Enegy Auditing

7/21/2019 Enegy Auditing

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PROJECT DISSERTAION

Table of Contents

1 Introduction to Project.....................................................4

1.1 Project Title:......................................................................................... 4

Implementation of Energy Conservation System in Heat Treatment Furnaces................4

1.1.1 Imortance of Project!.............................................................................................. 4

It is often found tat energy cost is one of te igest operating costs along !it la"our and

material in any industry. #ut of tese elements energy is te area !ere cost reduction

can "e done !it te proper understanding of te minimum re$uired energy levels and "y

arresting energy !astages in te system.................................................................. 4

1.1." Objecti#e of t$e Project!.......................................................................................... 4

1.% Project content..................................................................................... 4

1.& 'ene(ts to te company........................................................................ 5

" Introduction %$arat &or'e (imited....................................6

%.1 Introduction......................................................................................... 6

%.% )ision * Strategy.................................................................................. 6

%.& +lo"al Presence.................................................................................... 7

%., History................................................................................................ 8

%.- anufacturing Process Flo! at 'arat Forge: /0a! material in!ard to sipment 9

%.2 Functional 3epartments at 'arat Forge................................................... 9

) C$ater! Introduction to Self ..........................................11

* (iterature Re#ie+...........................................................12

,.1 Introduction........................................................................................ 12

,.% 4at is energy Conservation................................................................. 12

,.& Furnace 3esign:.................................................................................. 13

,., +eneral 5spects of Energy anagement..................................................13

*.*.1 Ener', scenario......................................................................................................... 13

*.*." Ener', and En#ironment........................................................................................ 15

*.*.) Ener', Strate',......................................................................................................... 15

,.- 'asics energy and its various forms........................................................ 15

*.-.1 Denition!.................................................................................................................... 15

*.-." Di/erent forms of ener',...................................................................................... 16

*.-.) 0rades of ener',....................................................................................................... 16

*.-.* %asics of Electrical Ener',.................................................................................... 16

,.2 Energy anagement and 5udit:............................................................. 17

*..1 Denition!.................................................................................................................... 17

*.." 2$at is Ener', Audit............................................................................................... 17*..) Need for Ener', Audit............................................................................................. 17

*..* Ener', Audit3 T,es 4 5et$odolo',.................................................................. 18

1



- %&(6s Continuous &urnace Desi'n /,666 7g 8 Hour capacity 9uenc and

Temper Furnace................................................................19

-.1 Heat Treatment Process: 9uenc * Temper.............................................. 19

-.% #perating Temperature and eat treatment cycle:.....................................19

-.& Furnace inside dimensions and ;oading of <o"s:....................................... 19

-., Fuel:..................................................................................................19

-.- Temperature uniformity and control:....................................................... 20

-.2 =um"er of control >ones....................................................................... 20

-.? Heating capacity * Connected ;oad:.......................................................20

-.@ Furnace insulation:.............................................................................. 21

-.A Instrumentation:................................................................................. 21

-.7.1 Temerature Control S,stem................................................................................ 21

-.7." Temerature Recordin'.......................................................................................... 21

-.7.) Control Panel!............................................................................................................. 22

-.7.* Tra, $andlin' s,stem!............................................................................................. 22

-.16 Tecnical Speci(cation 'F;Bs Continuous Furnace /9uenc * Temper ,666 7g 8 Hour 23

-.11 'F;Bs ,666 7g8Hour Continuous Furnace output........................................ 24

-.1% Introduction to Heat Treatment 3epartment............................................. 25

-.1& Heat Treatment #perations................................................................... 25

-.1).1.................................................................................................Annealin' 26

-.1)."............................................................................Iso8T$ermal Annealin'8 26

-.1).).............................................................................................. Normali9in' 26

-.1).*................................................................................................:ardenin' 26

-.1).-................................................................................................Temerin' 26

-.1)........................................................................................Stress Relie#in' 26

-.1).;...................................................................................................Nitridin' 26

-.1, Heat Treatment 3epartment Current Production ;evel................................27

-.1- Temperature 0anges............................................................................ 27

-.12 3epartment !ise Energy 0eports........................................................... 27

-.1? Fuel Consumption data......................................................................... 31

6 Importance of the project......................................................32

7 Energy Audit Study - eat !reatment "urnace#............................33

?.1 4at is Com"ustion........................................................................... 34

?.% HE5T ;#SS C5;CD;5TI#=S.................................................................... 34

?.& Energy Ecient #pportunities............................................................... 36

?., Energy 5udit of Continuous Furnace CF 1&1,...........................................37

?.- Furnace and Processing 3etails.............................................................. 38

?.2 Total Heat input in Gcal......................................................................... 38

?.? Total Heat losses in 7Cal....................................................................... 39

?. #"servations for furnace 3oor #pening................................................... 44

2



?.@ In a eat treatment furnace te eaust gases are leaving te furnace at 266oC at te

rate of A66 m&8our. Te total eat recovera"le at 1@6oC (nal eaust can "e calculated

as..................................................................................................... 53

?.A Types................................................................................................ 11

;.7.1 11

< 0esearc etodology........................................................ 12

@.1 etodology.......................................................................................12

7 3ata Collection.................................................................. 13

A.1 dfgdfgdf .............................................................................................13

A.% fgdfgfdStra......................................................................................... 13

A.& process.............................................................................................. 14

system. 5s so!n "elo!:............................................................14

7.).1 +aste in......................................................................................................................... 14

1= Current status of te Project................................................1$

11 Future Scope of te Project..................................................16

1" Conclusion........................................................................ 17

1) 0eferences.......................................................................19

1* 'i"liograpy:.....................................................................19

1- 5""reviations....................................................................2%

1 ;ist of (gures....................................................................21

1; 5ppendices:......................................................................22

3



1 Introduction to Project

1.1 Project Title!

Implementation of Energy Conservation System in Heat Treatment Furnaces

1.1.1 Imortance of Project!

It is often found tat energy cost is one of te igest operating costs along !it

la"our and material in any industry. #ut of tese elements energy is te area

!ere cost reduction can "e done !it te proper understanding of te minimum

re$uired energy levels and "y arresting energy !astages in te system.

Te energy consumption and te energy cost are te major factors in te

industry across te glo"e. Tere are many initiatives and developments are

appening across te industry to reduce te energy consumption and te energycost. 'arat Forge as also initiated action to minimise te energy consumption

and in turn te energy cost. In te todayBs competitive mar7et it is necessary to

"ring do!n te manufacturing cost !itout compromising on te $uality of te

products.

In te forging process it is re$uired to eat te ra! materials /"illets to certain

temperatures to improve te forga"ility of te material. #nce te forgings are

made te eat treatment is re$uired to improve mecanical properties andmetallurgical properties as per te customer speci(ed re$uirements.

Heating of te material is important in "ot te processes i.e. Forging * Heat

Treatment.

Tis eating is carried out in te dierent furnaces using dierent eating

mediums. In te total manufacturing cost forgings major sare is consumed "y

te energy cost.

1.1."Objecti#e of t$e Project!

#ut of 'F;Bs total energy cost almost 18,t of te cost is re$uired for eat

treatment process. 5n o"jective as "een set to reduce te eat treatment cost

"y 8-10% from the quarter IV of this year 2013-14 !ic elps to "ring

do!n te total manufacturing cost of te components or products.

Te main o"jective is to eplore te "est possi"ilities to minimise te !astage of

te energy and increase te savings.

5oreo#er3 it $els in sa#in' t$e non8rene+able fuels for lon'er use b,

man>ind.

4



Tere are additional inerent etra ordinary advantages of tis project li7eJ it !ill

reduce te environmental pollution C#% footprint reduction etc.

1." Project content

Te contents of te project are as given "elo!

To (nd out te energy !astages troug energy audits To improve te energy monitoring system

To study te design of eat treatment furnaces

To study dierent energy conservation tecni$ues

To study 'F;Bs continuous eat treatment process * identify te energy

improvement opportunities analyse te data "efore and after

improvements

1.) %enets to t$e coman,

Improved energy cost

+ro!t in te pro(t margin

Improved furnace eciency

5



" Introduction %$arat &or'e (imited

".1 Introduction

'arat Forge ;td. te Pune "ased Indian multinational * te Kagsip

company of te over LDS%.- "illion Galyani +roup is a glo"al forging

conglomerate. It is te largest eporter of auto components from India and

leading cassis component manufacturer in te !orld. 5 tecnology driven

glo"al leader endtoend capa"ility and manufacturing footprint across India

+ermany S!eden DS * Cina te company manufactures a !ide range of

igly engineered critical * safety components for several sectors including

5utomo"ile #il * +as 0ail * arine Energy /across rene!a"le *

nonrene!a"le sources Construction * ining and general engineering. 5

customer "ase tat includes virtually every glo"al automotive #E and Tier I

supplier 'F; today is among te fe! glo"al auto component manufacturers!it capa"ility to oer front line design * engineering dual sore

manufacturing and full service supply capa"ility.

'arat Forge is currently speareading a major up scaling of its capacity in

forging casting fa"rication macining and assem"ly to launc its multi

sectoral gro!t plans across sectors suc as energy transportation

construction * mining.

6



"." ?ision 4 Strate',

In epanding glo"al mar7ets tecnology "ased innovation is te most

important driver of gro!t. 4e ave "een "uilding !orld class manufacturing

plants and reacing glo"al scale capacities in our line of "usinesses. 4e are

no! "uilding partnersips !it major glo"al #Es and Tier I companiesaround te !orld oering full service supply capa"ility. Innovation runs

troug everyting tat !e do. #ur tas7 is to move fast in te direction set "y

our igly focused strategies. 4e "elieve tat fast eecution of our strategies

imparts tremendous velocity for us and our customerBs progress

".) 0lobal Presence

'F; is among te (rst in te Indian automotive component industry to ave

adapted inorganic gro!t as a means to esta"lis a glo"al manufacturingfootprint. In %66, 'F; ac$uired Carl 3an Peddingaus /C3P te %nd largest

forging company in +ermany tat is mainly engaged in te manufacture of

passenger car components follo!ed "y C3P 5luminiumtecni7 a company in

+ermany tat manufactures aluminum components for automotive

applications.

