Proud to be Making in India

Transcription

1 Proud to be Making in India Abstract Vishve Bandhu Mahendra, Director ENCON Thermal Engineers (P) Ltd. 297, Sector 21B, Faridabad EmaI: VBM@ENCON.CO.IN Sincerely thanking MECON for up-scaling the cause and plight of Indian Industries which we feel had been grossly underrated / undervalued. Though the Indian brains are the best among the equals but still to get recognition, we have to fish for endorsement from the coveted foreign bodies / universities / institutions. Getting back to the root cause for so low self-esteem, we find that this was the society which gave thinkers like Aryabhata, Chanakya, Dayananda Saraswati, Buddha and so on & today, we believe that whatever is Indian is not as good as Made in Foreign. ENCON- in its journey of innovations and developments of Indigenous technologies, have developed the following concepts, mentioned in chronological order. In our journey of 38 years, most of the things or concepts were approved / demonstrated outside India first to get an acceptance in the country of its origin. This is the irony of the situation and hard facts to be undone by aware minds Condensate recovery system with water pre-heater from boiler waste gases. Development of Indigenous Recuperator Conversion of Oil Fired Boiler to Coal cum Wood Firing. Designing of 4-5 tonnes per hour of Billet Reheating Furnace (BRHF) Achieving 30 % savings in BRHF for forging industries. Supplied 12 BRHFs to one forging plant in Gujarat, with all new concepts Development of Indigenous Recuperator. Introduction of IIP-ENCON film burner, which is an Icon in International Industry now Developed first Indigenous Recuperative Ladle pre-heaters with engineers of Mukand Ltd, Bombay. Step wise improvements resulted in 75 % savings.

2 1994 Major breakthrough in Aluminium melting technology by introducing Ceramic fiber Lining & Mono Block Burner. Resulted in 95 % saving in Electrical energy & 30 % in oil consumption Advent of rationalizing the use of energy- Converted electrical heating to indirect oil / gas firing Redesigned and modernized a 45 TPH - BRHF at Tata SSL, Tarapur on a modest investment of $150,000, resulting in the savings of $100,000 per month Development of RAD-Heat Gas heating elements for low temperature heating applications. Broadly retrofitted electrical heating to gas heating. Savings up to 70 % in the energy costs and CO 2 emission up to 33 % Development of Indigenous Industrial gas burner by our R&D Centre. Project sponsored by Ministry of Science & Technology and GAIL, in partnership with IIP, achieved savings up to 16 % in Industrial Gas Burners Advent of Raycon system to dry patch up line in induction furnaces resulting in energy transfer from electrical heating to oil - a prime fuel Development of Coke oven gas burners for steel plants using coke oven gas as predominant fuel. Now being used by - BSP, VIZAG, RSP, JSW, Bhushan steel plants etc. We hope our views will help fellow INDIANS to introspect and regain the dented selfesteem and EMERGE AS THE WORLD LEADERS what we are supposed to be.

3 Introduction ENCON s journey began during the 1970 s when the country was facing with petroleum crisis, as no foreign country was willing to provide petroleum oil to India. The industrial units which were dependent on this raw material were forced to purchase at a very high price. Today, ENCON offers start to end innovative and cutting edge solutions to various businesses to save energy. During the last four decades, ENCON has come out with over 19 new concepts/innovations in totality that provide solutions for conserving energy in different arena of Steel plants, Herbal medicine making, Automotive units and Transmission & Distribution (T&D). We help our clients to buy the right products rather than selling them. We ensure that our customers understand what they require and then we strive to provide them with the most energy efficient products that match their requirements. Most of the times, there are big gaps in the understanding of products. Rationalization of solutions is the way we work. We are working with Tata Steel, Tata Motors, JSW, SAIL plants, DCM, AREVA, Alstom and Primetals to name a few. ENCON s journey since Inception Several entrepreneurs tried new ways of production using latest technology available during 1970 s. ENCON was formed to fill this vacuum in We started advising various businesses on the ways and methods to reduce energy consumption as well as providing equipment for the same. By answering to the continued need of Energy Conservation and following the vision of Make in India, ENCON has come-up with comprehensive solution to Industrial heating applications which are elaborated below. Fig 1: IIP-ENCON Film Burners Fig 2: Gas Burners

