AN INTRODUCTION Established in 1978 during energy crisis in India Oriented towards energy Conservation Well known for Designing Manufacturing Supplying and Commissioning of FUEL EFFICIENT HEATING SYSTEMS ID: 1025884
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1. ENCON THERMAL ENGINEERS…Answer to the Continued Need for Energy Conservation
2. AN INTRODUCTIONEstablished in 1978 during energy crisis in India.Oriented towards energy ConservationWell known for Designing, Manufacturing, Supplying and Commissioning of FUEL EFFICIENT HEATING SYSTEMS on Turn Key Basis
3. WE SERVE… Steel Plants Transformers & Distribution [T&D] Industries Automotive Industries Foundries Aluminum Industries Pharmaceutical Industries Cement Industries Glass Industries Ceramics & Refractory Industries
4. R&D ACTIVITIESStarted in the year 1997Project sponsored by Gas Authority of India Limited (GAIL) and Ministry of Science & Technology in partnership with Indian Institute of Petroleum, DehradunDeveloped gaseous film burner with savings of up to 16% compared to conventional burnersInnovated Gas Heating Elements which can retrofit any heating elements (electric energized) application up to 550°C temperatureDeveloped Burners for COKE OVEN & BLAST FURNACE GASDeveloped Pilot Burners for Coke Oven/ Mixed Gas & LPG
5. Company ActivityFully integrated facilities for Engineering ,Design, Manufacture and Assembling ofFurnacesWaste Heat Recovery SystemsRAD HEAT Gas Heating ElementsCombustion EquipmentHot Air GeneratorsOvensSteel Melt shop Equipment's
6. FURNACES Design and manufacture furnaces on turn key basis for the following industries Rolling Mills Forging Plants Heat Treatment Centers Wire Drawing Plants Aluminum Plant Steel Plants Guaranteed fuel consumption of as low as 33 ltr/ton for billet reheating furnaces
7. DESIGN METHODOLOGYCapacity RatingMaterial HandelingHearth LoadingHeat Loading & ZoningAutomation levelsPlanning of Combustion System
8. Capacity RatingIs fixed after deliberation with the ClientDepends on the size and mix of produce to be preheated.The material of the billets play an important part in finalizing capacity.
9. Material HandlingPredominantly Preheating furnaces can be divided into the following categories: Pusher TypeWalking beam /Walking hearthRotary hearth Considering the charge we plan the material handling
10. Hearth loading Based on the type of furnace hearth loading is determined , with the focus on heat transfer , Decarburization pattern of heating i.e Top Heating or Top and Bottom heating
11. Heat loading and zoningConsidering the design and capacity of the furnace different types and sizes of burners are recommended in the different zones of the furnace.Types of BurnersLAP Burners High Velocity/ Oxy Fuel
12. Automation In the FurnaceIn order to achieve greater efficiency in the furnace and further increase production and reduce scale losses the following automation in the furnace can be carried out:Temperature ControlPressure ControlAir/Fuel or Oxygen/Fuel Ratio Control
13. Oxy Fuel Technology Reduced Emissions NOx emissions are reduced substantially with a oxy-fuel conversion.Improved Efficiency and ProductionImprovement in fuel efficiency as compared with traditional air-fuel furnaces. The energy savings partially offsets the cost of oxygen. There scale formation also comes down to 0.3%Increased Furnace Refractory Life Temperature homogeneity of the furnace increases thus minimizing the chances of thermal shocks in the refractorySimplified Operation With no recuperator, the furnace operation and maintenance are simplified
14. 3D Images of the Proposed Furnace
15. 3D Images of the Proposed Furnace cont.….
16. 3D Images of the Proposed Furnace cont.…
17. 3D Images of the Proposed Furnacecont….
18. 3D Images of the Proposed Furnacecont.….
19. CFD OF FURNACE
20. RESULTS OF CFD ANALYSIS
21. Case Study INDIAN STEEL AND WIRE PRODUCT (ISWP) , A Subsidy of TATA STEEL
22. BACKGROUND OF ISWP The Furnace was initially designed by OFAG , Germany.The Furnace was designed to produce 30 to 32 Ton/hrThe Furnace was based on Bull Nose Design.
23. PROBLEMS FACED BYISWP IN THE FURNACEFrequent failure of the Roof and Bullnose of the FurnaceHigh Fuel Consumption up to 42 ltr/tonScale loss were as high as 1.5 %The furnace controls were present but not operationalThe Furnace throughput was limiting the production of steel
24. SUGGESTION MADE BY ENCONFurnace ModificationRedesigning the Bull nose design of the furnace by Camel HumpChange in the design of the Roof Bricks and Hangers.