In %66- 'F; ac$uired Federal Forge no! 7no!n as 'arat Forge 5merica Inc.

!ic provided 'F; !it a manufacturing presence in DS5 M one of its largest

mar7ets. Tis !as follo!ed "y te ac$uisition of Imatra Gilsta 5' S!eden

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along !it its !olly o!ned su"sidiary Scottis Stampings Scotland

/togeter called as Imatra Forging +roup. In 3ecem"er %66- 'arat Forge

signed a <) !it F54 Corporation te largest automotive group in Cina.

Troug tis <) 'F; made a po!erful entry into te large and fast gro!ing

Cinese automotive mar7et. Te Forging Company of te F54 group is te

largest in Cina and "y joining ands !it tem 'F; instantly "ecame te

largest forging company in Cina.

Tese ac$uisitions ave provided 'F; access to customers in ne!

geograpies enanced tecnological capa"ilities and enlarged te

companyBs product range.

4it manufacturing facilities spread over 11 locations and - countries M , in

India & in +ermany 1 eac in S!eden =ort 5merica and % in Cina 'arat

Forge ;imited today is a glo"al corporation !it !orldclass engineering

capa"ilities stateofteart manufacturing facilities ig levels of service

and a glo"al customer "ase.

".* :istor,

N'arat Forge ;td is one of te most innovative and eciting companies to

emerge in te istory of te forging industry.

Te Indian 5utomotive Industry in te -6Bs !as more li7e te story of

imported 7its. 5ncillaries !ere nominal and infrastructure !as scarce and

inade$uate. It !as ten tat 'arat Forge came into eistence in 1A21 to

meet te forging needs of te Indian 5utomotive Industry.

Te ?6Bs !itnessed a spurt in te Indian forging industry !it more and moreunits coming up. For 'arat Forge it !as a period of consolidation and

gro!t. 4it te largest integrated facilities in 5sia and an un"eata"le trac7

record 'arat Forge emerged as te undisputed leader te (rst name in te

forgings industry in India.

4it an empasis on diversi(cation te @6Bs sa! 'arat Forge gro! from a

primarily automotive ancillary to an engineering enterprise focusing on

tecnological supremacy resilience and total customerorientation.

8



Today te art of forging metal is a tradition at 'arat Forge and all of our

products are "uilt !it te epertise necessary to accommodate various

industries. Eac customer speci(cation is carefully transformed into a cost

ecient reality. Every part !e create is a representation of our overall

dedication to craftsmansip.

5n outstanding reputation for customer service coupled !it te

anagement commitment to $uality as made 'arat Forge te preferred

domestic and glo"al supplier for major #EBs. Dnder te intense and caring

supervision of te Cairman * anaging 3irector r. 'a"asae" =. Galyani

te company continues to epand and its mar7ets continue to gro! !ile te

goal remains te same : to deliver competitive $uality products and services

time after time.

".- 5anufacturin' Process &lo+ at %$arat &or'e! /0a! material in!ard to

sipment

". &unctional Deartments at %$arat &or'e

ain facilities availa"le at 'arat Forge ;td. Pune are:

F#0+I=+ M It is te !or7ing of metals into a useful sape "y ammering or

pressing. Tere are & main sections dedicated to!ards tis operation

• C3F3 /Close 3ie Forging 3ivision M it includes & sops namely F3 1 % &

/Forge oderni>ation 3ivision !ic in all contains 1% presses.

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• #pen die Forging 3ivision M it includes % sops namely Heavy Forge

3ivision /HF3 1 * %.

• Forge Sop M it is te only sop !ere forging is carried out using

ammers.

5CHI=I=+ M It is te surfacing or (nising of te forged components. Tere are % main sections dedicated to!ards tis operation

• C3 /acined Component 3ivision 1

• C3 /acined Component 3ivision %

HE5T T0E5TE=T M It is mainly performed at Heat Treatment Sops. Tere

are total , eat treatment sops in C3F3 3ivision * % Heat Treatment

sops in HF3 3ivision.

3IE 3ESI+= * 5=DF5CTD0I=+ M Set of dies are (rst designed in te C3F3

Engineering section * ten manufactured in te 3IE SH#P.

9D5;ITO C#=T0#; * TEST CE0TIFIC5TI#= M It is done for "ot te 0a!

aterial as !ell as te forged components. Te certi(cation is divided in to

% aspects etallurgical /Pysical Properties of te (nised products and

3imensional.

etallurgical Certi(cation is done "y etallurgical 9uality Control /9C

Section and te 3imensional certi(cation is done "y te Inspection 9uality

Control /I9C department.

T053I=+ M Tere are % dierent segments in tis division one is for te

domestic mar7et /Sales 3ivision and te oter one is for international

mar7et. /IT3 International Trade 3ivision

10



) C$ater! Introduction to Self

I ave completed my 3iploma in etallurgical Engineering from +overnment

Polytecnic Pune in te year 1AAA. I ave started my carrier as a Trainee

engineer. y total eperience is 1, years. #ut of my total 1, year eperience

last @ years I am associated !it 'arat Forge ;imited till te date. y alleperience is in te (eld of etallurgy specialisation in eat treatment of

metals. I am aving ands on eperience of )acuum Heat Treatment Plasma

=itriding P)3 * C)3 coatings conventional eat treatment processes gas

nitriding car"urising car"onitriding etc.

I am !or7ing !it 'arat Forge Since Septem"er %662. I ave joined 'F; as an

N5ssistant anager and no! I am !or7ing as a NSenior anager eat

treatment department. I am reporting to te )ice President M Heat Treatment. y0ole and responsi"ilities are as mentioned "elo!

• Inprocess 9uality control

• =e! Part 3evelopment

• )endor 3evelopment for Heat Treatment of forgings.

• 5erospace parts eat treatment

• Implementation of certi(cations TS 12A,A8 5SA166 8 =53C5P 8 C9IA

•

Cali"ration of Heat Treatment E$uipments * Instruments.• Training * Continuous Improvement

11



* (iterature Re#ie+

*.1 Introduction

;iteratures survey is performed on furnace design te general aspects of te

energy management energy eciency in termal utilities and te energy

eciency in Electrical utilities Energy performance assessment for e$uipment

and energy audits. Te feasi"ility of deploying te tecni$ues or ideas

discovered troug te literature survey is cec7ed to use of it at eat treatment

furnaces at 'arat Forge ;imited.

*." 2$at is ener', Conser#ation

“ Energy Conservation and Energy Efciency are separate, but related concepts.

Energy conservation is achieved when growth o energy consumption is reduced,

on the other hand energy efciency is achieved when energy intensity in a

specic product, process or area o a production or consumption is reduced

without aecting output, consumption or comort level” Source! %ureau of

Ener', E@cienc,3 %oo> I3 "=113 a'e no. "1

Energy eciency is an integral part of te energy conservation. any energy

eciency projects are "ased on te use of cange of te energy resources.

Tere are certain teoretical "ases to manage te energy eciently "ut !e are

still aving a long !ay to acieve it. Te practices of energy eciency is started

after te (rst oil crises in te year 1A?& and over te time period it as

increased to a great etent considering te limitation of te availa"ility of te

energy resources. Te "ene(ts of te energy eciency is as given "elo!

Source! %ureau of Ener', E@cienc,3 %oo> I3 "=11

12



*.) &urnace Desi'n!

4ile designing eat treatment furnaces follo!ing tings are need to "e

considered

Typical eat treatment cycle !ic !ill "e follo!ed

#perating Temperature and eat treatment cycle

<o" Con(gurations /dimension * !eigt to select furnace dimensions

=um"er of Qones

Heating medium !.r.t. eat treatment parameters e.g. Temperature

uniformity re$uirement

Heating capacity and te connected load "ased on te furnace capacity

Com"ustion System

Furnace insulation

Furnace sell re$uirement "ased on te temperature range

Furnace door arrangement /Sealing etc.

Instrumentation

*.* 0eneral Asects of Ener', 5ana'ement

4.4.1 Ener', scenario

Energy plays an important role in te development of te country. Tere are

dierent types of energy !it respect to follo!ing criteria.

Primary * Secondary Energy

Commercial * =on Commercial Energy

0ene!a"le and =on0ene!a"le Energy

13



5ajor Primar, 4 Secondar, Sources


In terms of energy consumption in te year %611 India !as te fort largest

country in te !orld. Te oter & contries "efore India are Cina Dnited States

and 0ussia. India as a large coal reserves and also initiated a su"stantial gro!t

in te production of natural gas since last %6 years. Still India is a largely

dependent on te imported fossil fuels.

Tere is almost % times gro!t seen in te Primary energy consumption in India

during a period on 1AA6 to %61%.

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4.4.2 Ener', and En#ironment

Te use of energy resources crates pollution in te atmospere. Te (gure given

"elo! is a "est eample o! te Industrial process pollute te atmospere.


*.*.)Ener', Strate',

Energy strategy can "e divided into immediate medium and long term

strategies.Immediate term strate', includes optimum utilisation of te e$uipments

close monitor of te cost of te dierent energy products encourage energy

0*3 projects use of advance tecnology * practices arrest distri"ution losses

etc.

5edium term strate', includes conservation of energy optimum fuel mi

and sift from use of nonrene!a"le energy sources to rene!a"le energy

sources. E.g. Solar !ind etc. (on' term Strate', includes ecient generation of energy sources improve

energy infrastructures privatisation of te energy sector etc.

*.- %asics ener', and its #arious forms

4.5.1 Denition!

NEnergy is a fundamental entity of nature tat is transferred "et!een parts of a

system in te production of pysical cange !itin te system and usually

regarded as te capacity for doing !or7. BSource! 5erriam82ebster.com.

5erriam82ebster3 $tt!+++.merriam8+ebster.comdictionar,

15

http://www.merriam-webster.com/dictionary

http://www.merriam-webster.com/dictionary



Energy is also referred as an a"ility to perform !or7. It comes in dierent forms

suc as eat /termal energy mecanical energy ligt electrical cemical

energy and nuclear energy. Energy cannot "e created or destroyedJ it can "e

cange or transform to dierent forms as "elo!

