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BEE SME Program in
Jamnagar Brass Cluster
November 19, 2009
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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
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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
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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
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Major Energy ConsumingMajor Energy Consuming
EquipmentsEquipments
Melting furnaces
Induction furnaces
Reheating furnaces
Annealing furnaces
Hydraulic press (Motors)
Blowers
Cooling towers
Pumps
Compressors
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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
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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../-
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Energy Conservation OpportunitiesEnergy Conservation Opportunities
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../-
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Energy Conservation OpportunitiesEnergy Conservation Opportunities
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
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Energy Conservation OpportunitiesEnergy Conservation Opportunities
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../-
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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
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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
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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