VI NATIONAL FOUNDRY CONCLAVE PACL

USE OF

COKELESS

(GAS FIRED )

CUPOLA

CUSTOMERS

PERSPECTIVEBY

GUDURU MURALI

VI NATIONAL FOUNDRY CONCLAVE PACL

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 FIELDSMANUFACTURE OF DUCTILE (S.G ) AND GREY CAST IRON

CASTINGSA COMPLETE HOUSE FOR MACHINING SOLUTIONS

CONVENTIONAL & CNCMANUFACTURE OF DIESEL ENGINESMANUFACTURE OF SUPER ENAMELLED & SUBMERCIBLE COPPER

WIRESMANUFACTURE OF DECORATIVE ITEM CASTING PRODUCTS

VI NATIONAL FOUNDRY CONCLAVE PACL

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

PORWAL AUTO COMPONENTS LTD.

VI NATIONAL FOUNDRY CONCLAVE PACL

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

VI NATIONAL FOUNDRY CONCLAVE PACL

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.

FACILITIES

VI NATIONAL FOUNDRY CONCLAVE PACL

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

VI NATIONAL FOUNDRY CONCLAVE PACL

HIGHLY POLLUTANTNEED POLLUTION CONTROL EQUIPMENTNEED EXPERT OPERATOR TO OPERATEPOOR INSTRUMENTATIONMORE POLLUTION RELATED ISSUES WITH PCB’SNO CONTROL ON HEAT INPUTSULPHUR PICKUP

NO POLLUTION,CLEAN ENVIRONMENTDOES’NT REQUIRE POLLUTION CONTROL EQUIPMENTDO NOT REQUIRE EXPERT,EASY OPERATIONGOOD INSTRUMENTATIONLESS HURDLES WITH PCB’SPLC OPERATED,HEAT INPUT CAN BE CONTROLLEDNO SULPHUR PICKUP

COKE TYPE Vs COKELESS CUPOLA

VI NATIONAL FOUNDRY CONCLAVE PACLINDUCTION FURNACE VS COKELESS CUPOLA

EASY TO OPERATEBETTER CONTROLSENERGY EFFICIENTLOW LINING COSTNO LIMITATION ON CHARGE MATERIALSNEED POLLUTION EQUIPMENTINITIAL COST IS HIGH

EASY TO OPERATEBETTER CONTROLSLESS ENERGY EFFICIENTHIGH LINING COSTLIMITATION IN USING VARIETY OF SCRAPDO NOT REQUIRE POLLUTION EQUIPMENTINITIAL COST IS LOW

VI NATIONAL FOUNDRY CONCLAVE PACL

GAS FIRED CUPOLA

VI NATIONAL FOUNDRY CONCLAVE PACL

GAS FIRED CUPOLA

VI NATIONAL FOUNDRY CONCLAVE PACL

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

GAS FIRED CUPOLA CHARGE MIX

VI NATIONAL FOUNDRY CONCLAVE PACL

GAS PREUSSURE REGULATOR AIR PRESSURE SWITCHDIFFERENTIAL PRESSURE TRANSDUCERSAIR AND GAS MODULATING VALVESFUEL SHUT OFF SOLENOID VALVESMANOMETERSBAROW METER5POSITION ROTARY SWITCHMMI

REGULATES THE GAS PRESSURE BASED ON FLOW REUIREMENTTO IDENTIFY THE BLOWER RUNNINGTO GIVE FEEDBACK TO PLC THE RATE OF AIR & GAS FLOWTO CONTROL THE FLOW OF AIR AND GASTO CLOSE THE GAS IN CASE OF EMERGENCIESTO MAINTAIN DIFFERENTIAL PRESSURE OF AIR AND GAS FOR EACH BURNERTO MAINTAIN THE INTERNAL PRESSURE.TO CONTROL THE MELT RATE

TO SET AND MONITOR AIR & GAS PARAMETERS

INSTRUMENTATION

VI NATIONAL FOUNDRY CONCLAVE PACL

CONTROL PANEL

VI NATIONAL FOUNDRY CONCLAVE PACL

INSTRUMENTATIONGAS LINE PRESSURE REGULATOR

AIR PRESSURE SWITCH

VI NATIONAL FOUNDRY CONCLAVE PACL

INSTRUMENTATIONGAS SHUT OFF VALVE AIR MODULATION VALVE

VI NATIONAL FOUNDRY CONCLAVE PACL

INSTRUMENTATIONDIFFERENTIAL PRESSURE TRANSDUCER

INTERNAL PRESSURE GUAGE

VI NATIONAL FOUNDRY CONCLAVE 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 LIFEIMPROVED SKIP HOIST TO MINIMISE BREAKDOWNSINTRODUCED GRANULATION OF SLAG FOR EASY DISPOSAL

& FOR BETTER WORKING ENVIRONMENTINTRODUCED BRIQUETTING FOR COST SAVING

IMPROVEMENTS MADE BY PACL

VI NATIONAL FOUNDRY CONCLAVE PACL

INTRODUCED SLAG GUTTER FOR GRANULATION

VI NATIONAL FOUNDRY CONCLAVE PACL

BLOWERS & CONTROL PANEL SHITED TO MAZZENINE

VI NATIONAL FOUNDRY CONCLAVE PACL

INTRODUCED RR BREAKER TO IMPROVE PACK

VI NATIONAL FOUNDRY CONCLAVE PACL

15-20% BRIQUETTES ARE USED IN THE CHARGE FOR COST SAVING

INTRODUCED BRIQUETTING MACHINE FOR BRIQUETTING CI BOARING

VI NATIONAL FOUNDRY CONCLAVE PACL

COMPLETE CUPOLAS

VI NATIONAL FOUNDRY CONCLAVE PACL

PACL BELIEVES GAS FIRED CUPOLA IS AN ALTERNATE PRIMARY MELTING SOURCE WHERE

POLLUTION IS A MAJOR HURDLEPOWER IS A MAJOR HURDLENOT A REPLACEMENT FOR

INDUCTION FURNACE

CONCLUSION

VI NATIONAL FOUNDRY CONCLAVE PACL

THANK YOU