Source! %ureau of Ener', E@cienc,3 %oo> I3 "=113 C$ater "

*.-."Di/erent forms of ener',

- Potential Energy: It is stored energy and eists in te form of Cemicalenergy eg. ;P+ =uclear energy eg. Dranium atoms Stored mecanical

energy e.g. compressed spring and +ravitational energy /Hydropo!er

dam.

- Ginetic Energy: It eists in te form motion. Tere are dierent form of

Ginetic energy 0adiant energy e.g. Rrays Termal energy e.g. eat te

internal energy in te molecules of a su"stance otion energy e.g. !ind

energy Sound energy and electrical energy e.g. electricity*.-.)0rades of ener',

Tere are t!o dierent types of energy ig grade energy * lo! grade energy

depending on termodynamic concepts. Electrical and Cemical energy is

classi(ed as ig grade energy "ecause a small amount of energy of tis form

can perform a great amount of !or7. It can also "e easily converted entirely into

dierent form of energy from one form to oter. In case of lo! grade energy one

form of energy cannot "e entirely transformed to oter. E.g. Termal energy

cannot "e entirely transformed to electrical energy.

4.5.4 %asics of Electrical Ener',

To understand "asic of te fundamentals of electrical energy or electricity it is

important to ave a "asic 7no!ledge of concepts of electrical energy li7e

directional current /3C alternating current /5C voltage impedance and

po!er.

16

http://physics.about.com/od/glossary/g/heat.htm

http://physics.about.com/od/glossary/g/heat.htm



5C * 3C can "e dierentiating "ased on te direction of Ko! of electrons. Te

electrons Ko!s is unidirectional in case of 3C !ereas in case of 5C electron

7eep canging te direction as so!n in te (gure given "elo!

Source: http://www.rcpowers.com/community/threads/ac-dc-current-tutorial.10657/

*. Ener', 5ana'ement and Audit!

4.6.1 Denition:

Energy management is te discipline and actions eected to accomplis te

minimum possi"le use of energy cost and least environmental eect !ile

performing te !or7.NTe judicious and eective use of energy to maimise pro(ts /minimi>e costs

and enance competitive positions. Cape Hart Turner and Gennedy +uide to

Energy anagement Fairmont press inc. 1AA?

Tis energy eciency can "e acieved "y focusing on reducing necessary end

use increasing eciency plummeting !asted energy and (nding te more

eective energy alternatives

*.."2$at is Ener', Audit

Energy 5udit is te 7ey to inspect survey and analyse te energy consumptions

in a systematic manner !it te intent of measures to reduce te amount of

energy input !itout aecting te output of te system. It is also can "e termed

as estimation of te energy consumption.

5ny Industry it is often found tat energy cost is one of te igest operating

costs along !it la"our and material. #ut of tese elements energy is te area

!ere cost reduction can "e done !it te proper understanding of te minimum

re$uired energy levels and "y arresting energy !astages in te system.

17

http://www.rcpowers.com/community/threads/ac-dc-current-tutorial.10657/





4.6.3 Need for Ener', Audit

'asically energy audit provides te information a"out te variations in terms of

energy cost consumption availa"ility of te energy and te relia"ility of te

energy source etc. Tis !ill elp to ( up or set te "enc mar7s for te energy

consumption in te organisation. It !ill also provide te guideline to decide te

use of dierent of energy sources identify te energy conservation tecni$ues

and te upgradation of te type eisting e$uipments etc. Te main o"jective of

te energy audit is to reduce te energy consumption or energy cost.

*..*Ener', Audit3 T,es 4 5et$odolo',

'asically energy audit is dependent on te type or te function of te industry. If

an organisation !ants to conduct te audit ten it is necessary to 7no! at !at

dept audit as to "e carried out and te proposed cost reduction potential. 5s

suc tere are t!o types of energy audit

Preliminary 5udit

3etailed 5udit

Preliminary 5udit: It is "ased on te eisting data

Preliminary energy audit is a relatively $uic7 eercise to:

Esta"lis energy consumption in te organi>ation

Estimate te scope for saving Identify te most li7ely /and te easiest areas for attention

Identify immediate /especially no8lo!cost improvements8 savings

Set a reference point

Identify areas for more detailed study8measurement

Preliminary energy audit uses eisting or easily o"tained data

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- Desi'n of %&(6s Continuous &urnace Desi'n

/,666 7g 8 Hour capacity 9uenc and Temper Furnace

-.1 :eat Treatment Process! uenc$ 4 Temer

Te furnace is designed to !or7 on a continuous operating temperature as

follo!s

5usteniti>ing M @26 6C

Tempering M 2-6 6C

-." Oeratin' Temerature and $eat treatment c,cle!

Typical eat treatment cycle !ic !ill "e follo!ed as

- Hardening Heat and soa7 at @26°C M %.2 ours

- Tempering Heat and soa7 at 2-6 C M &.- ours- Cool to am"ient "y !ater spray

5t no time te furnace temperature is set a"ove A66°C for austeniti>ing and ?66

6C for tempering furnace. Tis can "e acieved "y setting te 1st set point of

Ecess controller /'TC of eac >one. Te 'TC is connected to te Emergency

solenoid valve of te main fuelJ and suts o te solenoid as soon as te

temperature crosses te limit.

-.) &urnace inside dimensions3 and (oadin' of Jobs!

Te furnace is designed for a maimum tray dimension 1166 mm A66 mm and

a maimum jo" eigt of ,,6 mm. Te jo"s can "e loaded in a !ellplanned

metod for "etter utili>ation of te furnace and as per te re$uirements of end

users.

Furnace Cam"er /5DSTE=ITIQI=+ U%%66 /! 1@-66 /; 1,66/H

3oor opening --6 mm HeigtFurnace Cam"er /TEPE0I=+ U%%66 /! %%%66 /; --6/H

3oor opening --6 mm Heigt

=um"er of Trays

5usteniti>ing M %6 num"er

Tempering M %, num"ers

;oad "an7 M 1% trays

19



-.* &uel:

Te furnace is provided !it com"ustion system !ic is suita"le to !or7 on

;3# as main fuel. ;P+ pilots are provided for all te "urners to enance te

"urner sta"ility at lo! !or7ing temperatures for only te tempering furnace.

-.- Temerature uniformit, and control!

Te furnace is designed to acieve a temperature uniformity of V16°C for

ardening furnace and V6?°C for tempering furnace trougout te cam"er of

te furnace during te soa7ing period. To acieve tis furnace is divided in

proper temperature control >ones eac >one is provided !it follo!ing:

3igital temperature controller to control te >one temperature of

tempering furnace and PI3 controller for Hardening furnace

otori>ed valve for com"ustion air control

1 =o. of Cr 8 51 Termocouple for control

3igital controller to control ecess temperature

'urners

0atiotrols solenoids sensitrols etc.

Termocouple CrW 51 for temperature recording

Temperature recorder.

Tese e$uipments are lin7ed !it eac oter in a proper se$uence so tat tey

perform eectively to acieve te desired temperature uniformity.

-. Number of control 9ones

5usteniti>ing : 6& num"ers

Tempering : 6- num"ers

-.; :eatin' caacit, 4 Connected (oad!

Te austeniti>ing furnace is provided !it a connected eat load of &%6 litres

per our ;3# i.e. %.A, illion Gcal per our and te Tempering furnace is

provided !it a connected eat load of 116 liters per our ;3# X A., 7g per our

;P+ i.e. 1.6% illion Gcal per our.

Te austeniti>ing furnace is provided !it 1@ =os. of =ort 5merican design

-,%%, si>e ecess air "urners aving a maimum (ring capacity of a"out 12

litres per our /at stoiciometric conditions plus , num"ers -,%%& si>e ecess

air "urners aving a maimum (ring capacity of a"out 11 litres per our /at

stoiciometric conditions.

20



Te tempering furnace is provided !it 16 =os. of =ort 5merican design -,%%&

si>e ecess air "urners aving a maimum (ring capacity of a"out 11 litres per

our. Te 2t >one tempering furnace is provided !it -,%%& si>e ecess air

"urners aving a maimum (ring capacity of a"out 11 litres per our.

Combustion piping:

Te furnace is e$uipped !it te follo!ing piping system for acieving tedesired eating soa7ing and cooling rates:

- Com"ustion air line consisting of motori>ed "utterKy valve manual

"utterKy valves pressure gauges * pipes. /To feed com"ustion air to

"urners.

- 5tomi>ing airline consisting of manual "utterKy valves * pipes. /to feed

atomi>ing air to "urners

-#il line Consisting of solenoid valve air W oil ratiotrol =0) pressuregauges * pipes. /to feed oil to te "urners.

- Pilot "urner line M Tis is consists of pilot "urners pressure regulator *

emergency sut o valve for ;P+.

-.< &urnace insulation!

'ot te furnaces are provided !it properly designed insulation of refractory

"ric7s for te eart and ceramic ("er lining for te side!alls as !ell as roof.

0efractory "ric7s of dierent grades suc IS@ X HF X CF "ric7s are used of

proper si>e and tic7ness. Te doors are insulated !it proper tic7ness ceramic

("re lining.

&urnace s$ell!

Tese are fa"ricated out of mild steel plates of suita"le tic7ness and stiened

!it structural of ade$uate dimensions so as to overcome te termal stress at

elevated temperatures. Furnace sell is (ed !it te elp of proper foundation

"olts.

&urnace door!

Tis is of rise and fall type and insulated !it ceramic "lan7et insulation. Te

rise and fall arrangement is pneumatic system consisting of cylinders and cain

sproc7et etc. Te door is erected at an inclined angle !it respect to te furnace

front plate so as to acieve proper sealing.

21



-.7 Instrumentation!

-.7.1Temerature Control S,stem

Eac >one !ill ave 6% =os. simple termocouples CrW5I type. #ne for te

temperature control and oter for temperature recording.

Eac >one !ill ave 3igital ain * Ecess temperature controller for safety

Honey!ell ma7e.

5..2 Temerature Recordin'

;ason Cino ma7e paper recorder !it 62 cannels is provided !ic as got

facility of grapical plotting of temperature as !ell as digital temperature display.

-.7.)Control Panel!

3ust and vermin proof control panel painted !it ? M tan7 process /Siemens

gray color sade and fa"ricated out of 1,8128%6 gauge seet is providedfor te furnace.

