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| Case Study 6 |
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| PLANT DESCRIPTION |
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The Furnace was initially designed by OFAG, Germany.
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Rated Capacity 30 to 32 Ton/hr.
- Bull Nose Design.
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| PROBLEMS FACED
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Frequent failures of the 'Roof' and 'Bull-nose' of the Furnace
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High Fuel Consumption (up to 42 ltr/ton)
- Scale loss as high as 2%
- No Auto controls
- Interrupted production
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| MODIFICATIONS CARRIED
BY ENCON
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| Furnace Modification |
- Except for Hearth and 2 meters of Preheating Zone the complete furnace was redesigned.
- 'Bull Nose' was changed to 'Camel Hump' design.
- Change in the design of the Roof Bricks and Hangers for longevity.
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| Combustion System
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Soaking zone burners were retained as LAP burners
- Heating zone burners were changed to High Velocity with their placement done on side walls for uniformty
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| Level 1 Automation incorporated
- Automatic temperature control
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- 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 controls were divided into 6 zones - 3 in soaking zone and 3 in Preheating zone.
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| BEFORE |
AFTER |
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| RESULTS
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SFC 32.6 ltr/Ton (earlier 42 ltr/ton)
- Scaling is down to 1%(earlier 2%)
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Continuous operations for 2 years (earlier breakdowns every 3 months)
- Uninterrupted yield of the rated capacity of 33-35 Ton/hr.
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