25. SUGGESTION MADE BY ENCONCombustion SystemThe top firing LAP burners of the heating zone of the furnace were replaced by High velocity burners on the side wallThe Soaking Zone burners were kept the same
26. SUGGESTION MADE BY ENCON contd..Level 1 AutomationAutomatic temperature controlThis was achieved by placing 6 thermocouples in the furnace, 3 Thermocouples were placed in the soaking zone and 3 Thermocouples were placed in preheating zone.The air to fuel ratio was governed by a combination valve. The Furnace was divided into 6 zones three in soaking zone and three in Preheating zone.
27. RESULTS ACHIEVED BYTHE RETROFITFuel consumption has come down to 32.6ltr/Ton of steel produced.Scaling is down to 1%There has been no failure in the furnace for the last 1 year the furnace has been operational.The furnace is constantly producing steel at the rate of 35 Ton/hr.
28. CASE STUDY -2Revamping of Furnace at TATA SSL, BOISAR
29. PROBLEMS FACED BYSSL IN THE FURNACEHigh Fuel Consumption up to 47 ltr/tonImproper Soaking of the BilletsHigh Power Consumption by the MillFrequent break down of the MillThe Furnace was only producing 36 Ton against the designed capacity of 45 ton
30. MODIFICATIONS MADE BY ENCONHeat Load calculation were done and accordingly the combustion equipment's were changedBurnersBlowersRecuperatorsAir and Oil pipeline were redesigned and modified accordingly.
31. MODIFICATIONS MADE BY ENCON contd..Complete refractory lining was done againWallsRoofHearth Water Cooled skid
32. RESULTS ACHIEVEDIncrease in production by 16-25% from 36 tons/hr to 42-45 tons/hr.Fuel consumption reduced by 23-30% from 47 ltrs/ton to 33-36 ltrs/ton.Electrical Power consumption reduced by about 8%.Reduction in breakdowns due to better quality heated billets
33. DIVINE ALLOY, RANCHI25 ton/Hr BRHF
34. Designed a Top and Bottom fired furnace with water cooled skids and PID based control.The furnace is designed for firing Mixed Gas (Blast Furnace Gas and Producer Gas). The gas will be either enriched with Oxygen or supplementary firing of furnace oil will be done.All the combustion equipments are being supplied by us.Furnace Design
35. ELEVATION OF THE FURNACE
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39. BURNERS Oil BurnersGas BurnersDual Firing Burning SystemsHigh Velocity Burners (OIL/GAS)Pilot Burner for Coke Oven Gas/ LPG/NGCoke Oven & Blast Furnace Burner
40. RECUPERATORS Recuperators with flue temperatures of up to 950oCPreheat temperature of combustion air as high as 450oC Guaranteed savings of 15-20% and a minimum life of 3 years for ENCON Recuperators
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42. Jupiter- Encon Oxy-Fuel Technologyis a patented process for the combustion of fossil fuels with pure oxygenuses an undiluted high flame temperature, but keeps the same process temperaturescombusts at or near stoichiometricretrofitted using the same furnace design and refractories
43. Conventional Combustion v/sOxy-Fuel Traditional CombustionAir fuel fired 21% oxygen, 79% nitrogen3 to 5% excess airRelatively Low Flame TemperatureReadily Available Nitrogen to Create NOX. Nitrogen Increases the combustion volumes78% Potent heat escapes through Stack.Higher Flame temperature No change in furnace design and materialsPossibility of variable processes No change in versatility of the usageDoes not affect Inclusions/impurities in the re-melted aluminum
44. OVENS BY ENCON3D DESIGNING & CFD.In House CFD Modulation.Energized by GAS HEATING ELEMENT.Minimal Heat Loses .MODULAR TYPECeramic Fiber INSULATIONProper Air CIRCULATION with minimum electric consumption.TEMPERATURE UNIFORMITYENERGY CONSERVATION 50% IN COST ( Approximately)20%– 30% IN CO2 EMISSIONS
45. OVENS FOR TRNASFORMER INDUSTRY
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48. CORE DRYING OVENS FOR FOUNDARY
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52. LADLE HEATING SYSTEMLadle capacities up to 300 ton/hr. Pioneered the unique concept of recuperative ladle preheating system with guaranteed fuel consumption as low as 1.2 ltr/ton.Saves 20 – 60% Energized by LDO/LPG/HFO/COG/OXY FUEL
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55. LAUNDER HEATING SYSTEMShort and High momentum flame length achieved through high velocity burners.Energized by LDO/LPG/HFO/COG/ OXY FUEL
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57. TUNDISH HEATING SYSTEM
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60. RAD-HEAT GAS HEATING ELEMENTS Retrofitted in many applications which use Electrical Heaters, Thermic fluid up to a temperature of 550 oC Savings from 30% - 70%‘BEST TECHNOLOGY' award from NSIC'EXCELLENCE IN TECHNOLOGY' award from CII -SIDBI
61. Designing ENCON believes in continuously Up –gradation & updating our standards and setting new standards in the industry.This is not possible without the backing of proper design team and software’s to support them.We are among the very few in the country to use 3D software for designing of all our products. We are using SOLIDWORKS designing software.
