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USE OF COKELESS (GAS FIRED ) CUPOLA CUSTOMERS PERSPECTIVE BY GUDURU MURALI

USE OF COKELESS (GAS FIRED ) CUPOLA CUSTOMERS PERSPECTIVE BY GUDURU MURALI. WELCOME TO PORWAL GROUP OF INDUSTRIES. PORWAL IS A WELL KNOWN AND ETABLISHED INDUSTRIAL GROUP IN M.P. STARTED IT’S BUSINESS IN THE YEAR 1963 AS A MANUFACTURER OF DIESEL ENGINES WITH A BRAND NAME FIELD MASTER.

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USE OF COKELESS (GAS FIRED ) CUPOLA CUSTOMERS PERSPECTIVE BY GUDURU MURALI

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  1. USE OF COKELESS (GAS FIRED ) CUPOLA CUSTOMERS PERSPECTIVE BY GUDURU MURALI

  2. WELCOME TO PORWAL GROUP OF INDUSTRIES • PORWAL IS A WELL KNOWN AND ETABLISHED INDUSTRIAL GROUP IN M.P. STARTED IT’S BUSINESS IN THE YEAR 1963 AS A MANUFACTURER OF DIESEL ENGINES WITH A BRAND NAME FIELD MASTER. • PORWAL GROUP HAS THEIR IDENTITY IN 5 DIFFERENT FIELDS • MANUFACTURE OF DUCTILE (S.G ) AND GREY CAST IRON CASTINGS • A COMPLETE HOUSE FOR MACHINING SOLUTIONS CONVENTIONAL & CNC • MANUFACTURE OF DIESEL ENGINES • MANUFACTURE OF SUPER ENAMELLED & SUBMERCIBLE COPPER WIRES • MANUFACTURE OF DECORATIVE ITEM CASTING PRODUCTS

  3. PORWAL AUTO COMPONENTS LTD. • ESTABLISHED IN THE YEAR 1995. • WE ARE AN AUTOMOBILE(S.G/GREY IRON) FOUNDRY WITH AN INSTALLED CAPACITY OF 1750 MT/MONTH • PRESENTLY PRODUCING AROUND 1200MT/MONTH • PACL PRODUCES ALL TYPES OF AUTOMOBILE CASTINGS OTHER THAN BLOCKS AND HEADS

  4. FACILITIES • HAVE TWO ARPA 450 CONVENTIONAL MOULDING LINES WITH SEMI AUTOMATED /MECHANISED MOULD HANDLING AND POURING SYSTEMS. • HIGH PRESSURE MOULDING LINE OF FONDARC. • AUTOMATED SAND PLANT OF 80 TPH WITH COOLING AND DUST EXTRACTION SYSTEM. • WELL ESTABLISHED CNC MACHINE SHOP.

  5. FACILITIES MELT SHOP CONSISTS • 650 KW 1000 KG DUAL TRAK FURNACE OF INDUCTOTHERM MAKE. • 1500 KW 2000 KG DUAL TRAK FURNACE OF INDUCTOTHERM. • GAS FIRED COKELESS TWIN CUPOLA OF WESMAN WITH 3T/Hrs CAPACITY.

  6. GAS FIRED COKELESS CUPOLA WHY GAS FIRED CUPOLA • PACL HAD COKE FIRED CUPOLA ALONG WITH INDUCTION FURNACE • PROBLEMS ASSOCIATED WITH COKE TYPE CUPOLA,POLLUTION AND POLLUTION CONTROLLING EQUIPMENT. • POLLUTION RELATED ISSUES WITH PCB’S • HIGH OPERATION AND ENERGY COSTS • PACL DISMANTLED COKE TYPE CUPOLA AND INSTALLED GAS FIRED COKELESS CUPOLA IN THE YEAR 2006

  7. HIGHLY POLLUTANT NEED POLLUTION CONTROL EQUIPMENT NEED EXPERT OPERATOR TO OPERATE POOR INSTRUMENTATION MORE POLLUTION RELATED ISSUES WITH PCB’S NO CONTROL ON HEAT INPUT SULPHUR PICKUP NO POLLUTION,CLEAN ENVIRONMENT DOES’NT REQUIRE POLLUTION CONTROL EQUIPMENT DO NOT REQUIRE EXPERT,EASY OPERATION GOOD INSTRUMENTATION LESS HURDLES WITH PCB’S PLC OPERATED,HEAT INPUT CAN BE CONTROLLED NO SULPHUR PICKUP • COKE TYPE Vs COKELESS CUPOLA