Te panel as front as !ell as "ac7 door openingJ !it ca"le entry from "ottom.

Te panel is consisting of fuses contractors timers relays indicating lamps

motor starters of reputed ma7e.

=ecessary safety interloc7s are provided in te panel to avoid any accidents

and ensure safe !or7ing of tis furnace. Te panel also ouses te

instruments and is of selfstanding type. Te panel also consists of 5llen"radely ma7e P;C system for controlling te

automation system for tray movements !it a I M for setting te cooling time

as !ell as cycle time.

It is essential for te end user to understand te !iring and logic se$uence of

te panel and study te panel!iring diagram.

5..4 Tra, $andlin' s,stem!

Te plant is designed for full automation system for tray andling and transfers

!ic consists of various allied e$uipments suc as follo!s M

ain ydraulic puser for 5usteniti>ing furnace to carge te trays in te

furnace P1

#veread etractor !it % for7s for transfer of te %6t position tray in

austeniti>ing furnace to te $uenc tan7 cradle. Tis overead etractor is

ydraulically operated system consisting of po!er pac7 ydraulic motor

and cylinders. Te system consists of cain drive as !ell as !eel fast coolcam"er as !ell as from fast cool cam"er to te cross transfer conveyor.

22



Cross transfer conveyor 6, num"ers M electromecanical M for transfer of

te trays Wcarge from.

Te discarge of te ardening furnace to entry of te tempering furnace.

Te discarge of tempering furnace to entry of te 2t >one tempering

cam"er.

Te eit of te !ater spray cam"er to te front of te load "an7.

Te eit of te load "an7 to te entry side of te ardening furnace.

Te conveyor is driven !it te elp of !ire rope and drum coupled !it

gear "o motor sproc7et etc.

ain ydraulic puser for Tempering furnace M to carge te trays in te

furnace. /P%

ain ydraulic puser for 2t >one tempering furnace to load trays. /P&.

Hydraulic puser for pusing te trays of te load "an7. /P,

Floor "ound etractor M electromecanical !it pneumatic up W do!n

cylinder for etraction of te %,t position tray from tempering furnace.

9uenc cradle system !ic is ydraulically operated to acieve te

smoot and $uic7 $uencing of te ot trays in te $uenc tan7. Te same

system is also capa"le to lift and "ring up te $uenced jo"s a"ove te

tan7 after te prede(ned $uenc time. Tis system is specially designed

to eliminate te conventional pneumatic operations !it counter !eigts. 5ll te a"ove e$uipments along !it te 2 num"er furnace doors !or7 in a

predetermined auto cycle se$uence so as to acieve te functioning of

te plant. Te control of te e$uipments is acieved troug te limit

s!itces !ic give te signal to te P;C.

-.1= Technical pecication !"#$s Continuous "urnace (Quench !em"er 4000 #$ &our'

Sr

Descrition Secication

1 Capacity ,666 7g per our for te reference jo" and @minutes pus time. It is advised tat teCustomer sould plan for acieving tetargeted output for te plant 7eeping in mindte follo!ing Ma. <o" loading pattern for various jo"s.". 0eduction of empty tray pusing due to

nonavaila"ility of jo"s.c. Eective planning so as to reduce empty

tray pusing due to temperature canges.

23



% Tray si>e 1166 A66 mm& =um"er of tray in

5usteniti>ing >one%6 num"ers including , trays in =on "urner>one.

, =um"er of tray in Tempering furnace

%, num"ers X additional - num"ers in te 2 t >one tempering furnace.

- Fuel used ;3# for main "urners ;P+ for pilot "urners2 Post cooling system 4ater spray cam"er to acieve and touc

temperature of jo"s.? =um"er of control >ones

in 5usteniti>ing6& num"ers

@ =um"er of control >onesin Tempering furnace

6- num"ers

A Tray andling androtation system

Fully 5utomated "y various allied e$uipmentssuc as ydraulic pusers etractors andcross conveyors and $uenc cradle.

16

#verall space re$uiredfor te main plant

-& meter lengt 1A.-6 meter !idt Tis does not co#er te etra space neededfor cooling to!ers pumps eat ecangerscimney $uenc transfer tan7.

11

=um"er of rails infurnace

6& ro!s for "etter tray support

1%

=um"er of "urners in5usteniti>ing >one

1@ num"ers of si>e -,%, and6, num"ers of si>e -,%&

1&

=um"er of "urners in Tempering

16 num"ers of si>e 2,%&

-.11 %&(6s *=== >':our Continuous &urnace outut

Furnace is designed for te eat treatment of ,6667g material 8 our under ideal

conditions. Te said furnace is used for te 9uencing and Tempering of te

dierent parts li7e Front 5le 'eam 8 Cran7safts8 Steering Gnuc7les 8Safts 8

+ears etc.

Tere are certain eat treatment rules and te metallurgical re$uirements !ic

need to "e considered !ile designing of te eat treatment cycle of te

dierent parts as stated a"ove. Tis is dependent on te material 8 geometryand te mass of te parts. Te rule for soa7ing time is as stated in te ta"le

given "elo!

Heat Treatment

Process

Soa7ing Time

Hardening 8

9uencing

&6 inutes 8 Inc cross section of

te part Tempering 26 inutes 8 Inc cross section of

te part

24





-.1" Introduction to :eat Treatment Deartment

'arat Forge is aving a one of te largest eat treatment facilities under one

roof in te !orld. Heat Treatment capacity at C3F3 division is more tan @-66

tons 8 mont. Heat Treat Capa"ilities is "eing used to enance te $uality of te

forgings "y means of dierent eat treatment processes. 5lmost all 7ind of eattreatments re$uired for te forgings are carried out in ouse to meet various te

customer speci(c and speci(c industry re$uirements. 'arat Forge Heat

Treatment facility:

:T &acilities In %&( 5und$a+a3 Pune

Sr.No.

T,e Of &urnace&urnace Caacit,

BTonst,.BNos.

1Continuous&urnace

1 Ton :our 1" Ton :our 8 1) Ton :our 8 1* Ton :our )

" %atc$ T,e &urnace=.< Ton %atc$BPairs

1=

"%o'ie :eart$&urnace

Ton %atc$ 1< Ton %atc$ )

7

)Iso Annealin'

&urnace

1 Ton :our 1

*Sealed uenc$&urnace

=.- Ton :our "

- Pit T,e &urnace1 Ton %atc$ "" Ton %atc$ )

-

Nitridin' &urnace 1= Ton %atc$ 8 " "

;Nitridin' Pre8:eat&C

1= Ton %atc$ 1

26



-.1) :eat Treatment Oerations

-.1).1 Annealin'

5nnealing is de(ned as eating of steel to austenite pase and cooling slo!ly in

transformation range. 5nnealing involves slo! cooling of te parts inside te

furnace till room temperature "y just s!itcing o te furnace. It gives coarse

pearlite structure

5.13.2 Iso8T$ermal Annealin'8

Iso termal annealing is de(ned as te process of force cooling of steel from

austeniti>ing temperature to a constant temperature just "elo! 51. Te steel is

eld at tis temperature until te transformation is completed. Ten it as to "e

cooled to room temperature.

-.1).) Normali9in'

=ormali>ing is te process of raising te temperature to over 26 6C /16@ 6F

a"ove line 5& or line 5C fully into te 5ustenite range. It is eld at tis

temperature to fully convert te structure into 5ustenite and ten removed from

te furnace and cooled at room temperature under natural convection. Tis

results in a grain structure of (ne Perlite !it ecess of Ferrite.

-.1).* :ardenin'

Hardening is a process of eating te steel to te elevated temperature a"ove

5c& line of Iron car"ide diagram and $uenced in a suita"le $uenc medium li7e

!ater8oil8polymer to get te desired mecanical properties

27



-.1).- Temerin'

Tempering is a process done su"se$uent to ardening. 5fter ardening parts are

too ard or "rittle ence tere is a cance of premature failure of te parts if

supplied !itout tempering. Tempering involves eating of te parts at a lo!er

temperature /%66 6C M ?66 6C eld at tis temperature for some time * ten

allo! it to cool to te room temperature. Tempering results in a desired

com"ination of ardness ductility tougness strengt and structural sta"ility.

-.1). Stress Relie#in'

Stress relieving is normally done to remove te internal stress present in te

parts. It is normally carryout "elo! &6-6 6C tan te tempering temperature.

-.1).; Nitridin'

=itriding is a process of diusing =itrogen into te surface of steel. Te =itrogen

forms =itrides !it elements suc as 5luminum Cromium oly"denum and

)anadium. any cases te parts are eattreated and tempered "efore nitriding.

=itriding is a (nal process. Tere is no operation involve after nitriding.

28



-.1* :eat Treatment Deartment Current Production (e#el

Continuous

Type

Furnace

FD0=5CE C5P5CITO

TS H503 H0S TEP

H0S

CF ,- --6 266

CF 2? 16%6 266CF A16 1@66 266

CF 111% 1@66 266

CF 1& 1, 1@66 266

CF 1-12 %666 266

IS# 5== ,-6 266

'atc

Type

Furnace

'atc /@

Pairs@66 266 266

'#+IE 2-6 1@66 1@66

5luminum -6 266 1%66

S 9.F. 1@6 1%66 1%66

PIT TOPE %66 1%66 1%66

Total 5T113*

==

-.1- Temerature Ran'es

Furnace #peration Temp. 0ange

:i'$

Temerature

=ormali>ing 8 =P @%6A66ZC

5nnealing A66A-6ZCHardening @%6@@6ZC

(o+

Temerature

Tempering ,-6266ZC

3ou"le Tempering ,-6266ZCStraigten ,-6266ZCStress 0elieving -66-26ZC

Table ! %&(6s :eat Treatment &urnace6s Oeratin' Temeratures

-.1 Deartment +ise Ener', Reorts

Fuel consumption at 'arat forge is captured department !ise according to

te type of fuel. Te ta"le given "elo! so!s te 'F;Bs daily energy report.

