Transcript Slide 1

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 PRODUCTS
PORWAL AUTO COMPONENTS LTD.
 ESTABLISHED IN THE YEAR 1995.
 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
FACILITIES
 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.
 1500 KW 2000 KG DUAL TRAK FURNACE OF
INDUCTOTHERM.
 GAS FIRED COKELESS TWIN CUPOLA OF WESMAN
WITH 3T/Hrs CAPACITY.
GAS FIRED COKELESS CUPOLA
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
COKE TYPE Vs COKELESS CUPOLA
 HIGHLY POLLUTANT
 NO POLLUTION,CLEAN
 NEED POLLUTION CONTROL
EQUIPMENT

 NEED EXPERT OPERATOR TO
OPERATE

 POOR INSTRUMENTATION
ENVIRONMENT
DOES’NT REQUIRE POLLUTION
CONTROL EQUIPMENT
DO NOT REQUIRE EXPERT,EASY
OPERATION
 MORE POLLUTION RELATED  GOOD INSTRUMENTATION
ISSUES WITH PCB’S
 LESS HURDLES WITH PCB’S
 NO CONTROL ON HEAT
INPUT
 PLC OPERATED,HEAT INPUT CAN
 SULPHUR PICKUP
 NO SULPHUR PICKUP
BE CONTROLLED
INDUCTION FURNACE VS COKELESS CUPOLA
 EASY TO OPERATE
 EASY TO OPERATE
 BETTER CONTROLS
 BETTER CONTROLS
 ENERGY EFFICIENT
 LESS ENERGY EFFICIENT
 LOW LINING COST
 HIGH LINING COST
 NO LIMITATION ON
CHARGE MATERIALS
 NEED POLLUTION
EQUIPMENT
 INITIAL COST IS HIGH
 LIMITATION IN USING VARIETY
OF SCRAP
 DO NOT REQUIRE POLLUTION
EQUIPMENT
 INITIAL COST IS LOW
GAS FIRED CUPOLA
GAS FIRED CUPOLA
GAS FIRED CUPOLA CHARGE MIX
 PIG IRON 35-40%
 RUNNER RISER,REJECTED CASTINGS 40-45%
 SPILLAGE & TRAMP IRON 10-15%
 C.I.BRIQUETTES 10-15%
 TAPPING TEMPERATURE 1320-1350 Deg.C
INSTRUMENTATION
 GAS PREUSSURE








 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
REGULATOR

AIR PRESSURE SWITCH

DIFFERENTIAL PRESSURE

TRANSDUCERS

AIR AND GAS MODULATING

VALVES
FUEL SHUT OFF SOLENOID 
VALVES

MANOMETERS
BAROW METER
 TO SET AND MONITOR AIR & GAS
5POSITION ROTARY SWITCH PARAMETERS
MMI
CONTROL PANEL
INSTRUMENTATION
GAS LINE PRESSURE REGULATOR
AIR PRESSURE SWITCH
INSTRUMENTATION
GAS SHUT OFF VALVE
AIR MODULATION VALVE
INSTRUMENTATION
DIFFERENTIAL PRESSURE
TRANSDUCER
INTERNAL PRESSURE GUAGE
IMPROVEMENTS MADE BY PACL
 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
INTRODUCED SLAG GUTTER FOR GRANULATION
BLOWERS & CONTROL PANEL SHITED TO MAZZENINE
INTRODUCED RR BREAKER TO IMPROVE PACK
INTRODUCED BRIQUETTING MACHINE
FOR BRIQUETTING CI BOARING
15-20%
BRIQUETTES
ARE USED IN
THE CHARGE
FOR COST
SAVING
COMPLETE CUPOLAS
CONCLUSION
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