BEE Brass Jamnagar Cluster Presentation_v1

8/7/2019 BEE Brass Jamnagar Cluster Presentation_v1

1/15

BEE SME Program in

Jamnagar Brass Cluster

November 19, 2009


2/15

Presentation ContentsPresentation Contents

Brief introduction of cluster

Energy utilization profile in Brass units

Energy conservation opportunities in Brass units

Possible technology modifications

Barriers/issues in Energy Efficiency Penetration


3/15

Cluster Brief OverviewCluster Brief Overview

About cluster:

Around 2500 units: GIDC Shankartekri, Udyognagar & Dared

Type of units: Brass foundry, Brass parts Manufacturing, Electroplating &

Extrusion Products: Cycle wall tubes, Battery terminals, Electrical parts, stove parts,

Furniture products & Pen parts etc..

Raw materials: Brass scrap, Copper, zinc, Lead & other metal alloys

Average production: 20-50 tons per month & 200-500 tons per month

(Extrusion)

Energy cost is : 25-35% in Foundry, 3-7% in Manufacturing & 3-5% in

Electroplating of production cost

Around 15-20% of energy efficiency potential existing in cluster


4/15

Fuel used & typical end useFuel used & typical end useenergy requirementenergy requirement

Major fuels used in cluster are: Electrical Energy

Coal

Furnace oil

Typical End use energy

requirement In Brass foundry

units: 200 Kg of coal/day

10 hp Electrical Energy

In Brass parts Manufacturing &

Electroplating units:

10-30 hp Electrical Energy


5/15

Major Energy ConsumingMajor Energy Consuming

EquipmentsEquipments

Melting furnaces

Induction furnaces

Reheating furnaces

Annealing furnaces

Hydraulic press (Motors)

Blowers

Cooling towers

Pumps

Compressors


6/15

Typical process flow chartTypical process flow chart

Preparation of raw material &

feeding into Crucible

Energy consuming process

Pouring into Moulds

Melting

Thermal Energy

Electrical Energy

Electrical Energy

Electrical Energy

Preparation of raw material &

feeding into Crucible

Cutting the edges

Punching operation

Drilling operation

Smoothing and Threading

Cleaning

Electroplating

Energy consuming process

Pouring into Moulds

Melting

Thermal Energy

Preparation of raw material &feeding into Crucible

Electrical Energy

Electrical Energy


7/15


8/15

Reheating Furnace (contd..)

Air-fuel control mechanism, forefficient combustion

Installation of waste heat recoveryoption in Reheating furnace

Improved design of recuperativesystem in Reheating furnace

Exhaust gasses location in Reheatingfurnace

Insulation of fuel supply & air supplylines

Energy Conservation OpportunitiesEnergy Conservation Opportunities

Contd../-


9/15


Melting Furnace

Improving the melting furnacelining and insulation

Redesign of melting furnace

Temperature control of moltenmaterial

Fuel switching option inmelting furnace

Selection and proper capacity

and scientifically designedblower

Air-fuel control system

Contd../-


10/15


Induction Furnaces

Reducing the loading time of raw

material (using the bundle raw

material instead of uneven scrap)

Improving the power factor ofinduction furnace

Reducing the idle time by installing

exclusive energy meters for

Induction furnace

Percentage load in InductionFurnace

Adopting Best Operational

Practices

Contd../-


11/15


Electrical utilities:

Replacement of conventional motorswith Energy Efficient ones

Use of flat belts in place of

conventional belts

Replacement of conventionalBlowers with efficient ones

Adopting Best Operational PracticesBlowers & Compressors

Replacement of conventional coolingtowers with efficient ones

Installation of timers in coolingtowers

Contd../-


12/15

Possible Technology Upgradations in clusterPossible Technology Upgradations in cluster

Areas for

Energy

conservation

Existing

technology

Opportunities for technology

modifications

Percentage of

energy saving

potential (%)

Melting furnace

(Crucible)

Crucible melting

furnaces using

coal as fuel formelting Brass

Redesigning of existing melting furnace (by increasing

the hot gasses retention time and temperature control of

molten material)

5-10%

Shifting to gas operated melting furnace 15-20%

Shifting to electrical operated induction melting furnace 20-25%

Reheating

furnace

Reheating

furnaces using

furnace oil to

reheat billets

Redesigning of existing reheating furnace (by waste heat

recovery options in flue gas, optimal control of air-fuel

system)

4-10%

Shifting to gas operated reheating furnace 12-18%

Shifting to electrical operated reheating furnace 15-20%

Molding system Manual molding

Continuous casting machineProductivity and

quality improvement

Low pressure die casting machineProductivity and

quality improvement


13/15

Issues/Barriers in penetration ofIssues/Barriers in penetration ofEnergy EfficiencyEnergy Efficiency

Lack of awareness on the Energy efficiency

Lack of organizational commitment

Narrow focus on Energy

Not clear about their existing level of operations andefficiency, due to lack of instrumentation & nonavailability of Energy consumption data

Limited manpower

Lack of trained manpower Limited information on new technologies

Implementation cost of Energy conservation options


14/15


15/15

Status / Work Progress in ClusterStatus / Work Progress in Cluster

Completed Energy use & Technology audit studies in 40units

Identified the areas of major energy consuming equipments

Identified Energy conservation measures in various types ofbrass industries

Identified possible technology modifications in the cluster

Local service providers identified for above technologies

Technology suppliers are identified for above technologies

Drawings & Development of proto concepts for newtechnologies are under finalization

Implemented the no or low cost measures in the cluster

Date post:	08-Apr-2018
Category:	Documents
Upload:	gangadharkasinathsastry
View:	220 times
Download:	0 times

BEE Brass Jamnagar Cluster Presentation_v1

Documents