Cart to "e added from <ayant 3esmu7

29



:eat Treatment Ener', Consumtion 5ont$ BJune "=1*

:eat Treatment Ener', Consumtion June "=1*

30



SG# * Furnace #il is used for eating all Forging Furnaces !ereas SG#% *

;P+ is used for eating te eat treatment furnaces. Tere are some

electrically eated furnaces also availa"le in eat treatment department for

te special processes li7e car"on restoration gas nitriding and solution

annealing of te titanium etc.

Te fraction of oil consumption across te 'arat Forge is as given in te Cart

1.6 almost -6Y of te oil is consumed "y Forging 3epartment /F3 X Forge

Sop * remaining -6 Y is consumed "y te Heavy Forge 3ivision and Heat

Treatment 3epartment.

%$arat &or'e (td3 Oil Consumtion

Te fraction of ;P+ consumption across te 'arat Forge is as given in te

"elo! Cart almost ,-Y of te ;P+ is consumed "y Heat Treatment

3epartment Forging 3epartment consumes a"out /F3 X Forge Sop %1Y

* remaining &, Y is consumed "y te Heavy Forge 3ivision.

31



%$arat &or'e (td3 (P0 Consumtion

:eat Treatment Ener', Consumtion 5ont$

o Heat Treatment furnaces are used SG#% * ;P+

o Current energy cost is very ig "ecause of ig fuel rates.

o ;P+ consumption to "e reduced "y SG#% and Furnace #il

o SG#% is miture of ?6 Furnace oil X &6 Super Gerosene #il

o ;P+ rates are also ig.

o ;P+ is clean fuel ence maintenance free.

o S!itc over te Hardening furnaces ig cost to lo! cost i.e. ;3# to SG#

%.

32



o ;P+ prices are less compared to ;3# prices.

o 'y s!itcing over te all ardening furnaces from ;3# to Furnace oil

energy saved "y [&6

33



-.1; &uel Consumtion data.

FuelGcal

)alue#ct =ov 3ec <an

5verag

e

SG#% 16-,6 %,,,1% %21-1- %62,&1 -?%?A%1?,6

A

;3# 16?66 %6A&, &6&6? @&?62 &A,A2 ,&211

F.#. 16&66 1,&66 1?2-, 1-A??

;P+ in T 11&66 12, 1-? @- -2 11-

Total Gcalin

Gcal

&661 &&1@ &,&? %&?A &112

Production

T

Hard. ,211 ,-&@ ,62- %,,? &A1-

Temp &?%A ,6@6 &%12 1?2& &1A?

0$.Heat in

7cal

Hard. ,,@ ,,1 &A- %&@ &@1

Temp &2% &A? &1& 1?1 &11

Total @11 @&@ ?6@ ,6A 2A1

E@cienc, "; "- "1 1; ""

34



Imortance of t$e roject

Energy cost is al!ays on of te top tree epenses of te company. Tere is

al!ays scope for improvement in te energy cost. 5s stated in te "eginning it

is decided to concentrate on te energy consumption of te eat treatment

department. Identify te potential cost saving projects generate ideas tominimise te energy cost. 3o te implementation of te project and ideas in te

eat treatment department. onitor te results and ori>ontally deploy te

improvements in te oter departments.

Energy monitoring is already "eing done in te 'F; from te "eginning. #ver te

period of time tere are improvements made in te data capturing system. Te

said data is "eing compiled in te standard format and used for te analysis "y

te top management during management revie! meeting eld every mont.Heat treatment department as formed a cross functional team /core team for

te energy cost reduction programme !ic includes te mem"er from te

maintenance production $uality and planning. Tis team ad a "rain storming

sessions and meetings along !it te sop Koor team and identi(ed te num"er

of cost saving projects and ideas.

Include Poto aintenance meeting

Te team generated follo!ing ideas 8 metods to do te improvement in te

energy cost.

3etailed energy audit of te continuous furnace to "e done to identify te

potential cost saving areas as ?6Y of te eat treatment production is

"eing done from te continuous furnace.

Cec7 te possi"ility of using alternate fuel for eating !itout aecting

te product $uality

35



Improve te furnace utilisation "y improving (turing to accommodate

optimum $uantity.

Dse of advance e$uipment 8 latest tecnology to reduce te energy cost.

36



; Ener', Audit Stud, :eat Treatment &urnaces

5ssessment of furnace: 5ll te eat added to te furnace sould "e used to

eat load or stoc7 "ut lot of eat is lost in several !ays.

:eat losses in industrial $eatin' &urnaces

T,e of :eat (osses Y

&lue 'as -=

5oisture in &uel 1.)

:" in &uel 7.1)

Door oenin' -.-

&urnace s>in ".*

Total <.7

E@cienc, )1.)1

Source: Flue gases losses: Part of te eat remains in com"ustion gases inside

te furnace. Tis loss is also called !aste gas loss or stac7 loss.

;oss from moisture in fuel: Fuel usually contains some moisture and

some eat is used to evaporate te moisture inside te furnace. ;oss due to ydrogen in fuel: 0esults in te formation of !ater.

37



;oss troug openings of door in furnace: 0adiation loss occurs !en

tere are openings in furnace enclosure. Second loss is troug air in(ltration

"ecause of !ic te draft of furnace stac7s cause a negative pressure inside

te furnace dra!ing in air troug crac7s or lea7s !enever te furnace

doors are opened. Furnace s7in or surface losses: Tese are also called as !all losses. 4ile

te temperature inside furnace are ig eat is conducted troug roof

Koor !alls and emitted to am"ient air once it reaces te furnace s7in or

surface.

#ter losses:

Stored eat losses: 4en te furnace is started te furnace structure

and insulation is also eated and tis eat only leaves te structure again!en furnace suts do!n.

aterial andling losses: E$uipment used to remove te stoc7 troug

te furnace suc as conveyer "elts !al7ing "eams "ogies etc. also a"sor"

eat.

Cooling media loss: 4ater and air are used to cool do!n e$uipment and

rolls "ut eat is lost "ecause tese media a"sor" eat.

Incomplete com"ustion: Heat is lost if com"ustion is incomplete "ecause

un"urnt fuel or particles ave a"sor"ed eat "ut tis eat as not "een put

to use.

;.1 2$at is CombustionF

Com"ustion is a cemical process "y !ic molecules com"ine !it oygen

and are oidi>ed. If you com"ust an organic molecule as muc as possi"le

you !ill "rea7 it all te !ay do!n into !ater /H %# and car"on dioide /C#%.

For eample if you ad a molecule of metane /CH, mied it up !it some

oygen /#% and gave it a little "it of eat to get te reaction started you

!ould oidi>e te metane into t!o !ater molecules and one car"on dioide.

Te cemical e$uation !ould loo7 li7e tis:

CH, X %#% \ %H%# X C#% XE=E0+O

;.":EAT (OSS CA(CG(ATIONSa. &urnace E@cienc, U /Heat Input 8 Heat #utput ]166

38



". :eat Outut U ass ] Cp / Sp.Heat #f Steel ] ^T

c. :eat Inut U Total Fuel Consumption In Gg ] +C) in 7Cal

87g

39



&(GE 0AS

d. Ecess 5ir /E5 U #% measured 8 /%1#% measured

1. E.+. 1% 8 /%11% U 1&&

e. 5ass Of Air SuliedH 17g fuel X /E5 8 166 ]Teoretical 5ir

U /1X1.&& ]1, U&%.2% 7g87g Fuel #il

f. :eat (oss In &lue 0as

U ] Cp ] ^T

'. 5oisture In &uel

Heat ;oss due to oisture in Fuel U

] _-@, X Cp /Tfg Tam"`

4ere

U Gg of oisture in 1 Gg of Fuel #il

TfgU Fuel +as Temp ZC

Tam"U 5m"ient Temp ZC

. :" In &uel

Heat ;oss 3ue To Hydrogen in Fuel

UA ] H% ] _-@, X Cp /TfTam"`

i. Door Oenin'

40



j. &urnace S>in

;.) Ener', E@cient Oortunities

In order to overcome all te losses tere are fe! !ays troug !ic te

eciency of te furnace can "e improved as te primary o"jective sould "e to

minimi>e te amount of !aste eat generated troug energy conservation

measures li7e:

Complete com"ustion !it optimum ecess air

Proper Heat distri"ution

#peration at optimum furnace temperature

0educing eat losses from furnace door openings and radiation

#ptimum capacity utili>ation

Dse ceramic coating Select rigt refractoriness

4aste eat recovery from furnace Kue gases.

41



;.* Ener', Audit of Continuous &urnace C& 1)81*

Note Furnace oil com"ustion eciency is ma @6Y 0ef. Indial #il

Corporation

42





SG#% 7Cal 8 7g 16,66 11?66

3ensity 7g8mb& 6.A1

7Cal 8 liters A,2A

Total 7Cal 8r 13;);3-

"

11?666 13<-*3-"88888888

A

Total Fuel Consumption in ;iters MSG#% ,,6, ;iters 8 3ay

SG# % Consumption U1@&.-6 ;iters8Hr

3ensity of SG#% 6.A1 7g 8;iter

Total Fuel Consumption in Gg M &A2& 7g 8 3ay .i.e. 12-.1- 7g 8Hr

Calori(c )alue of SG#% A,2A Gcal 8 7g

;P+ Consumption 16 7g 8 Hr

;.; Total :eat losses in >Cal

1. :eat used b, 5aterial

Total T Processed [email protected] 83ay

H 5ass S.:eat of 5ass KT

U -@-26 Gg 6.1% /@?6ZC,6ZC X/-?6ZC166CZ

44



U?6%?.%6 @&6X,?6

U?6%?.%6 1&66Z

U A1&-&26 7Cal83ay

matl H )<=3*= >Cal :r LLLLLL%

45



&urnace e@cienc, calculation b,

Direct 5et$od H ReMuire :eat for t$e Stoc>

8888888888888888888888888888888888888888888888888888888888

:eat in t$e fuel consume for $eatin' t$e stoc>

U ' 8 5

U &@62,6 ]166

1@-,-2%

&urnace T$ermal E@cienc, H "=.-"8888888888888888888888888888888888888888881

". :eat loss b, Tra, and &itures

Total noBs of Tray processed U - noBs8 Hr /Cycle time 1% min

Tray 4eigt in Gg 1,@ Gg Total 4eigt M 1,@]-U?,6 Gg

tra,H 5ass S.:eat of 5ass KT

U ?,6 Gg ] 6.1% ] /@?6ZC,6ZC X/-?6ZC166CZ

U?6%?.%6 ] @&6X,?6

U?6%?.%6 1&66

tra,U 11-,,6

U 11-,,6 ]1661@-,-2%

:eat loss b, Tra, and &itureH

.""*888888888888888888888888888888888888888888888888888888"

