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Energy Switch

Impact of LPG on Galvanising Process

Benefits of Switching to SR-Grade LPG from Furnace Oil

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.  

Role of LPG in Galvanising

Galvanisation 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 galvanisation process.

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.

    Operational Impact Study

While Using Furnace Oil After Switching to LPG 
Separate workforce needed to monitor seasonal FO viscosity changes. No manual intervention due to the automation of the process. 
FO smoke created an unhealthy plant environment, causing employee health issues.  Clean combustion with no pilferage or spillage led to a healthier plant environment.
Unplanned shutdowns due to FO use caused productivity loss from breakdowns.  Uninterrupted supply and controllable flame with high calorific value enhanced product quality.
 

Carbon Impact Study 

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