ENCON THERMAL ENGINEERS …Answer to the Continued Need for Energy Conservation

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 on Turn Key Basis

WE SERVE… Steel Plants Transformers & Distribution [T&D] Industries Automotive Industries Foundries Aluminum Industries Pharmaceutical Industries Cement Industries Glass Industries Ceramics & Refractory Industries

R&D ACTIVITIES Started in the year 1997 Project sponsored by Gas Authority of India Limited (GAIL) and Ministry of Science & Technology in partnership with Indian Institute of Petroleum, Dehradun Developed gaseous film burner with savings of up to 16% compared to conventional burners Innovated Gas Heating Elements which can retrofit any heating elements (electric energized) application up to 550°C temperature Developed Burners for COKE OVEN & BLAST FURNACE GAS Developed Pilot Burners for Coke Oven/ Mixed Gas & LPG

Company Activity Fully integrated facilities for Engineering,Design, Manufacture and Assembling of  Furnaces  Waste Heat Recovery Systems  RAD HEAT Gas Heating Elements  Combustion Equipment  Hot Air Generators  Ovens  Steel Melt shop Equipment's

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

DESIGN METHODOLOGY Capacity Rating Material Handeling Hearth Loading Heat Loading & Zoning Automation levels Planning of Combustion System

Capacity Rating Is fixed after deliberation with the Client Depends on the size and mix of produce to be preheated. The material of the billets play an important part in finalizing capacity.

Material Handling Predominantly Preheating furnaces can be divided into the following categories: –Pusher Type –Walking beam /Walking hearth –Rotary hearth Considering the charge we plan the material handling

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

HEAT LOADING AND ZONING Considering the design and capacity of the furnace different types and sizes of burners are recommended in the different zones of the furnace. Types of Burners –LAP Burners –High Velocity/ Oxy Fuel

Automation In the Furnace In 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 Control Pressure Control Air/Fuel or Oxygen/Fuel Ratio Control

Oxy Fuel Technology Reduced Emissions NOx emissions are reduced substantially with a oxy-fuel conversion. Improved Efficiency and Production Improvement 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 refractory Simplified Operation With no recuperator, the furnace operation and maintenance are simplified

3D Images of the Proposed Furnace

3D Images of the Proposed Furnace cont.….

3D Images of the Proposed Furnace cont.…

3D Images of the Proposed Furnace cont….

3D Images of the Proposed Furnace cont.….

CFD OF FURNACE

RESULTS OF CFD ANALYSIS

Case Study INDIAN STEEL AND WIRE PRODUCT (ISWP), A Subsidy of TATA STEEL

BACKGROUND OF ISWP The Furnace was initially designed by OFAG, Germany. The Furnace was designed to produce 30 to 32 Ton/hr The Furnace was based on Bull Nose Design.

PROBLEMS FACED BY ISWP IN THE FURNACE Frequent failure of the Roof and Bullnose of the Furnace High Fuel Consumption up to 42 ltr/ton Scale loss were as high as 1.5 % The furnace controls were present but not operational The Furnace throughput was limiting the production of steel

SUGGESTION MADE BY ENCON Furnace Modification –Redesigning the Bull nose design of the furnace by Camel Hump –Change in the design of the Roof Bricks and Hangers.

SUGGESTION MADE BY ENCON Combustion System –The top firing LAP burners of the heating zone of the furnace were replaced by High velocity burners on the side wall –The Soaking Zone burners were kept the same

SUGGESTION MADE BY ENCON contd.. Level 1 Automation –Automatic temperature control This 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.

RESULTS ACHIEVED BY THE RETROFIT Fuel 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.

CASE STUDY -2 Revamping of Furnace at TATA SSL, BOISAR

PROBLEMS FACED BY SSL IN THE FURNACE High Fuel Consumption up to 47 ltr/ton Improper Soaking of the Billets –High Power Consumption by the Mill –Frequent break down of the Mill The Furnace was only producing 36 Ton against the designed capacity of 45 ton

MODIFICATIONS MADE BY ENCON Heat Load calculation were done and accordingly the combustion equipment's were changed »Burners »Blowers »Recuperators Air and Oil pipeline were redesigned and modified accordingly.

MODIFICATIONS MADE BY ENCON contd.. Complete refractory lining was done again Walls Roof Hearth Water Cooled skid

RESULTS ACHIEVED Increase in production by 16-25% from 36 tons/hr to tons/hr. Fuel consumption reduced by 23-30% from 47 ltrs/ton to ltrs/ton. Electrical Power consumption reduced by about 8%. Reduction in breakdowns due to better quality heated billets

DIVINE ALLOY, RANCHI 25 TON/HR BRHF

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

ELEVATION OF THE FURNACE

BURNERS Oil Burners Gas Burners Dual Firing Burning Systems High Velocity Burners (OIL/GAS) Pilot Burner for Coke Oven Gas/ LPG/NG Coke Oven & Blast Furnace Burner

RECUPERATORS Recuperators with flue temperatures of up to 950 o C Preheat temperature of combustion air as high as 450 o C Guaranteed savings of 15-20% and a minimum life of 3 years for ENCON Recuperators

Jupiter- Encon Oxy-Fuel Technology 1.is a patented process for the combustion of fossil fuels with pure oxygen 2.uses an undiluted high flame temperature, but keeps the same process temperatures 3.combusts at or near stoichiometric 4.retrofitted using the same furnace design and refractories

