bee sme program in jamnagar brass cluster november 19, 2009
TRANSCRIPT
BEE SME Program in Jamnagar Brass Cluster
November 19, 2009
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
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
Fuel used & typical end use Fuel used & typical end use energy 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
Major Energy Major Energy Consuming EquipmentsConsuming Equipments
Melting furnaces Induction furnaces Reheating furnaces Annealing furnaces Hydraulic press (Motors) Blowers Cooling towers Pumps Compressors
Typical process flow chartTypical process flow chartPreparation 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
Energy Conservation OpportunitiesEnergy Conservation Opportunities
Reheating Furnace Selecting proper capacity and
scientifically designed burners Reducing the radiation losses, by
improving the insulation Design improvements in Reheating
furnace (by zoning and flame direction) Fuel switching option in Reheating
furnace Appropriate capacity of heating and
pumping unit in oil service tank Temperature control inside the Re
heating furnace
Reheating Furnace (contd..) Air-fuel control mechanism, for
efficient combustion Installation of waste heat recovery
option in Reheating furnace Improved design of recuperative
system in Reheating furnace Exhaust gasses location in Reheating
furnace Insulation of fuel supply & air supply
lines
Energy Conservation Energy Conservation OpportunitiesOpportunities
Contd../-
Energy Conservation OpportunitiesEnergy Conservation Opportunities
Melting Furnace
Improving the melting furnace lining and insulation
Redesign of melting furnace Temperature control of molten
material Fuel switching option in
melting furnace Selection and proper capacity
and scientifically designed blower
Air-fuel control system
Contd../-
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 of induction furnace
Reducing the idle time by installing exclusive energy meters for Induction furnace
Percentage load in Induction Furnace
Adopting Best Operational Practices
Contd../-
…
Energy Conservation OpportunitiesEnergy Conservation Opportunities
Electrical utilities: Replacement of conventional motors
with Energy Efficient ones
Use of flat belts in place of conventional belts
Replacement of conventional Blowers with efficient ones
Adopting Best Operational Practices Blowers & Compressors
Replacement of conventional cooling towers with efficient ones
Installation of timers in cooling towers
Contd../-
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 for melting 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
Issues/Barriers in penetration Issues/Barriers in penetration of of
Energy 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 and efficiency, due to lack of instrumentation & non availability of Energy consumption data
Limited manpower
Lack of trained manpower
Limited information on new technologies
Implementation cost of Energy conservation options
Status / Work Progress in Status / Work Progress in ClusterCluster
Completed Energy use & Technology audit studies in 40 units
Identified the areas of major energy consuming equipments
Identified Energy conservation measures in various types of brass 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 new technologies are under finalization
Implemented the no or low cost measures in the cluster