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Can LPG Contribute to a Cleaner Work Environment?

A case study on how choosing LPG over Furnace Oil (FO) created a pollution-free environment in and outside the industry.

Abstract

This insightful case study showcases the transformative journey of India's largest barbed wire manufacturer as they embrace a pivotal shift in their energy consumption. Beginning operations in 2005, our esteemed customer relied on Furnace Oil for critical processes like wire annealing and galvanizing. SUPERGAS stepped in to propose an innovative switch to LPG—a cleaner, more efficient fuel alternative. Through a tailored 4X450 KG Maxima installation, we aimed to meet the manufacturer's robust energy needs seamlessly.  

Hot Dip Galvanising

 

 Role of LPG in Galvanising

Galvanization is the practice of coating iron, steel, or any such ferrous metal with a protective layer of zinc to prevent rusting.

This involves the metal being dipped into a hot zinc bath, for which the heating efficiency and uniformity are paramount for a high-quality product.

LPG prominently serves two functions in this process. First, it provides the heat for the bath, thus acting as the primary fuel source of the furnace where the metal pieces are dipped.

Second, LPG helps in reducing the preheating time of the bath. Efficient preheating is instrumental to the galvanization process.

The use of LPG allows for a steady and adjustable flame, enabling precise control over temperature parameters. This results in a consistent and quality galvanizing process, ensuring that the zinc coating is effectively applied on the steel. 

 

Conquering Operational Challenges with SUPERGAS LPG

         Before Switching to LPG 

 After Switching to LPG 

 Separate manpower requirements to monitor FO due to its viscosity drop during each season. 

 Manpower is not required due to the automated changeover and ordering system. Cleaner burning and foot-free combustion- no Pilferage, adulteration, or spillage observed in the plant 

 Smoke generated by burning FO and unhealthy plant environment caused health issues for employees.

 Pollution-free environment inside and outside the plant.

 They were facing unplanned shutdowns leading to a loss in productivity due to breakdowns caused due to usage of FO. 

 Uninterrupted supply, higher calorific value and instantly controllable flame temperature resulted in quality finished product.  

Benefits of Partnering with SUPERGAS

Partnering with SUPERGAS led to a series of significant improvements for our customers. A noteworthy benefit was the reduction in monthly fuel consumption from 35 KL/month for furnace oil (FO) to 25 MT/month for LPG. This demonstrated efficiency and indicated a lowered operational and maintenance cost. The high-quality, uninterrupted LPG supply resulted in improved product quality. Storage problems were effectively addressed with a 4x450Kg Maxima installation, simplifying inventory management.

 

"The transition to LPG contributed to reduced carbon footprints, exhibiting our commitment to a sustainable future".

 

 Carbon Footprint Parameters    FO (KL)    LPG (MT)
  Monthly fuel consumption    350000    250000 
  Calorific value/kg   9490    11800 
  Total calorific value    332150000   296250000 
  Production - kg CO2/100000 Kcal    33    25 
  Carbon footprint    109609.5    74062.5 
  Monthly carbon footprint saved (KG)    -   35547 
  Yearly carbon footprint saved (kg)   -    426564