#perational eciency of te furnace can "e calculated "y calculating te

individual losses and ten su"tracting tese from 166. Te calculation of eac

loss is given "elo!.). Sensible :eat (oss b, :ardenin' furnace BC& 1)

Ecess 5ir U #% Y ] 166

/%1#%Y

Hardening Furnace: #% U ,.6Y

Hardening F8C Ecess 5ir U

U , ] 166

/%1,U %&.-%Y

46



Hardening F8C Ecess 5ir U %,Y

Teoretical 5ir re$uired to "urn 1 Gg #il U1, Gg

U /1X6.%, 1, Gg 8 Gg of #il

Total 5ir supplied U1?.&2 Gg for one Gg of #il

*. Sensible :eat loss

9U Flue gas ass Sp.Heat of Flue gas ^T

4ere ass of Flue gas is 1@.&2 Gg 8 Gg of Fuel

. /1?.&2 5ir X1 Gg Fuel

Total Kue gas U1@.&2 ] 1-6 ]6.A1!ere Fuel consumption 1-6 ltrs8Hrs

SG#% density 6.A1 7g8mb&

U%-62 7g

Cp U Sp. Heat U 6.%&

^T U -?-ZC,6ZC U -&-ZC

9sensi"le U%-627g ] 6.%&7Cal87g8ZC ] -&-ZC

U&6@&-& 7Cal 8Hr

Hardening Furnace eat ;oss U &6@&-& ]166

1@-,-2%

sensible:H1."

888888888888888888888888888888888888888888888888888888888888888888888&.1

-. Sensible :eat (oss b, Temerin' furnace BC& 1*

Ecess 5ir U #% Y ] 166

/%1#%Y

Hardening Furnace: #% U 2.-6Y

Hardening F8C Ecess 5ir U

U 2.-6 ] 166 /%12.-

U,-Y

Hardening F8C Ecess 5ir U ,-Y

Teoretical 5ir re$uired to "urn 1 Gg #il U1, Gg

U /1X6.,- 1, Gg 8 Gg of #il

Total 5ir supplied U%6.& Gg for one Gg of #il

47



Sensible :eat loss

9U Flue gas ass Sp.Heat of Flue gas ^T

4ere ass of Flue gas is %1.& Gg 8 Gg of Fuel

. /%6.& 5ir X1 Gg Fuel

Total Kue gas U%1.& ] //&&.-]6.A1 X16

4ere Fuel consumption &&.- ltrs8Hrs X16 7g 8Hr ;P+

SG#% density 6.A1 7g8mb&

U@2% 7g

Cp U Sp. Heat U 6.%&

^T U -?-ZC,6ZC U -&-ZC

9sensi"le U@2%7g ] 6.%&7Cal87g8ZC ] -&-ZC

U16262A 7Cal 8Hr

Hardening Furnace eat ;oss U 16262A ]166

1@-,-2%

sensible TH-.;1

888888888888888888888888888888888888888888888888888888888888888888888&.%

48



. :eat (oss Due To Door Oenin'

Source to "e mentioned

49





Te Sape of te furnace opening is rectangular U 38R

RU4all Tic7ness U %-6 mm

3U#pening eigt U 1%&.@ cm

'lac7 'ody 0adiation at @26 ZCU 1, Gcal 8 cm%8Hr

'lac7 'ody 0adiation at 266 ZCU 16 Gcal 8 cm%8Hr

5rea of #pening Hardening Furnace U1%&.@ ] %,2.6 U )=3*-* C5"

Emissivity U U6.@6

Total :eat (osses :ardenin' &urnaceU

'lac7 'ody radiation #pening 5rea 0adiation Factors Emissivity

U1, Gcal 8 cm%8Hr &6,-, C% 6.@- 6.@6

U%@AA%% 7cal 8Hr % 3oor

U%@AA%% 7cal 8Hr ] Total #pening 3uration 8 Hr ] =os of 3oors

U%@AA%% 7cal 8Hr ] 6.6&- ]%

U1A?1- Gcal 8Hr

:ardenin' &urnace oenin' (ossesH 173;1- >Cal:rL .

LLLLLL.*.1

Temerin' &urnace

Te Sape of te furnace opening is rectangular U 38R

RU4all Tic7ness U %1.2 mm

3U#pening eigt U ?- cm

'lac7 'ody 0adiation at 266 ZCU 16 Gcal 8 cm%8Hr

5rea of #pening Tempering Furnace U%1&., cm ] ?- cm U 13==- C5"

Emissivity U U6.@6

Total :eat (osses Temerin' &urnaceU

'lac7 'ody radiation #pening 5rea 0adiation Factors

Emissivity

51



U16 Gcal 8 cm%8Hr 1266- C% 6.@% 6.@6

U16,AA& 7cal 8Hr % 3oor

U16,AA& 7cal 8Hr ] Total #pening 3uration 8 Hr ] =oBs of

3oors

U 7cal 8Hr ] 6.6&- ]%

U?&-6 Gcal 8Hr

Temerin' &urnace oenin' (ossesH ;31*= cal

:r.,.%

Total Furnace #pening Heat ;ossesU Hardening X Tempering /,.1X,.%

U1A?1- Gcal 8HrX?&-6 Gcal 8Hr

U %2@-- Gcal 8Hr

3oor #pening ;osses U %2@-- Gcal 8Hr

U%2@-- ]166

1@-,-2%

U1.,-

Y.....................................................................*

Furnace S7in Temp ZC #perating

Temp. ZC

CF 1& Entry

&,, &11 &&2

@&6ZC&-% &,? &%,

&&& &%% &A&

CF 1& Eit

%&& %-@ %%?

@26ZC&2- %@1 %-2

%@6 &%6 %@6

CF 1, Entry

11- 1,1 11-

--6ZC11? 1AA 1@6

1%2 %A6 %&,

CF 1,Eit

1,% 1?2 1?6

-2-ZC126 %&- %,6

126 &%, %,6

52



53



<. :eat (osses b, S>in Temerature

Hardening Furnace

Heat losses troug furnace s7in !all and 0oof J

Total average surface temp. A6ZC

Heat losses at A6ZC / 0ef 0ediation Heat cart U

5rea 5vergae

Surface

Temp.ZC

Heat ;oss

Gcal 8%8

Hr

Total 5rea

%

Total

Gcal 8Hr

Hardening Furnace

Side

4all

A6 ?66 A&.& 2-%A2

Ceiling ?- -?- 2%., &-@A?

Heart 116 A66 2%., -21@2

Total %[email protected] 1-?&?A

Tempering Furnace

Side

4all

26 &-6 16,.6 &2,66

Ceiling 26 &66 2,.@ 1A,-%

Heart @6 -66 2,.@ &%,%6

Total %&&.? @@%?%

3oor

CF 1&

Entry

&,6 &%66 &.1 A?A%

CF 1&

Eit

%?@ %?66 &.1 @%2%

CF 1,

Entry

12A 1@66 %.A -%2-

CF 1,

Entry

%6- %666 %.A -@-6

Total %A12A

Total Heat ;osses 8Hr ";*3<"=

7. (oss due to E#aoration of 5oisture resent in &uel

54



Heat ;oss U ass _-@, X Cp /^T

166

+C) of Fuel

4ere

oisture in Fuel U 6.-6

Cp Sp.Heat of Flue gas U 6.%,

^T Flue +as Temp.ZC U -&- ZC /-?-,6

+C) +ross Calori(c )alue of FuelU A,2A Gcal

Heat ;oss U ass _-@, X Cp /^T

166

+C) of Fuel

;oss per 7g fuel oil U 6.-6 _-@, X 6.,- /-?-,6`

U ,1& Gcal87g of Fuel

Heat ;osses M ,.?A

U,1&] 1@&.-6 SG# %X16 Gg ;P+

U?AA1- Gcal

:eat (oss due to 5oisture in &uel H *.;7

7. (oss due to E#aoration of +ater form :,dro'en in &uel

Heat ;oss U A H% _-@, X Cp /^T

4ere

H % M Gg of H% in 1 Gg of FuelU 1%

Cp Sp.Heat of Flue gas U 6.%,

^T Flue +as Temp. ZC U -&- ZC /-?-,6

+C) +ross Calori(c )alue of FuelU A,2A GcalU /A 6.1% /-@,X6.%, -&- 8 A,2A

U?2A 7Cal 8 ltrs

U?2A] 1@, ltrs

U1,1-2@

Heat loss U 1,1-2@81@-, -2%]166

:eat (oss due to E#aoration of +ater form :,dro'en in &uelU;.=

0EC#E=35TI#=

55



Eamining te cost of energy allo!s us to identify priorities and

monitor $uality improvements. Energy management is an increasingly important aspect of system

design Proposed model provides te frame!or7 for te operating system to

manage energy as a (rstclass resource 5fter implementation of tese actions energy saving are found

satisfactory. Te same metod !ill "e applied in all eat treatment furnaces and

energy cost !ill "ring do!n up to 16. In tis project past data is analy>ed unit !ise and ig energy !ise

3ata analysis so!s te top ten ig energy unit for energy are contri"uting

a"out ?6 energy cost. Te action plan is prepare for tis major energy.

Control plan is prepared for reducing and controlling energy cost andimproves. Tis report can "e used as a tool to understand te current energy

environment.

Tis study empasi>es te need for proper implementation of energy

audit recommendations in a planned and systematic manner. Te implementation programme !as successful as !e entered Suc an arrangement made it possi"le to (ne tune te (ndings of te

"ase line studies !or7 in close coordination !it operators * maintenancepeople. 5fter te system !as commissioned !e monitored te furnace operation

troug esta"lised measurement and veri(cation procedures to $uantify te

savings.

