Galvanizing Application – FO to LPG

LPG for Industry | Case Study

Eco-Friendly & Versatile fuel for your industry 

Galvanizing Application

Conversion from FO to LPG- enhancing productivity

LPG for Industry

Conversion Assistance : Galvanizing Application 

THE ESTEEMED CUSTOMER

Our customer has evolved as a leader in the Transmission and Distribution (T&D) Segment of the Power Sector- the only player to offer a one-stop solution for most items in the T&D segment in the world of manufacturing like the Transmission Lines and Telecom Towers, High Tensile and Mild Steel Fasteners, OHTL Hardware Fittings & Accessories, Hot Rolled Structural Steel and Solar Structures. The business caters to the Power Generation, Transmission & Distribution Industry, Telecom Tower Industry etc., with HT & MS Fasteners having a manufacturing capacity of 24000 MT.

The challenges faced by the customer pre-conversion to LPG:

Initially, the customer started with LPG for their Angle Bending application with a monthly LPG Consumption of 12 MT. Their Galvanizing Furnace was mainly running on FO with monthly consumption of 70 KL. SUPERGAS had approached the customer for conversion to LPG, and talks had been going on for two years, but due to the cost factor, the customer had not decided on conversion. Due to the regular breakdown of furnace and loss of production along with an increase in the production capacity hurdles, the customer decided to go for LPG fired furnace and placed an order for a new furnace and decided to scrap the existing furnace.

The customer was already using LPG at their plant to manufacture Fasteners, and the monthly consumption comes to 27MT. Hence, the customer had given preference to SUPERGAS for the LPG manifold.

Technical Issues in FO fired furnace:

  • Major pollution issues due to FO
  • Frequent maintenance issues of the furnace/burners
  • Unable to meet export market requirements
  • Manually operated furnace leads to frequent rejection
  • Temperature control and instrumentation are not possible
  • Carbon content & productivity are major concerns during inspections
  • Inconsistent quality of Furnace Oil

The benefits of partnering with SUPERGAS:

SUPERGAS signed an SGS Agreement with the Installation Size: 6 X 450 Kg Maxima

After the successful commissioning of the furnace, our valued customer observed the following benefits of LPG and SUPERGAS’s services against Furnace Oil:

  • Cleaner and soot-free burning
  • Increased life of the equipment and burners - nil Maintenance to date
  • Instantly controllable flame temperature
  • Easy to avoid scaling and decarburizing of parts
  • Sulphur-free emissions- more environmentally desirable
  • High combustion efficiency
  • No carbon deposition at the furnace
  • Excellent temperature control
  • Environmentally friendly fuel with a high calorific value

Carbon Footprint metrics:

Particulars

FO

LPG

Monthly consumption (Ltrs)

70000

51520

Calorific value/Unit (Net)( KCal/Ltr/Kg)

8970

10900

___Kgs of CO2 Generated from  Ltr/ Kg of Fuel

2.79

2.74

Heat Transfer Efficiency

0.85

0.95

Carbon Footprint per month (MT)

195

141

Monthly Carbon Footprint saved (MT)

54

Yearly reduced carbon emission (MT)

648