ENCON THERMAL ENGINEERS

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

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

3. 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 FURNACES on Turn Key Basis • Supplied the first Coal Fired furnace to Kissan Eng works, Bulandsher in 1982 • Supplied the first bull nose furnace in 1983 to Mohata Ispat, Ratlam

4. cont… • After supplying more than 50 furnaces in India ,modified over 10 Turnkey Rolling mills (including new furnaces from 5-20 Ton/hr) in Africa. • The first “Camel Hump” Furnace was supplied to GTB Colombo in 1995. • In 1996 we carried out major modifications for TATA SSL, Tarapur in their 45 Tons/hr Top and Bottom heating furnace. This included designing, re-engineering, complete combustion equipments, Recuperator etc.

5. cont… • The achievements at TATA SSL of nearly 25% Energy savings and 20% production increase was widely published in all the leading publications of the world

6. FEATURES • 3D DESIGNING • In House CFD Modulation • Energised by COG/FO/LPG/NG etc • Minimal Heat Losses • MODULAR TYPE • REFRACTORY and INSULATION • TEMPERATURE UNIFORMITY • OXY FUEL HEATING • ENERGY CONSERVATION • Fuel consumption 33 ltr/ton • Scale losses max 1%

7. BASIC PARAMETERS • Capacity Rating • Material Handling • 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 determining the capacity.

9. Material Handling • Predominantly Reheating 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 and zoning • Configuration of the burners in the Soaking, Heating and Preheating Zones are rationalized from the following types of burner mix: • LAP Burners • High Velocity • Oxy Fuel Firing

12. Automation • Temperature Control • Pressure Control • Air/Fuel • Oxygen/Fuel Ratio Control The above can be automated to Level 4(PLC based) Controls.

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 OF INDIAN STEEL AND WIRE PRODUCT (ISWP) , A Subsidy of TATA STEEL

22. BACKGROUND • The Furnace was initially designed by OFAG , Germany. • Rated Capacity 30 to 32 Ton/hr • Bull Nose Design.

23. PROBLEMS FACED • Frequent failures of the ‘Roof’ and ‘Bull-nose’ of the Furnace • High Fuel Consumption (up to 42 ltr/ton) • Scale loss as high as 2 % • No Auto controls • Interrupted production

24. MODIFICATIONS CARRIED BY ENCON • Furnace Modification • Except for Hearth and 2 meters of Preheating Zone the complete furnace was redesigned • ‘Bull Nose’ was changed to ‘Camel Hump’ design • Change in the design of the Roof Bricks and Hangers for longevity

25. cont.. • Combustion System • Soaking zone burners were retained as LAP burners • Heating zone burners were changed to High Velocity with their placement done on side walls for uniformty

26. cont.. • Level 1 Automation incorporated • 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 controls were divided into 6 zones - 3 in soaking zone and 3 in Preheating zone.

27. Design of The Old Furnace

28. Design Of the Modified Furnace

29. ROOF BEFORE AFTER

30. BULL NOSE/CAMEL HUMP BEFORE AFTER

31. SIDE WALL BEFORE AFTER

32. RESULTS • SFC 32.6 ltr/Ton (earlier 42 ltr/ton) • Scaling is down to 1%(earlier 2%) • Continuous operations for 2 years (earlier breakdowns every 3 months) • Uninterrupted yield of the rated capacity of 33-35 Ton/hr.

33. Future Plans • OXY-FUEL firing in the Heating Zone • Level 4 controls – Temperature & Pressure • Top-Bottom heating to use 150 mm cross section of Billets/Blooms

34. THANK YOU! “ Adopt eco-friendly technologies that your children can be proud of ” Vishve Bandhu Mahendra