-. RECGPERATOR SSTE5

Objecti#e: Energy saving troug uses 0ecuperative System

Scoe! Heat Treatment Hardening Furnace

Trials M Initial trials CF 1& Hardening Furnace

&uel8 SG#%

1. 2$at Is RecueratorF

5 0ecuperator is a special purpose counterKo! eat ecanger used to

recover !aste eat from eaust gases. In many types of processes

56

http://en.wikipedia.org/wiki/Heat_exchanger

http://en.wikipedia.org/wiki/Heat_exchanger



com"ustion is used to generate eat and te 0ecuperator serves to

recuperate tis eat in order to reuse or recycle it.

0ecuperator is often used in association !it te "urner portion of a eat

engine to increase te overall eciency. For eample in a gas tur"ine engine

air is compressed mied !it fuel !ic is ten "urned and used to drive a

tur"ine. Te recuperator transfers some of te !aste eat in te eaust to te

compressed air tus preeating it "efore entering te fuel "urner stage. Since

te gases ave "een preeated less fuel is needed to eat te gases up to

te tur"ine inlet temperature. 'y recovering some of te energy usually lost as

!aste eat te recuperator can ma7e a eat engine or gas tur"ine

signi(cantly more ecient.

Eternal recuperators are most common "ut oter tecni$ues are also used

suc as selfrecuperative "urners. For eample a modern recuperator use

furnace eaust gas of 1666ZC can preeat te com"ustion air to over -66ZC

!ic results in energy savings of up to &6 compared !it using cold

com"ustion air entering te furnace.

Tis project !as concerned !it (tting of recuperator in eat treatment

furnace. 5 recuperator is a special purpose eat ecanger tat etracts eat

from !aste gases and transfers it to com"ustion air and preeating it. Tus

saving fuel tat !ould ave "een used instead. For preeating te com"ustion

air. 5s per te data availa"le !it te eat treatment dept. use of recuperator

reduces te total consumption "y 16 average values.

57

http://en.wikipedia.org/wiki/Combustion

http://en.wikipedia.org/wiki/Heat_engine


http://en.wikipedia.org/wiki/Gas_turbine

http://en.wikipedia.org/wiki/Combustion



http://en.wikipedia.org/wiki/Gas_turbine



58



Tese are of te sell * tu"e type used for recovering !aste eat from Kue

gases up to a temperature of &66?66ZC. Te Heat Transfer is predominantly

"y Convection. Te material of construction can "e SS &168SS &6,8Car"on

Steel or a com"ination of tese depending on te duty conditions. Te Kue

gases Ko! outside te tu"e !ile clean 5ir Ko!s troug te Tu"es. Tis

facilitates easy maintenance.

59



:eat reco#er, from $eat treatment furnace

;.< %n a heat treatment urnace, the e&haust gases are leaving the

urnace at '((oC at the rate o )(( m* +hour. The total heat recoverable at

-(oC nal e&haust can be calculated as

H ? C QT

9 is te eat content in 7Cal

) is te Ko!rate of te su"stance in m&8r

h is density of te flue gas in 7g8m&

Cp is te speci(c eat of te su"stance in 7Cal87g oC

T is te temperature difference in oC

Cp /Speci(c eat of Kue gas U 6.%, 7Cal87g8oC

'y installing a recuperator tis eat can "e recovered to preeat te

com"ustion air. Te fuel savings !ould "e 1- Y /[ 1Y fuel reduction for

every %%oC reduction in Temperature of Kue gas.

60



0ecuperator capacity calculations.

Follo!ing are te capacity calculations

a :eat reMuired for $ot combustion Air3

9 U m Cp ^T

4ereJ

m ass of 5ir/'lo!er 1266CFU2AA2 b&8Hr%?1@

7g

h 3ensity of air 1.12,

Eciency of 'lo!er ?6Y

Cp Sp. Heat of 5ir Gcal8Gg ZC [266mm!c 6.%,

^T Com"ustion 5ir Temp. di. /%@6ZC&6ZC

9U %?1@ ] 1.12,, ] ?6Y ] 6.%, ] %-6

Total eat re$uire for pre eating of com"ustion air.

H1)"37") >CalLLLLLLLLLLLLLLLL..a

b :eat Reco#ered from Recuerator

9 U m Cp ^T

4ereJ

m ass of Kue gas Gg8Hr

Cp Sp. Heat of Flue gas Gcal8Gg ZC [266mm!c

^T Com"ustion 5ir Temp. di. /-@6ZC&66ZC

61



9U &622 ]?6Y ] 6.%, ] %@6

:eat Reco#ered from Recuerator H"=3=)- >Cal

E@cienc, H 8Air 8 &lue 0as

H1)"37") "=3=)-

H-

Eciency U2- Y eat transfer from 0ecuperator to com"ustion air.

62



Source to "e mentioned

4ere

T1 Inlet sell side Kuid Temp -@6ZC

T% #utlet sell side Kuid Temp &-6ZC

t1 Inlet tu"e side Kuid Temp ,6ZC

t% #utlet tu"e side Kuid Temp %-6ZC

63

//T1t%/T%t1

^TlmU ;n //T1t%8 /T%t1



9U D 5 ^Tlm

4ere

9 M Heat transfer per unit time 1&&6&, Gcal

/-%?21& 'tu

D Te #verall eat transfer coecient - "tu8r ftb%

5 Heat Transfer 5rea b%

KTlm log mean Temp di. ?&?ZC

5U98 D ^Tlm

U-%?21& 8 /- ]?&?

U1,& Fb%

5U1&.&1 b%

4ere If assign follo!ings

=o of Tu"es 166

#3 %- mm

Curcumference [email protected] mm

Tu"e ;engt 1?66 mm

5rea 8Tu"e 1&&,-6 mmb%

Total Surface 1&.&- mb%

64

//-@6%@6/&66&6 ^TlmU

ln//-@6%@68/&66&6 in ZC

^TlmU ?&? ZC



4ere

DoU #ver all Heat Transfer coecient

oU Heat Transfer coecient outside

HiU Heat Transfer coecient in side

0fo U Fouling resistance outside

0( U Fouling resistance inside ^ !U Tic7ness of tu"es

G!U Termal conductivity

5U Surface area of tu"es /inner outer and mean

65



0ecuperator 9uotations from suppliers

66



=e! 0ecuperator installed at CF 1& furnace

Tis 0ecuperator purcased from

E5STE0= E9DIPE=T * E=+I=EE0S Pvt. ;td.

?' GS 0oy 0oad Gol7ata ?66 661 I=3I5.

67



%enets of 2aste :eat Reco#er,

'ene(ts of k!aste eat recoveryB can "e "roadly classi(ed in t!o categories:

Direct %enets!

0ecovery of !aste eat as a direct eect on te eciency of te process.

Tis is reKected "y reduction in te utility consumption * costs and process

cost.

Indirect %enets!

a 0eduction in pollution: 5 num"er of toic com"usti"le !astes suc ascar"on monoide gas sour gas car"on "lac7 o gases oil sludge

5crylonitrile and oter plastic cemicals etc. releasing to atmospere

if8!en "urnt in te incinerators serves dual purpose i.e. recovers eat

and reduces te environmental pollution levels.

" 0eduction in e$uipment si>es: 4aste eat recovery reduces te fuel

consumption !ic leads to reduction in te Kue gas produced. Tis

results in reduction in e$uipment si>es of all Kue gas andlinge$uipmentBs suc as fans stac7s ducts "urners etc.

c 0eduction in auiliary energy consumption: 0eduction in e$uipment si>es

gives additional "ene(ts in te form of reduction in auiliary energy

consumption li7e electricity for fans pumps etc..

68



F;DE +5S TEPE05TD0E 5=5;OSIS 'EF#0E 0ECDPE05T#0

5 4aste gas loss also 7no!n as Kue gas or stac7 loss is made up of te eat

tat cannot "e removed from te com"ustion gases inside te furnace. Te

reason is eat Ko! from iger temperature source to te lo!er temperatureeat receiver.

4e ave cec7ed te eaust Kue gas temp !it te elp of eternal

termocouple. Eaust Kue gas temp found very ig -26Z to 266Z !en

Furnace temp is @@6ZC.

F;DE +5S TEPE05TD0E 5=5;OSIS 5FTE0 0ECDPE05T#0

0epor

t

Flue In

Temp ZC

Flue #ut

Temp ZC

Com". 5ir Temp. Temp

ZC

1 21? ,,? %-A

% -@1 ,&, %?-

& -,2 ,%? %,-

, -@2 ,&6 %-,

- -A1 ,&- %2&

2 -@A ,&& %&1

? -@- ,%@ %%%

69



F;DE +5S C#=SDPTI#= 'EF#0E 5=3 5FTE0 0ECDPE05T#0

0ecuperat

or

Condition

#il

0eading5ctual

Consumpti

on ;trs

Production

in T

#il

cons.8

T

Saving

Initial Final;trs8

T Y

'efore 62A@-%%A-

61-A2- 1?, A%.6

11 1%

5fter &%&1%,@2A

212&@, %61 @1.,

70



E=E0+O C#=SDPTI#= 'EF#0E 5=3 5FTE0 0ECDPE05T#0 SOSTE

CA(CG(ATIONS

'efore recuperator energy consumption is A% ;trs 8 T

5fter recuperator energy consumption is @1 ;trs 8 T

Energy saving 11 ;trs8T

Energy saving [ 16 ltrs

For tis system min @ energy saving is epected.

Energy consumption of 'HF furnace is 1666 liters8 3ay i.e. 0s &-1668

Energy saving @ is 0s. %@6@83ay i.e. 0s ?66668 per mont per Furnace

71



CONC(GSION

For tis system to get te @ energy saving in Heat Treatment furnaces

Heat Treatment Hardening furnaces montly fuel consumption is %-6 G;

&(GE 0AS ANA(SIS

Cec7list

onitor #% Co% C# and control ecess air to te optimum pressure

Improve te "urners design com"ustion controls and instrumentation

Ensure te furnace com"ustion cam"er is under sligt positive pressure

Dse ceramic ("ers in te case of "atc operations.

atc te load to te furnace capacity.

Investigate cycle time and reduce

Provide temperature controllers.