4 IIP - ENCON Film Burners (Save : 5-15 %) Winner of President s award for saving fuel Designed and developed by Indian Institute of Petroleum (IIP) & Petroleum Conservation Research Association (PCRA) Useful for a wide range of industrial applications Multi-fuel usage High Velocity Burners (Save : %) Ideal for Non-Ferrous Melting Furnaces Tundish & Launder Pre Heating Gas Burners (Save : 5-15 %) Developed by IIP - ENCON at ENCON s R & D Centre. A project sponsored by Ministry of Science & Technology (DST) and Gas Authority of India Limited (GAIL) We design Burners for Gases with calorific value as low as 780 kcal/nm³ Fig 3: Ladle Pre-heaters/Dryers Fig 4:Waste heat recovery Recuperators Ladle Pre-Heaters / Dryers (Save : %) Long & lazy flame leads to uniform heating across the Ladle length eliminating chances of any cold zone in the Ladle

5 Pioneered the unique concept of RECUPERATIVE ladle preheating system to guarantee fuel consumption as low as 1.2 liters/ton of Ladle capacity heated CERAMIC FIBRE is used for the lining of the system, the minimum life of the lining is one year These systems can be energized by LDO/LPG/ HFO/COKE OVEN GAS/OXY FUEL Waste heat recovery Recuperators (Save : %) Special Alloy Finned Tubes Preheat Temperature C Expected Life - 7 to 10 years Service Duty up to 550 C Flue Gas Temperature of 950 C Fig 5: Tundish Pre-heaters/Dryers Fig 6: Launder Pre-heaters/Dryers Tundish Pre-Heaters/Dryers (Save : %) Short and high momentum flame length achieved through HIGH VELOCITY BURNER Faster and Uniform Heating CERAMIC FIBRE is used for the lining of the system, the minimum life of the lining is one year These systems can be energized by LDO/LPG/ HFO/COKE OVEN GAS/OXY FUEL

6 Launder Pre-Heaters/Dryers (Save : %) The systems are tailor-made as per the requirement of the plant Same advantages as that of Tundish Pre-heaters Fig 7 : Raycon Systems Fig 8 : Oxy-Fuel Systems Raycon Systems All the Induction Furnaces producing M.S. Ingots require their worn-out refractory lining to be patched-up in 22 to 24 Heats For example, in a 7 Ton Induction Furnace, the heating time of the Freshly Patchedup Lining in the furnace should come down by 30 minutes Reduced Heating Time Substantial savings in energy cost More No. of Heats per Month Oxy-fuel systems World Patented Technology for Process Heating Awarded Star of Energy Efficiency by Alliance to Save Energy Increase in Production Decrease in Fuel Consumption

7 Natural gas fuel reduction up to 73 % Oil fuel usage reduction up to 68 % The improved Efficiency/Production is due to: Elimination of Airborne Nitrogen Increase in Radiant Heat Transfer Longer gas residence time Reduction in Green House Gases: 69 % reduction in CO 69 % reduction in SO x 31 % reduction in VOC s Apart from the above mentioned technologies, we also provide solutions for Low Temperature heating by using the equipment, Transformer drying Ovens Paint Baking Ovens Core Drying Ovens Sand Dryers Fig 9 : Schematic of Tray Drying Ovens Fig 10 : Schematic of Paint Drying Ovens Encon R&D Centre was established in 1996 to develop Gas Based Combustion Technologies. We have developed RAD-HEAT Gas Heating Elements (Fig 9 & 10), High Velocity Gas

8 Burners, and Lances etc. at this centre with more innovations being tested for benefiting the industries. ENCON s other verticals Now we are looking at expanding our verticals viz., Renewable energies like Solar and Nano Hydro technologies. Air cleaning systems for which tie-up with established German partners is already formed We are also looking for technical or investment partners, who believe in our philosophy, our vision, and mission, which would accelerate our growth. Conclusions Make in India is a great initiative started by the Government. In order for this initiative to succeed, lot of changes is required in the mindset of the people. We, as Indian creed, should have respect and believe in Indian innovations and the capability of Indian manufacturer. It becomes painful and nearly impossible to do business with PSUs and such like organizations when they have different measuring rods in accepting Indian produced vis-a-vis the foreign produced products / technologies. Although, operational and performance parameters and guarantees with proven track record are the same.