  8. INDUCTION FURNACE VS COKELESS CUPOLA EASY TO OPERATE BETTER CONTROLS ENERGY EFFICIENT LOW LINING COST NO LIMITATION ON CHARGE MATERIALS NEED POLLUTION EQUIPMENT INITIAL COST IS HIGH EASY TO OPERATE BETTER CONTROLS LESS ENERGY EFFICIENT HIGH LINING COST LIMITATION IN USING VARIETY OF SCRAP DO NOT REQUIRE POLLUTION EQUIPMENT INITIAL COST IS LOW

  9. GAS FIRED CUPOLA

  10. GAS FIRED CUPOLA

  11. GAS FIRED CUPOLA CHARGE MIX • PIG IRON 35-40% • RUNNER RISER,REJECTED CASTINGS 40-45% • SPILLAGE & TRAMP IRON 10-15% • C.I.BRIQUETTES 10-15% • TAPPING TEMPERATURE 1320-1350 Deg.C

  12. GAS PREUSSURE REGULATOR AIR PRESSURE SWITCH DIFFERENTIAL PRESSURE TRANSDUCERS AIR AND GAS MODULATING VALVES FUEL SHUT OFF SOLENOID VALVES MANOMETERS BAROW METER 5POSITION ROTARY SWITCH MMI REGULATES THE GAS PRESSURE BASED ON FLOW REUIREMENT TO IDENTIFY THE BLOWER RUNNING TO GIVE FEEDBACK TO PLC THE RATE OF AIR & GAS FLOW TO CONTROL THE FLOW OF AIR AND GAS TO CLOSE THE GAS IN CASE OF EMERGENCIES TO MAINTAIN DIFFERENTIAL PRESSURE OF AIR AND GAS FOR EACH BURNER TO MAINTAIN THE INTERNAL PRESSURE. TO CONTROL THE MELT RATE TO SET AND MONITOR AIR & GAS PARAMETERS • INSTRUMENTATION

  13. CONTROL PANEL

  14. INSTRUMENTATION GAS LINE PRESSURE REGULATOR AIR PRESSURE SWITCH

  15. INSTRUMENTATION GAS SHUT OFF VALVE AIR MODULATION VALVE

  16. INSTRUMENTATION DIFFERENTIAL PRESSURE TRANSDUCER INTERNAL PRESSURE GUAGE

  17. IMPROVEMENTS MADE BY PACL • MODIFIED LINING METHOD TO IMPROVE HEARTH LINING LIFE FROM 48 HRS TO 144 HRS • RE INSTALLED BLOWERS AND CONTROL PANELS IN THE MAZZENINE FROM GROUND TO AVOID BREAKDOWNS & MORE WORKING SPACE • INTRODUCED RR BREAKER TO IMPROVE PACK DENSITY. • IMPROVED WATER COOLING SYSTEM TO IMPROVE GRATE BAR AND LINING LIFE • IMPROVED SKIP HOIST TO MINIMISE BREAKDOWNS • INTRODUCED GRANULATION OF SLAG FOR EASY DISPOSAL & FOR BETTER WORKING ENVIRONMENT • INTRODUCED BRIQUETTING FOR COST SAVING

  18. INTRODUCED SLAG GUTTER FOR GRANULATION

  19. BLOWERS & CONTROL PANEL SHITED TO MAZZENINE

  20. INTRODUCED RR BREAKER TO IMPROVE PACK

  21. 15-20% BRIQUETTES ARE USED IN THE CHARGE FOR COST SAVING • INTRODUCED BRIQUETTING MACHINE • FOR BRIQUETTING CI BOARING

  22. COMPLETE CUPOLAS

  23. CONCLUSION • PACL BELIEVES GAS FIRED CUPOLA IS AN ALTERNATE PRIMARY MELTING SOURCE WHERE • POLLUTION IS A MAJOR HURDLE • POWER IS A MAJOR HURDLE • NOT A REPLACEMENT FOR INDUCTION FURNACE

  24. THANK YOU

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