There are around 300 forging units in Ludhiana & Mandi Gobindgarh. Most of the forging units in Ludhiana are making Hand tools and cycle parts, while in Mandi Gobindgarh are making machine parts as per the requirement. Majority of the units are using free hammer to forge the heated steel. The temperature required for forging is around 9000C. The material of construction of raw materials in the Hand tool and Cycle parts industry is mild steel, while in big units making machine parts, it is alloy steel. The fuel used in units is furnace oil. As such the status of energy conservation is poor and needs attention. The observations with respect to the status of energy conservation are as:
Traditionally designed furnaces having no waste heat recovery arrangement from the discharge of flue gas.
High pressure inside the furnace resulting in excessive fuel consumption, less refractory life and high scale loss. Flame and smoke was seen bulging out of the doors of the furnace.
Unscientifically designed burners.
Poor preheating arrangement of furnace oil. No provision of heating and pumping units resulting in inefficient combustion of furnace oil.
Use of local made blowers.
Operation of the furnaces at high excess air, resulting in high fuel consumption and excessive scale loss.
No instrumentation to control the operation of the furnace.
No or unscientific waste heat recovery system.
The fuel consumption in these units varies from 150-250 lts/tonne of product, which is on higher side and needs to be reduced.
Objectives
The objective was to carry out a diagnostic study to assess the status of energy consumption, suggest and demonstrate energy conservation measures so as to make the forging cluster energy efficient and profitable.
Deliverables
Inventorization of few forging units to study their working practices, scale of operations and energy consumption levels with the assistance of the local industry association.
Selection of 5 units to carry out detailed Material and Energy Balance through energy audits.
Selection of three units based on criterion like their efficiency of operations, scale of operation and willingness of entrepreneur to implement recommendations for demonstration of energy conservation measures.
Demonstration of Energy Conservation Measures by implementing the researched and recommended measures in all the three units.
Performance Evaluation in three Demonstration units through energy audits to assess the quantum of savings accrued.
Assess the scope of reduction of green house gas emissions and their viability for getting CDM benefits.
Organizing awareness workshops for entrepreneurs and operators and also for bankers for making them aware about giving loans to SMEs for energy efficiency projects.
Preparation and submission of strategy/plan for replication of demonstrated energy conservation measures in the remaining units of the clusters in future.
Achievements and Present status of project:
Inventorization of forging units in Ludhiana completed
Selection of five units for preliminary energy audits done
Energy audit done at all five units selected. This established their present fuel consumption profile scale losses associated with furnace operation were also assessed
All possible measures to reduce fuel consumption role and ---- fuel consumption have identified. Changes required in furnace design, fans furnace equipment like burners, etc. and other auxiliaries and accessories have been marked.
Selection of these limits for demonstration purposes done. selection done on the basis of already laid objective and subjective criteria.
Project has entered the demonstration phase and necessary logistics are being worked out.
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