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Tata Lucknow Waste Heat Recovery Project

Tata Lucknow has 3 no of Durr Ovens ED Oven, TC Oven 1 & TC Oven 2.

Heat recovery unit will be installed in ED Oven, TC Oven 1 & TC 2 Oven

Total Heat Recovery from Hot flue gas from oven Exhaust is approximately=

Waste heat of Oven will be used to raise the temp of water used in PT CED line from 85o C to 95 o C

Total project cost = Rs 1.06 cr.

Return on investment 10 months

Propane savings 75 kg/hr with annual savings of Rs 2.2 cr (propane price Rs 72 per kg)

Project Highlights

828100 Kcal/hr

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TC-2 Oven

TC-1 Oven

ED Oven

Hot Water Generator 1

KOD Hot Water Rinse Degrease ActivationPhosphating

Hot Water Generator 2

PT Tanks

Hot Water Supply (85°c) to PT tanks

Return Water from PT tanks (75°c) to Heat Exchanger then Hot Water Generator

Exhaust to atmosphere 100°c

Exhaust to atmosphere 100°c

Exhaust to atmosphere 100°c

• With Heat Recovery Units (HRU’s)

Tata Lucknow Waste Heat Recovery Project

HRU

HRU

HRU

Hot Water at 100°c

Heat Exchanger

Return Cold water

Hot Water Generator will not run as oven exhaust heat will be sufficient to maintain the PT tanks temperatures

Total Heat Recovered 318500 Kcal/hr-ED

Total Heat Recovered 254800 Kcal/hr-TC2

Total Heat Recovered 254800 Kcal/hr –TC1

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HRU

HRU

TC-2 Oven (5.6mtr)

TC-1 Oven (5.6 mtr)

ED Oven (5.6 mtr)

Boiler 1

Boiler 2

Return water from PTED at 75'c

Supply water to PTED at 90'c

Hot water at 85'c

Cold water at 75'c

Heat Exchanger

Pipings at 16 mtr

Boiler at 0mtr

HRU

Location of HRU with piping's at 5.6 mtr in TML Lko Paint Shop

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Calculation sheet – Heat Recovery system

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Installation of Heat Exchanger With diverter valve Assy- E.D. Oven

Shell & Tube Heat Exchanger

Motorized Actuated

Diverter valve

Stainless Steel Ducting

Flow Meter

Hot Water O/P

Cold water I/P

Pressure Indicator

Resistance temperature

detectors

DP Water Switch

Flue Gas Back Pressure Switch

Allen Bradley PLC panel

Control Logic L71

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Heat Recovery from ED Oven

TOTAL Savings from 3 Systems = 828100 Kcal /Hr.

Propane Savings of approx. 75 Kg/ Hr.

Total Project Cost= Rupees 1.06 cr

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Propane Gas consumption Trend

Start of ED & Top coat Heat Recovery System

( partially ) without Insulation