USE OF COKELESS (GAS FIRED ) CUPOLA CUSTOMERS PERSPECTIVE BY GUDURU MURALI

WELCOME TO PORWAL GROUP OF INDUSTRIES PORWAL IS A WELL KNOWN AND ETABLISHED INDUSTRIAL GROUP IN M.P. STARTED IT’S BUSINESS IN THE YEAR 1963 AS A MANUFACTURER OF DIESEL ENGINES WITH A BRAND NAME FIELD MASTER. PORWAL GROUP HAS THEIR IDENTITY IN 5 DIFFERENT FIELDS MANUFACTURE OF DUCTILE (S.G ) AND GREY CAST IRON CASTINGS A COMPLETE HOUSE FOR MACHINING SOLUTIONS CONVENTIONAL & CNC MANUFACTURE OF DIESEL ENGINES MANUFACTURE OF SUPER ENAMELLED & SUBMERCIBLE COPPER WIRES MANUFACTURE OF DECORATIVE ITEM CASTING PRODU CTS

ESTABLISHED IN THE YEAR WE ARE AN AUTOMOBILE(S.G/GREY IRON) FOUNDRY WITH AN INSTALLED CAPACITY OF 1750 MT/MONTH PRESENTLY PRODUCING AROUND 1200MT/MONTH PACL PRODUCES ALL TYPES OF AUTOMOBILE CASTINGS OTHER THAN BLOCKS AND HEADS PORWAL AUTO COMPONENTS LTD.

HAVE TWO ARPA 450 CONVENTIONAL MOULDING LINES WITH SEMI AUTOMATED /MECHANISED MOULD HANDLING AND POURING SYSTEMS. HIGH PRESSURE MOULDING LINE OF FONDARC. AUTOMATED SAND PLANT OF 80 TPH WITH COOLING AND DUST EXTRACTION SYSTEM. WELL ESTABLISHED CNC MACHINE SHOP. FACILITIES

MELT SHOP CONSISTS 650 KW 1000 KG DUAL TRAK FURNACE OF INDUCTOTHERM MAKE KW 2000 KG DUAL TRAK FURNACE OF INDUCTOTHERM. GAS FIRED COKELESS TWIN CUPOLA OF WESMAN WITH 3T/Hrs CAPACITY. FACILITIES

WHY GAS FIRED CUPOLA PACL HAD COKE FIRED CUPOLA ALONG WITH INDUCTION FURNACE PROBLEMS ASSOCIATED WITH COKE TYPE CUPOLA,POLLUTION AND POLLUTION CONTROLLING EQUIPMENT. POLLUTION RELATED ISSUES WITH PCB’S HIGH OPERATION AND ENERGY COSTS PACL DISMANTLED COKE TYPE CUPOLA AND INSTALLED GAS FIRED COKELESS CUPOLA IN THE YEAR 2006 GAS FIRED COKELESS CUPOLA

HIGHLY POLLUTANT NEED POLLUTION CONTROL EQUIPMENT NEED EXPERT OPERATOR TO OPERATE POOR INSTRUMENTATION MORE POLLUTION RELATED ISSUES WITH PCB’S NO CONTROL ON HEAT INPUT SULPHUR PICKUP NO POLLUTION,CLEAN ENVIRONMENT DOES’NT REQUIRE POLLUTION CONTROL EQUIPMENT DO NOT REQUIRE EXPERT,EASY OPERATION GOOD INSTRUMENTATION LESS HURDLES WITH PCB’S PLC OPERATED,HEAT INPUT CAN BE CONTROLLED NO SULPHUR PICKUP COKE TYPE Vs COKELESS CUPOLA

INDUCTION FURNACE VS COKELESS CUPOLA EASY TO OPERATE BETTER CONTROLS ENERGY EFFICIENT LOW LINING COST NO LIMITATION ON CHARGE MATERIALS NEED POLLUTION EQUIPMENT INITIAL COST IS HIGH EASY TO OPERATE BETTER CONTROLS LESS ENERGY EFFICIENT HIGH LINING COST LIMITATION IN USING VARIETY OF SCRAP DO NOT REQUIRE POLLUTION EQUIPMENT INITIAL COST IS LOW

GAS FIRED CUPOLA

PIG IRON 35-40% RUNNER RISER,REJECTED CASTINGS 40-45% SPILLAGE & TRAMP IRON 10-15% C.I.BRIQUETTES 10-15% TAPPING TEMPERATURE Deg.C GAS FIRED CUPOLA CHARGE MIX

GAS PREUSSURE REGULATOR AIR PRESSURE SWITCH DIFFERENTIAL PRESSURE TRANSDUCERS AIR AND GAS MODULATING VALVES FUEL SHUT OFF SOLENOID VALVES MANOMETERS BAROW METER 5POSITION ROTARY SWITCH MMI REGULATES THE GAS PRESSURE BASED ON FLOW REUIREMENT TO IDENTIFY THE BLOWER RUNNING TO GIVE FEEDBACK TO PLC THE RATE OF AIR & GAS FLOW TO CONTROL THE FLOW OF AIR AND GAS TO CLOSE THE GAS IN CASE OF EMERGENCIES TO MAINTAIN DIFFERENTIAL PRESSURE OF AIR AND GAS FOR EACH BURNER TO MAINTAIN THE INTERNAL PRESSURE. TO CONTROL THE MELT RATE TO SET AND MONITOR AIR & GAS PARAMETERS INSTRUMENTATION

CONTROL PANEL

INSTRUMENTATION GAS LINE PRESSURE REGULATOR AIR PRESSURE SWITCH

INSTRUMENTATION GAS SHUT OFF VALVEAIR MODULATION VALVE

INSTRUMENTATION DIFFERENTIAL PRESSURE TRANSDUCER INTERNAL PRESSURE GUAGE

MODIFIED LINING METHOD TO IMPROVE HEARTH LINING LIFE FROM 48 HRS TO 144 HRS RE INSTALLED BLOWERS AND CONTROL PANELS IN THE MAZZENINE FROM GROUND TO AVOID BREAKDOWNS & MORE WORKING SPACE INTRODUCED RR BREAKER TO IMPROVE PACK DENSITY. IMPROVED WATER COOLING SYSTEM TO IMPROVE GRATE BAR AND LINING LIFE IMPROVED SKIP HOIST TO MINIMISE BREAKDOWNS INTRODUCED GRANULATION OF SLAG FOR EASY DISPOSAL & FOR BETTER WORKING ENVIRONMENT INTRODUCED BRIQUETTING FOR COST SAVING IMPROVEMENTS MADE BY PACL

INTRODUCED SLAG GUTTER FOR GRANULATION

BLOWERS & CONTROL PANEL SHITED TO MAZZENINE

INTRODUCED RR BREAKER TO IMPROVE PACK

15-20% BRIQUETTES ARE USED IN THE CHARGE FOR COST SAVING INTRODUCED BRIQUETTING MACHINE FOR BRIQUETTING CI BOARING

COMPLETE CUPOLAS

PACL BELIEVES GAS FIRED CUPOLA IS AN ALTERNATE PRIMARY MELTING SOURCE WHERE POLLUTION IS A MAJOR HURDLE POWER IS A MAJOR HURDLE NOT A REPLACEMENT FOR INDUCTION FURNACE CONCLUSION