Ensure te Kame does not te stoc7

Dse te dumper for cimney to control te furnace pressure

To control te air fuel ratio

72



&(GE 0AS ANA(SIS

73



Hori>ontal deployment for rest of units

Investment and Pay"ac7 calculation

74



TIPS &OR ENER0 SA?IN0

Tips for Energy conservation for Heat treatment

Preeat com"ustion air !it !aste eat /%%ZC reduction in Kue

gas temperature increase furnace eciency

Dse varia"le speed drives on large 'lo!ers and fans !it varia"le

Ko!s.

Clean "urners =o>>les and Strainers etc.

Inspect oil eater for proper oil temperature.

Close "urner air and8 or stac7 dampers !en te "urner is o to

minimi>e eat losses up to stac7

Improve #ygen trim control /limit ecess air to less tan 16 on

clean fuel/ - reduction in ecess air increase furnaces eciency

"y 1

Inspect door seal. Sell temperature 3oor eat losses

Inspect for soot Kas and slag on te (re side.

Esta"lis a furnace maintenance program start !it an energy

audit and follo! up ten a furnace eciency maintenance

program a part of your continuous management program.

Ensure process temperatures are correctly controlled.

Cec7 against in(ltration of air Dse door or air curtains.

onitor #% Co% C# and control ecess air to te optimum level.

Improve "urner design com"ustion control and instrument

Ensure tat te furnace com"ustion cam"er is under sligt

positive pressure.

Ensure tat Kame does not touc te stoc7.

1



%IO ADDETI?E

Objecti#e! To energy saving troug using te 'io 5dditives !it

furnace oil

a. To assess !eter sifting of fuel from SG#% to F#X4#=3E0 is

possi"le. Here $uality parameters from production point of vie!

and maintenance parameters !ere to "e studied.

". To study te cost impact if te a"ove s!itc is successful.

c. To study te impact on fuel consumption per metric ton "asis if

te cange of fuel is successful.

d. To assess te net impact in terms of cost saving if te cange of

fuel is successful.

e. To study maintenance issue and life of furnace liningBs.

Point No.1 M So far furnace !as running on SG#%. 4e carried out

modi(cations as mentioned "elo! M

Eternal insulation of te day tan7s !it ceramic lining.

5dditional inline (lter to furnace of !ire mes si>e 1,A.

Half Inc Garmsell ma7e direct acting solenoid valve provided

for eac >one instead of 5vcon ma7e 3iapragm type solenoid

valve.

5fter tis 4onder additive !as added in F# /Initially -Y

"lending

Furnace !as (red te results !ere $uite encouraging. Te

furnace !as running smootly !itout any pro"lem.

Point No." To study te impact on fuel consumption per metric ton

"asis if te cange of fuel is successful.

2



Part !ise study done "efore and after adding te N4onder

additive o! muc !as te consumption per etric ton.

Point No.) To assess te net impact in terms of cost saving if te

cange of fuel is successful.

5lso ere it !as o"served tat te com"ustion air temperature as

increased "y an average of -6ZC visvis SG#%.

4e are monitoring future results for "etter com"ustion eciency troug

ecess Kue out temperature tan previous one M SG#%

Point No.- To study maintenance issue and life of furnace linings

aintenance Issues: 3uring te trials of F#X&Y4#=3E0 follo!ing tings

!ere o"served and con(rmed "y Heat 3epartment aintenance

Tere as "een a drastic reduction in S##T formation

Car"on monoide as "een reduced.

'urner co7ing visvis SG#% is reduced.

'urner lea7age issue is solved.

Heater temperature is reduced from @6ZCto 2-ZC.

S# ave reduced. Tis is due to te property of te additive

!ic may lead to increase in furnace life.

Curning time can "e minimi>ed up to -6Y.

Here a special mention on maintenance issue is essential. F#X&Y

4#=3E0 gave a muc "etter performance tan SG#% on maintenance

issues is te feed"ac7 given "y Heat Treatment aintenance of 'F;.

0eduction in Electricity consumption:

SG#% is a miture of F.#. /?6Y aving density of 6.A? plus and SG#

/&6Y aving density of 6.?A. So to 7eep tis miture from separating a

continuous stirring or miing e$uipment is run in te tan7s !it te elpof a tree orsepo!er motor.

Te cost of electricity is calculated "elo! for te same:

3





,,.

@2 %-666 11%1-66

Ener',

Sa#in'

)

.-*

<

<3-==

?.&1Y

Electricity Saving Epected per tan7 on stirring "asis 0s.26668 on %-

days !or7ing "asis.

odi(cations 0e$uired To #perationalise te System of F# X

4onder

Eternal "io"ased fuel modi(er N4#=3E0 is re$uired. It can "e

done at te main tan7 of te stores itself.

Eternal insulation of te day tan7s !it ceramic lining is re$uired.

5dditional inline (lter provided near to furnace of !ire mes si>e

1,A.

Half Inc Garmsell ma7e direct acting solenoid valve provided for

eac >one instead of 5vcon ma7e 3iapragm type solenoid valve.

Te a"ove ependiture !ould "e to te tune of a"out 0s. &66668

per system !ose pay"ac7 period !ill "e in days.

5



(aborator, Reort

2.1 So report

2.% =o 0eport

6



2.& Hydrocar"on 0eport

2., Particulate matter 0eport

7



? #I; CE=T0IFD+5; SOSTE

#"jective: Energy saving troug uses #il Centrifugal System

Scope: Heat Treatment Hardening Furnace

FuelFurnace #il

Te simplest of pumps. 5 vaned rotor rotates inside te pump "ody. Te oil

spins to te outside of te pump rotor and is forced out of te outlet pipe.

Te dierential pressure across te pump continuously reprimes it. )ery

common in oil (ltration systems

2$at is t$e rincile of Oil Centrifu'al s,stemF

Centrifugal #il Cleaner operates on te 0eaction tur"ine principle. #il enters

te Centrifuge under pressure and passes into te rotor tru ollo! rotor

saft. Te oil pressure and Ko! is converted in rotational energy as te oil

escapes troug te jets producing speed up to ?666 0P * a"ove. Te

resultant Centrifugal force removes dirt from te engine oil depositing it on

te inner !all of rotor in a dense ca7e form. Clean oil drains "ac7 directly to

te tan7.

8



Centrifu'al Oil Cleanin' Process8

4en using te furnace oil in eat treatment furnace to not get te proper

com"ustion of te "urner system it is very dicult to run te furnace. Soot

formation.

%od,! Te aluminum "ody !ic ouses te rotor and te drive cam"er

allo!s te !ole system to "e mounted to an eternal structure an engine

cart or trolley. 3irty oil enters te centrifuge troug an inlet at te "ase of

te "ody. #il travels up troug a ollo! spindle until it encounters a "ae

at te top. Te "ae distri"utes te oil uniformly into te centrifuge rotor.

Rotor! Te rotor does te real "usiness of cleaning. #il pressure !itin te

rotor causes te assem"ly to rotate !itin te outer "ody at speeds

"et!een 2666 and ?-66 rpm. Tis in turn creates a centrifugal force tat is

%-66 times greater tan gravity. Dnder te inKuence of suc a strong force

particles do!n to onetent of a micron move radially to!ard te !all of te

rotor !ere tey form a dense ca7e. In some models te dirty rotor is

9



simply replaced !it a ne! oneJ in oter models te rotor is cleaned and

reused.

Dri#e C$amber! Clean oil eits te rotor and enters te drive cam"er

troug t!o opposing jets creating te propulsive force tat drives terotor. Eventually te oil eits te centrifuge at te "ase and returns to te

engine.

Result!

#il viscosity reduced

3ensity canged

4e are getting te sediment 1-66 grams of -666 liters furnace oil

!itin 1% rs. #il centrifuge.

Com"ustion improve

=o soot formation

Ecess air not re$uired.

Ad#anta'es of Centrifu'al S,stem3

• 5 centrifugal pump ta7es up little Koor space relative to say a plunger

pump and !eigs comparatively little so minimal structural

reinforcement is re$uired for te load "earing Koor space.

• It as a lo! initial cost as !ell as lo! maintenance cost since all motion is

rotary and tere are no sensitive parts suc as te valves in a plunger

pump.

• 5 centrifugal pump as te a"ility to andle muddy dirty and corrosive

li$uids it can pump !ater at temperatures of up to ,66 and circulate oil

at ig temperatures providing it reaces te pump at ig pressure ie. a

full pressure system.

• Tere is little if any vi"ration and te discarge of li$uid is continuous

and !itout soc7 and te Ko! can "e controlled from full Ko! to no Ko!

!itout sutting te pump do!n or damaging te pump or pipes

providing suita"le s!itcing gear as "een installed.

@.6 C#=C;DSI#=

10



Eamining te cost of energy allo!s us to identify priorities and

monitor $uality improvements.

Energy management is an increasingly important aspect of system

design

Proposed model provides te frame!or7 for te operating system to

manage energy as a (rstclass resource

5fter implementation of tese actions energy saving are found

satisfactory.

Te same metod !ill "e applied in all eat treatment furnaces and

energy cost !ill "rougt do!n up to 16 . In tis project past data is analy>ed unit !ise and ig energy !ise

3ata analysis so!s te top ten ig energy unit for energy are

contri"uting a"out ?6 energy cost. Te action plan is prepare for tis

major energy.

Control plan is prepared for reducing and controlling energy cost and

improves.

Tis report can "e used as a tool to understand te current energy

environment.

Tis study empasises te need for proper implementation of energy

audit recommendations in a planned and systematic manner.

Te implementation programme !as successful as !e entered

Suc an arrangement made it possi"le to (ne tune te (ndings of te

"ase line studies !or7 in close coordination !it operators * maintenance

people.

5fter te system !as commissioned !e monitored te furnace

operation troug esta"lised measurement and veri(cation procedures to

$uantify te savings.

11



;.7 !y"es

;.7.1

12



< 0esearc etodology

etho)o*o$y

13



7 1= Current status of te Project

14



11 Future Scope of te Project

15



1" Conclusion

16



1) 0eferences

1* 'i"liograpy:

17



1- 5""reviations

18



1 ;ist of (gures

19



1; 5ppendices:

20



Date post:	16-Mar-2016
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Enegy Auditing

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