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ENCON THERMAL ENGINEERS

Established in 1978, ENCON Thermal Engineers is a leading provider of fuel efficient heating systems and energy conservation solutions for various industries. Our expertise includes designing, manufacturing and commissioning of furnaces, waste heat recovery systems, combustion equipment and more.

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ENCON THERMAL ENGINEERS

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  1. ENCON THERMAL ENGINEERS …Answer to the Continued Need for Energy Conservation

  2. AN INTRODUCTION • Established in 1978 during energy crisis in India. • Oriented towards energy Conservation • Well known for Designing, Manufacturing, Supplying and Commissioning of FUEL EFFICIENT HEATING SYSTEMS on Turn Key Basis

  3. WE SERVE… • Steel Plants • Transformers & Distribution [T&D] Industries • Automotive Industries • Foundries • Aluminum Industries • Pharmaceutical Industries • Cement Industries • Glass Industries • Ceramics & Refractory Industries

  4. R&D ACTIVITIES • Started in the year 1997 • Project sponsored by Gas Authority of India Limited (GAIL) and Ministry of Science & Technology in partnership with Indian Institute of Petroleum, Dehradun • Developed gaseous film burner with savings of up to 16% compared to conventional burners • Innovated Gas Heating Elements which can retrofit any heating elements (electric energized) application up to 550°C temperature • Developed Burners for COKE OVEN & BLAST FURNACE GAS • Developed Pilot Burners for Coke Oven/ Mixed Gas & LPG

  5. Company Activity • Fully integrated facilities for Engineering ,Design, Manufacture and Assembling of • Furnaces • Waste Heat Recovery Systems • RAD HEAT Gas Heating Elements • Combustion Equipment • Hot Air Generators • Ovens • Steel Melt shop Equipment's

  6. FURNACES • Design and manufacture furnaces on turn key basis for the following industries Rolling Mills Forging Plants Heat Treatment Centers Wire Drawing Plants Aluminum Plant Steel Plants • Guaranteed fuel consumption of as low as 33 ltr/ton for billet reheating furnaces

  7. DESIGN METHODOLOGY • Capacity Rating • Material Handeling • Hearth Loading • Heat Loading & Zoning • Automation levels • Planning of Combustion System

  8. Capacity Rating • Is fixed after deliberation with the Client • Depends on the size and mix of produce to be preheated. • The material of the billets play an important part in finalizing capacity.

  9. Material Handling • Predominantly Preheating furnaces can be divided into the following categories: • Pusher Type • Walking beam /Walking hearth • Rotary hearth • Considering the charge we plan the material handling

  10. Hearth loading • Based on the type of furnace hearth loading is determined , with the focus on • heat transfer , • Decarburization • pattern of heating i.e Top Heating or Top and Bottom heating

  11. Heat loading andzoning • Considering the design and capacity of the furnace different types and sizes of burners are recommended in the different zones of the furnace. • Types of Burners • LAP Burners • High Velocity/ Oxy Fuel

  12. Automation In the Furnace • In order to achieve greater efficiency in the furnace and further increase production and reduce scale losses the following automation in the furnace can be carried out: • Temperature Control • Pressure Control • Air/Fuel or Oxygen/Fuel Ratio Control

  13. Oxy Fuel Technology • Reduced Emissions NOx emissions are reduced substantially with a oxy-fuel conversion. • Improved Efficiency and Production Improvement in fuel efficiency as compared with traditional air-fuel furnaces. The energy savings partially offsets the cost of oxygen. There scale formation also comes down to 0.3% • Increased Furnace Refractory Life Temperature homogeneity of the furnace increases thus minimizing the chances of thermal shocks in the refractory • Simplified Operation With no recuperator, the furnace operation and maintenance are simplified

  14. 3D Images of the Proposed Furnace

  15. 3D Images of the Proposed Furnace cont.….

  16. 3D Images of the Proposed Furnace cont.…

  17. 3D Images of the Proposed Furnacecont….

  18. 3D Images of the Proposed Furnacecont.….

  19. CFD OF FURNACE

  20. RESULTS OF CFD ANALYSIS

  21. Case Study INDIAN STEEL AND WIRE PRODUCT (ISWP) , A Subsidy of TATA STEEL

  22. BACKGROUND OF ISWP • The Furnace was initially designed by OFAG , Germany. • The Furnace was designed to produce 30 to 32 Ton/hr • The Furnace was based on Bull Nose Design.

