore, India. Improving our Customers’ Profitability. Norican group history. Our Global Presence. Technology Centers, Manufacturing Sites & Major Service Centers.
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Disa and Wheelabrator Global Trends in Furnace Fume Extraction And Filtration VI National Foundry Conclave 2013 Coimbatore, India Improving our Customers’ Profitability
Our Global Presence Technology Centers, Manufacturing Sites & Major Service Centers • Broadest coverage in the industry: • Over 475 marketing and sales professionals • Over 35 direct sales & service centers serving an installed base in approximately 100 countries • Global network of > 80 agents Burlington, ON W&A: OEM Birmingham, UK, MF: OEM & Parts Herlev, Denmark M: OEM & Parts Metelen, Germany W&A: OEM Wrzesnia, Poland Zagorow, Poland W: OEM Waukesha, WI Cast parts Nagoya, Japan M & W: OEM & Parts Changzhou, China W: OEM & Parts Oswego, IL M: OEM & Parts Legend M - Molding W – Wheelblast A – Airblast MF – Mass Finishing LaGrange, GA W: Aftermarket Charleville, France A: OEM & Parts Zurich, Switzerland W: OEM & Parts Pribram, Czech Rep W: OEM & Parts Tumkur, India M: OEM & Parts Hoskote, India W: OEM, Parts & Filters Our Sales Channels
FURNACE FUMES Metal fumes are formed by the evaporation, condensation, and oxidation of metals in air. In foundries furnace operators, melters, casters, ladle men, pourers, and crane operators are exposed to the smoke and fumes from molten metal. The total emission of smoke and fumes depends upon the quality of the scrap charged. If the scrap contains large quantities of impurities, high concentrations of organic and inorganic compounds are emitted. Inorganic material emitted from furnaces, ladles and castings in iron foundries is primarily composed of oxides of iron, manganese, calcium, magnesium, aluminium, and silicon. The fumes of steel melting contain the same oxides plus those of chromium and nickel. Iniron and steel foundries, the oxides of lead and zinc are the predominant minor constituents in the fumes. Lead and zinc come from galvanized or painted scrap and from nonferrous alloys or automation steels that are occasionally present in the charge. The pyrolysis of oil, grease, synthetic material and rubber in the furnace during the melting and the decomposition of the ingredients may produce a complex mixture of organic compounds, including poly aromatic hydrocarbons and traces of suphur compounds also.
Melting Shop - Hazards Health effects of heat exposure Potential health effects for persons under increasing levels of heat stress include: • discomfort • heat fainting • heat stroke • prickly heat • irritability • dehydration • reduced concentration • heat rash • reduced tolerance to chemicals and noise exposure • heat cramps • heat exhaustion • heat stroke.
Evolution of Foundry Fume Pollution Control 2. Jet Hood + Wet Scrubber 1. Canopy Hood + Fan 3. Close Capture Hood + Pulsejet Filter 4. Tornado Hood + RA Bag Filter
History of Wet Type Scrubber • In 1990s fabric filters were used without proper spark arresters and Sulphur abatement units. • Resulted in failure of bags by fire or Acidic attack. • Usage of poor quality of scrap resulted in SOx emissions. • Wet scrubbers introduced to handle this. • With current technologies, chances of fire in a Induction Furnace Fume Extraction system is negligible. • Foundry Industry use very good quality Scrap resulting in no major SOx emissions. • Use of Wet Scrubbers have stopped in advanced countries and modern foundries.
Dry Fabric Filters vs. Wet Scrubbers FABRIC FILTER WET SCRUBBER In fabric filters dirty air goes in and clean air + Dust comes out. In scrubbers dirty air goes in, gets scrubbed by water and clean air + slurry (contaminated Water) comes out. This slurry is to be treated before it is fed back into the scrubber. In a sense we are converting air pollution problem into water pollution problem.
Extraction and Filtration of Furnace Fume Fabric filter: It is purely a dry system where the flue gas is cleaned using filter elements made of fabric and occasionally they are cleaned by a Reverse air or compressed air. Here the pressure drop is max 150 mm wc. It can bring down the emissions down to 5 to 10 microns. Venturi Scrubber: Here the gas is cleaned by scrubbing with a film of water whereby dust is intercepted and falls down. The water becomes slurry and is treated in a treatment plant before it is re-circulated. Here, we are converting air pollution problem into water pollution problem. As the gas has to overcome the water film resistance the fan pressure drop is min 300 mm wc.
TYPICAL CHEMICAL ANALYSIS OF FURNACE DUST * Sulphur > 1 % can cause considerable damage.
IMPORTANT SAFETY FEATURES AVAILABLE • Cyclonic Spark Arrestor before filter. • Explosion Vent provided in case of explosive nature dust. • Lime / Dust dosing system injects small quantities of lime powder into the filter inlet duct, it gets coated on to the filter bags. Lime being an inert material prevents sparks from directly impinging on to the filter fabric. • Temperature of gas is continuously measured at filter inlet, incase of upset condition, Emergency dilution Damper is actuated to allow ambient air to bring down the temperature of the gas. • Emergency bypass Damper routes the flue gas directly to the stack incase of any emergency condition. • CO2 Dosing system offered as an optional safety feature. • All Hoppers are fitted with Rotary Airlock Valves (RALs) to ensure no dust accumulation.
Tornado Furnace Hoods – German cutting edge Technology • Effective extraction in all phases of operation • For new or to retrofit already existing furnaces individuallydesigned • Saves Energy • Easy to Maintain • Safe and Robust Design • Space-saving, flat design • Goodaccessandvisibilitytothecrucibleandfurnacespout
Air pollution control in foundries: Work space air management Forced ventilation system with dust extraction Fresh air ventilation system Deliveriy of unpolluted air to areas where dust collection is not possible or where diffuse emissions cause increased dust concentrations Fresh air zone at floor level Dust source Dust is collected, the air condition is kept by forced ventilation
Filters Business – DISA India Limited- 27 Years of presence- Over 800 installations- Undisputed Market leader in Foundry APC- Dedicated Sales, Service Spares Teams- State of the art Manufacturing Facility
Garant Filters Cartridge Filter BMD in India George Fischer DISA Norican Group DISA INDIA LTD. HOSAKOTE Plant DISA sold this Air Division– the Indian Operations were not part of this sale and DISA INDIA Ltd. (DIL) continued its operations of Filters Business and fully own the Original BMD Garant Technology for Industrial Filters. Norican Group was formed in May 2009, after the merger of DISA – World’s Leading Moulding & Sand Plant Solutions Company & Wheelabrator – the World’s largest in Surface Preparation Solutions. Name changed to Georg Fischer DISA Ltd BMD Foundry Machinery Ltd started in Tumkur ARPA Moudling Mc TM Mixers Sand Plants Shot Blast Range Wheelabrator Shot Blast Mc HB-1 launched with DISA Cartridge filters for non-foundry markets BMD Garant Filters introduced 2nd Plant started in Hosakote DISA India’s Technology Absorption - Filters 1992 1984 1996 2005 2010 2009
Energy savings in Disa low pressure reverse air Filters Comparison of different type of filter cleaning systems - Energy consumption K.W. Rs. 144000 p.a. Expenses on Power are estimates only
Thank you for your attention Don’t hold your breath any longer, please speak out for Clean Air To know more about our products and services, please visit www.disagroup.com and www.wheelabratorgroup.com