62. LIST OF MACHINERY
63. SL.NOTYPE OF MACHINESMAKECAPACITYAVAILABLEQTY1Shearing M/CNIMOGA1-6 MM12Bending M/C NIMOGA1-6 MM13Lathe M/CAMT DELHI, TURNWELL6FT,9 FT,10FT34Rolling M/CUPTO 16 MM15Radial Drilling M/C UPTO 50 MM26Bench Drill M/C UPTO 12MM17Power Hecksaw M/C 14"18Welding SET(INVERTER TYPE)HM400 AMP39Welding Set (RECTIFIRE)BANSAL,WELDER,SUNSHINE400 AMP510Welding Set (TWO PHASE)MATADOR400 AMP211Welding set (3 PHASE)JMT400 AMP412Mig Welding M/CMATADOR,ARMAC.400 AMP413Hammer drill M/CDEWALT 114Angle Grinder BOSCHAG-71215Angle Grinder BOSCH (NEW)AG-51016Angle Grinder BOSCHAG-4117Hand Drill MachineBOSCH12 MM518ComperessorATLAS COPCO,MOTHERSONMOTOR CAP-7.5 HP, 5HP119Genset MAHINDRA82.5 KW120Hydra CraneESCORTS8/15 TON221Hand Press 222Weighing M/CACU WEIGH0-100KG,0-1000 KG223Pipe Cutting M/CDEWALTUPTO 4"124Magnet Drill M/CNEUTRON 125Gas Cutter SET[ESSAB]ESSABUPTO 50MM326Pug Cutting M/CESSABUPTO-20MM127Testing FurnaceENCON 128Testing OvenENCON 129Plasma cutting m/cMATADORUPTO-20MM130Electrode Heating ovenESSAB 831Channel Straightening132PIPE Cutting M/CUNIQE MACHINE 133CNC Plasma/Gas Cutting m/cHypertherm Max Pro 2001 TO 25 MM of SS& 300 MM of MS 1
64. Machinery Photo
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67. FACTORYTotal Land Available 10,120 SQMTTotal Covered Area 4600 SQMTOffice area 285 SQMT, 145 SQMT on ground floor & 140 SQMT on First floor Shed Area 2,620 SQMTPaint Booth 100 SQMTSand Blasting Booth 64 SQMT
68. WORKSHOP PHOTOS
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70. BOOTH FORSand Blasting & Painting
71. STORE
72. SOME OF OUR ESTEEMED CLIENTSAarti Steel Ltd.ABB LimitedAreva T & D India Ltd.Bajaj Auto Ltd.B.H.E.L.Bhilai Steel PlantBhushan Steels Ltd.Cummins India Ltd.Danielli India Ltd.DCM Engineering Ltd.Electrotherm (I) Ltd.Emirates Steel Co. LLCEscorts Ltd.Exide Industries Ltd.Godrej & Boyce Mfg. Co. Ispat Inds. Ltd.ISWP, Ltd.Jindal Strips Ltd.Jindal Stainless Ltd.JSW Steel Ltd.Kajaria Ceramics Ltd.Kirloskar Ferrous Inds. L G Electronics Ltd.Lloyds Steel Industries Mahavir AluminiumMahindra and Mahindra Mehru ElectricalsMukand Ltd.NALCOOrient Abrasives Ltd.Orient FansPolycab Cables Inds.Power Solutions Ltd.RHI Clasil Ltd.Rourkela Steel PlantSAILSamtel Color Ltd.Shriram Pistons & RingsShah Alloys Ltd.Siemens VAI MetalSimplex Castings Ltd.Skipper ElectricalsTata Motors Ltd.Tata Refractories Ltd.Tata Steels Ltd.Usha Martin Industries Viraj Profiles Ltd.Visa Steel Ltd.Visakhapatnam Steel PlantWelspun Steel Ltd.Whirlpool India Ltd.
73. THANK YOU!“ Adopt eco-friendly technologies that your children can be proud of ” Vishve Bandhu Mahendra