bee sme program in jamnagar brass cluster november 19, 2009

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../-


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../-


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../-

…


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

bee sme program in jamnagar brass cluster november 19, 2009

Documents