Conventional Combustion v/s Oxy-Fuel Traditional Combustion –Air fuel fired 21% oxygen, 79% nitrogen –3 to 5% excess air Relatively Low Flame Temperature Readily Available Nitrogen to Create NO X. Nitrogen Increases the combustion volumes 78% Potent heat escapes through Stack. Higher Flame temperature No change in furnace design and materials Possibility of variable processes No change in versatility of the usage Does not affect Inclusions/impurities in the re-melted aluminum

OVENS BY ENCON 3D DESIGNING & CFD. In House CFD Modulation. Energized by GAS HEATING ELEMENT. Minimal Heat Loses. MODULAR TYPE Ceramic Fiber INSULATION Proper Air CIRCULATION with minimum electric consumption. TEMPERATURE UNIFORMITY ENERGY CONSERVATION »50% IN COST ( Approximately) »20%– 30% IN CO2 EMISSIONS

OVENS FOR TRNASFORMER INDUSTRY

CORE DRYING OVENS FOR FOUNDARY

LADLE HEATING SYSTEM Ladle 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

LAUNDER HEATING SYSTEM Short and High momentum flame length achieved through high velocity burners. Energized by LDO/LPG/HFO/COG/ OXY FUEL

TUNDISH HEATING SYSTEM

RAD-HEAT GAS HEATING ELEMENTS Retrofitted in many applications which use Electrical Heaters, Thermic fluid up to a temperature of 550 o C Savings from 30% - 70% ‘BEST TECHNOLOGY' award from NSIC 'EXCELLENCE IN TECHNOLOGY' award from CII -SIDBI

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.

LIST OF MACHINERY

SL.NOTYPE OF MACHINESMAKE CAPACITY AVAILABLE QTY 1Shearing M/CNIMOGA1-6 MM1 2Bending M/CNIMOGA1-6 MM1 3Lathe M/CAMT DELHI, TURNWELL6FT,9 FT,10FT3 4Rolling M/CUPTO 16 MM1 5Radial Drilling M/C UPTO 50 MM2 6Bench Drill M/C UPTO 12MM1 7Power Hecksaw M/C 14"1 8Welding SET(INVERTER TYPE) HM 400 AMP 3 9 Welding Set (RECTIFIRE)BANSAL,WELDER,SUNSHINE 400 AMP 5 10 Welding Set (TWO PHASE)MATADOR 400 AMP 2 11 Welding set (3 PHASE)JMT 400 AMP 4 12Mig Welding M/CMATADOR,ARMAC.400 AMP4 13Hammer drill M/CDEWALT 1 14Angle GrinderBOSCHAG Angle GrinderBOSCH (NEW)AG Angle GrinderBOSCHAG-41 17Hand Drill MachineBOSCH12 MM5 18ComperessorATLAS COPCO,MOTHERSONMOTOR CAP-7.5 HP, 5HP1 19GensetMAHINDRA82.5 KW1 20Hydra CraneESCORTS8/15 TON2 21Hand Press 2 22Weighing M/CACU WEIGH0-100KG, KG2 23Pipe Cutting M/CDEWALTUPTO 4"1 24Magnet Drill M/CNEUTRON 1 25Gas Cutter SET[ESSAB]ESSABUPTO 50MM3 26Pug Cutting M/CESSABUPTO-20MM1 27Testing FurnaceENCON 1 28Testing OvenENCON 1 29Plasma cutting m/cMATADORUPTO-20MM1 30Electrode Heating ovenESSAB 8 31Channel Straightening1 32PIPE Cutting M/CUNIQE MACHINE 1 33CNC Plasma/Gas Cutting m/cHypertherm Max Pro TO 25 MM of SS& 300 MM of MS1

Machinery Photo

FACTORY Total Land Available 10,120 SQMT Total Covered Area 4600 SQMT Office area 285 SQMT, 145 SQMT on ground floor & 140 SQMT on First floor Shed Area 2,620 SQMT Paint Booth 100 SQMT Sand Blasting Booth 64 SQMT

WORKSHOP PHOTOS

BOOTH FOR Sand Blasting & Painting

STORE

SOME OF OUR ESTEEMED CLIENTS Aarti Steel Ltd. ABB Limited Areva T & D India Ltd. Bajaj Auto Ltd. B.H.E.L. Bhilai Steel Plant Bhushan Steels Ltd. Cummins India Ltd. Danielli India Ltd. DCM Engineering Ltd. Electrotherm (I) Ltd. Emirates Steel Co. LLC Escorts 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 Aluminium Mahindra and Mahindra Mehru Electricals Mukand Ltd. NALCO Orient Abrasives Ltd. Orient Fans Polycab Cables Inds. Power Solutions Ltd. RHI Clasil Ltd. Rourkela Steel Plant SAIL Samtel Color Ltd. Shriram Pistons & Rings Shah Alloys Ltd. Siemens VAI Metal Simplex Castings Ltd. Skipper Electricals Tata Motors Ltd. Tata Refractories Ltd. Tata Steels Ltd. Usha Martin Industries Viraj Profiles Ltd. Visa Steel Ltd. Visakhapatnam Steel Plant Welspun Steel Ltd. Whirlpool India Ltd.

THANK YOU! “ Adopt eco-friendly technologies that your children can be proud of ” Vishve Bandhu Mahendra