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Energy Switch

Impact of LPG on Galvanising Process

Benefits of Switching to SR-Grade LPG from Light Diesel Oil

A case study of a customer who switched to LPG for fuel, achieving significant cost savings and a drastic improvement in environmental sustainability in the plant.

Abstract

 

This case study explores the journey of a global leader in the Transmission Tower industry, also renowned in the Polymer sector, transitioning from HSD to LDO and finally to LPG for their galvanizing processes due to escalating operating costs. The shift to LDO saw an unexpected rise in maintenance costs and unplanned shutdowns, significantly impacting productivity. This strategic decision to adopt SR-Grade LPG from SUPERGAS, not only reduced operational costs but also created a healthier plant environment. 

Role of LPG in Galvanising Process

The galvanizing process involves preparing the steel surface, immersing the steel in a bath of molten zinc for coating, and then inspecting the final product. The key difference between using LDO and LPG as fuels lies in their calorific values and carbon footprints. This means that for a given amount of LPG, more energy can be generated compared to the same amount of LDO, making LPG a potentially more efficient fuel choice.

Benefits of Partnering with SUPERGAS

SUPERGAS provided a tailored 2 X 60 SLOT installation, effectively addressing the company's fuel requirements. The comprehensive approach from the initial proposal, through the meticulous execution, to the final handover highlights the effectiveness of LPG in reducing operational costs. Additionally, it covers the seamless integration of a required burner system to facilitate the switch from liquid to gas fuel, underscoring the project’s success. 

    Operational Impact Study

While Using Light Diesel Oil After Switching to LPG 
Elevated operational expenses and fuel consumption, the demand for LDO stood at 17-19 L/MT Due to high calorific value of LPG, the demand for fuel has reduced to 12- 16 Kg/MT. 
The smoke produced from burning LDO was deteriorating the plant's environment, making it potentially hazardous to health. Since the soot formation outside the Zinc Kettle is zero, it has increased the heat transfer efficiency and resulted in cleaner work environment. 
Maintenance cost increased very rapidly because the number of breakdowns increased with LDO. They had to take unplanned shutdowns leading to a loss in productivity..  The cost of Fuel, Burner spares & maintenance for production has been reduced to 2-2.5Lac INR/month approximately.
 

Carbon Impact Study 

Carbon Footprint Parameters      LDO (KL)    LPG (MT)
Monthly fuel consumption   72  54
Calorific value/kg    9490  11850
Production - kg CO2/100000 Kcal    32  25
Carbon footprint    213,581     159,975
Monthly carbon footprint saved (KG)       - 53,606
Yearly carbon footprint saved (MT)         - 643