  23. PROBLEMS FACED BYISWP IN THE FURNACE • Frequent failure of the Roof and Bullnose of the Furnace • High Fuel Consumption up to 42 ltr/ton • Scale loss were as high as 1.5 % • The furnace controls were present but not operational • The Furnace throughput was limiting the production of steel

  24. SUGGESTION MADE BY ENCON • Furnace Modification • Redesigning the Bull nose design of the furnace by Camel Hump • Change in the design of the Roof Bricks and Hangers.

  25. SUGGESTION MADE BY ENCON • Combustion System • The top firing LAP burners of the heating zone of the furnace were replaced by High velocity burners on the side wall • The Soaking Zone burners were kept the same

  26. SUGGESTION MADE BY ENCON contd.. • Level 1 Automation • Automatic temperature control • This was achieved by placing 6 thermocouples in the furnace, 3 Thermocouples were placed in the soaking zone and 3 Thermocouples were placed in preheating zone. • The air to fuel ratio was governed by a combination valve. • The Furnace was divided into 6 zones three in soaking zone and three in Preheating zone.

  27. RESULTS ACHIEVED BYTHE RETROFIT • Fuel consumption has come down to 32.6ltr/Ton of steel produced. • Scaling is down to 1% • There has been no failure in the furnace for the last 1 year the furnace has been operational. • The furnace is constantly producing steel at the rate of 35 Ton/hr.

  28. CASE STUDY -2 Revamping of Furnace at TATA SSL, BOISAR

  29. PROBLEMS FACED BYSSL IN THE FURNACE • High Fuel Consumption up to 47 ltr/ton • Improper Soaking of the Billets • High Power Consumption by the Mill • Frequent break down of the Mill • The Furnace was only producing 36 Ton against the designed capacity of 45 ton

  30. MODIFICATIONS MADE BY ENCON • Heat Load calculation were done and accordingly the combustion equipment's were changed • Burners • Blowers • Recuperators • Air and Oil pipeline were redesigned and modified accordingly.

  31. MODIFICATIONS MADE BY ENCON contd.. • Complete refractory lining was done again • Walls • Roof • Hearth • Water Cooled skid

  32. RESULTS ACHIEVED • Increase in production by 16-25% from 36 tons/hr to 42-45 tons/hr. • Fuel consumption reduced by 23-30% from 47 ltrs/ton to 33-36 ltrs/ton. • Electrical Power consumption reduced by about 8%. • Reduction in breakdowns due to better quality heated billets

  33. DIVINE ALLOY, RANCHI25 ton/Hr BRHF

  34. Furnace Design • Designed a Top and Bottom fired furnace with water cooled skids and PID based control. • The furnace is designed for firing Mixed Gas (Blast Furnace Gas and Producer Gas). The gas will be either enriched with Oxygen or supplementary firing of furnace oil will be done. • All the combustion equipments are being supplied by us.

  35. ELEVATION OF THE FURNACE

  36. BURNERS • Oil Burners • Gas Burners • Dual Firing Burning Systems • High Velocity Burners (OIL/GAS) • Pilot Burner for Coke Oven Gas/ LPG/NG • Coke Oven & Blast Furnace Burner

  37. RECUPERATORS • Recuperators with flue temperatures of up to 950oC • Preheat temperature of combustion air as high as 450oC • Guaranteed savings of 15-20% and a minimum life of 3 years for ENCON Recuperators

  38. is a patented process for the combustion of fossil fuels with pure oxygen uses an undiluted high flame temperature, but keeps the same process temperatures combusts at or near stoichiometric retrofitted using the same furnace design and refractories Jupiter- Encon Oxy-Fuel Technology

  39. Conventional Combustion v/sOxy-Fuel Traditional Combustion • Air fuel fired 21% oxygen, 79% nitrogen • 3 to 5% excess air Relatively Low Flame Temperature Readily Available Nitrogen to Create NOX. Nitrogen Increases the combustion volumes 78% Potent heat escapes through Stack. Higher Flame temperature No change in furnace design and materials Possibility of variable processes No change in versatility of the usage Does not affect Inclusions/impurities in the re-melted aluminum

  40. OVENS BY ENCON • 3D DESIGNING & CFD. • In House CFD Modulation. • Energized by GAS HEATING ELEMENT. • Minimal Heat Loses . • MODULAR TYPE • Ceramic Fiber INSULATION • Proper Air CIRCULATION with minimum electric consumption. • TEMPERATURE UNIFORMITY • ENERGY CONSERVATION • 50% IN COST ( Approximately) • 20%– 30% IN CO2 EMISSIONS

  41. OVENS FOR TRNASFORMER INDUSTRY

  42. CORE DRYING OVENS FOR FOUNDARY

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