TUNNEL FURNACE 1 Continuous Scrap Preheating before charging

TUNNEL FURNACE 1. Continuous Scrap Preheating before charging in Induction furnace 2. Superheating of Billets in Hot Rolling Process WWW. ENCON. CO. IN 1

Company Profile q. Established in 1978 during energy crisis in India. q. Oriented towards energy Conservation q. Have introduced various New & Innovative technology to the market q. Well known for Designing, Manufacturing, Supplying and Commissioning of FUEL EFFICIENT HEATING SYSTEMS on Turn Key Basis q. Exporting to more than 35 countries world wide q. Presence in Various industries like : q. Steel , Aluminum & other non ferrous industries , Automobile, Foundries, Heat treatment Ceramics & refractories, Glass & Transformer WWW. ENCON. CO. IN 2

R&D ACTIVITIES q. ENCON THERMAL ENGINEERS has given the country many firsts in the field of Combustion technology, The R&D Activities in the company were officially started in the year 1997 q. Project sponsored by Gas Authority of India Limited (GAIL) and Ministry of Science & Technology in partnership with Indian Institute of Petroleum, Dehradun q. Developed gaseous film burner with savings of up to 16% compared to conventional burners q. Innovated Gas Heating Elements which can retrofit any heating elements (electric energized) application up to 550°C temperature q. Developed Burners for COKE OVEN & BLAST FURNACE GAS q. Developed Pilot Burners for Coke Oven/ Mixed Gas & LPG q. Developed & Tested Indigenously designed Regenerative Burners at almost 1/3 rd the cost of the imported systems WWW. ENCON. CO. IN 3

SCRAP PREHEATER Scarp is conveyed through a tunnel furnace using a conveyor , the furnace is fitted with burners with Short and intense flame. We aim to heat the scrap up to a max temperature of 450°C. The preheater burns all the volatile material on the scrap and raises the temperature of charge of the scrap and removes any dirt and moisture from the scrap material prior to charging in the furnace. Benefits of Preheating & Drying of Scrap are as following: - 1. Safer Work environment 2. Increased melt rate by up to 20% 3. Reduction in Electric power consumption up to 100 k. Wh/Ton of molten metal 4. Reduction in the overall cost of production 5. Increase in the life of refractory and electrode due to reduce in energy required for melting 6. Atmosphere around the furnace is also cleaner WWW. ENCON. CO. IN 4

Saving calculation for a 5 Ton Induction furnace BASE DATA Material Melting Temperature Preheat Temperature Cost of electricity C V of Natural Gas Cost of Natural Gas Working Hrs. Number of days : MS, Scrap : 1600 °C : 450 °C : 8. 5 Rs. /k. Wh : 8500 Kcal/Nm 3 : 25 Rs. /Nm 3 : 12 Hr. /day : 330 Days/Annually Energy USED /Cycle CASE a. Electrical load to melt 5 Tons/heat. MS material from ambient to 1600 °C : 2268 k. Wh CASE b. Electrical load to melt 5 Tons/heat. MS material from 450 °C to 1600 °C : 1822 k. Wh Fuel consumption to heat scrap 5 tons/heat from ambient to 450 °C : 56 Nm 3/hr. WWW. ENCON. CO. IN 5

Saving calculation for a 5 Ton Induction furnace ENERGY SAVINGS Electricity Saved Cost of Fuel used Total Saving Per Cycle = 2, 268 -1, 822 = 446 (k. Wh) = 446*8. 5 = 3, 791 (Rs) = 56*25 = 1, 400 (Rs) = 3791 -1400 = 2, 391 (Rs) Annual Saving considering 20 heats/day and 330 days of working Saving IN RUNNING COST = 2391*20*330 = 1. 57 Crore (Rs) Saving of Electricity Consumption = 446*20*330= 29, 43, 600 k. Wh =2, 943. 60 MWh CO 2 saving = 2943. 60 *1 ton(1) = 2, 945. 60 Ton of CO 2 produced by burning NG = 56*20*330*8500/860*. 20/1000 ton (2)= 730. 60 Ton of CO 2 NET SAVING IN CO 2 Annually = 2, 943. 60 -730. 60= 2, 213 Tons of CO 2 1. http: //cea. nic. in/reports/others/thermal/tpece/cdm_co 2/user_guide_ver 10. pdf 2. https: //www. volker-quaschning. de/datserv/CO 2 -spez/index_e. php WWW. ENCON. CO. IN 6

BILLET SUPERHEATER for Hot Charging The billets lose about 50 -100°C of their surface temperature and around 100 -200°C of their core temperature during the travel from the caster to the rolling mill during hot charging process. At these temperature, the rolling of billets lead to serious problems like: 1. Breaking of the rolls of the roughing mill 2. Miss Roll of the billet 3. Inferior quality of the finished product 4. Rejection of finished material Benefit of Billet Super Heaters are as following: 1. Properly Soaked billets 2. Reduction in the cost of electricity for rolling by up to 8% 3. 15 -30% (in running) cheaper than the Induction heater 4. 50% of the Capital cost of an Induction heater WWW. ENCON. CO. IN 7

Saving calculation for a 10 Ton/hr Mill Cost of electricity CV of Natural Gas Cost of Natural Gas Working Hrs. Number of days Gas Consumption : 8. 5 Rs. /k. Wh : 8500 Kcal/Nm 3 : 25 Rs. /Nm 3 : 12 Hr. /day : 330 Days/Annually : 40 Nm 3/Ton Case 1. Reheating of Billet from Ambient to 1, 100 °C Cost of fuel(NG) : 40*10 x 25 = Rs. 10, 000/hr. Cost of Running Blower : 30*. 75*8. 5 = Rs. 191. 25/hr. CASE 2. Superheating by Induction Heater(to raise billet temperature by 200 °C) Cost of Running : 1000*8. 5 =Rs. 8, 500/hr. CASE 3. Superheating by Tunnel Heater(to raise billet temperature by 200 °C) Cost of Fuel(NG) : 9. 3*10*25 = Rs. 2, 325/hr. CO 2 Production/Annually 1. Reheating furnace (CO 2) Produced : 3, 220 Tons of CO 2 (1, 2) 2. Induction Furnace (CO 2) Produced : 3, 960 Tons of CO 2 (1) 3. Tunnel Furnace (CO 2) Produced : 728 Tons of CO 2 (2) 1. http: //cea. nic. in/reports/others/thermal/tpece/cdm_co 2/user_guide_ver 10. pdf 2. https: //www. volker-quaschning. de/datserv/CO 2 -spez/index_e. php WWW. ENCON. CO. IN 8

Savings calculation for a 10 Ton/hr Mill Annual Savings in Running Cost of the Tunnel Super Heater in comparison to: 1. Reheating furnace(Rs): 7866. 25*12*330 = Rs. 3. 11 Crore /Annum 2. Induction Furnace(Rs): 6175*12*330 = Rs. 2. 44 Crore /Annum CO 2 Savings per annum : 1. Reheating furnace (CO 2) Produced : 2, 492 Tons 2. Induction Furnace (CO 2) Produced : 3, 232 Tons WWW. ENCON. CO. IN 9

Contact Details Vishve Bandhu Mahendra vbm@encon. co. in +91 981 006 3702 J P Singh Puneet Mahendra Atul Saxena vadodara@encon. co. in pm@encon. co. in as@encon. co. in +91 982 509 7240 +91 997 149 9079 +91 965 090 0279 WWW. ENCON. CO. IN 10