ENCON THERMAL
ENGINEERS
…Answer to the Continued Need for Energy Conservation
AN INTRODUCTION
• Established in 1978 during energy crisis in India.
• Oriented towards energy Conservation
• Well known for Designing, Manufacturing, Supplying and
Commissioning of FUEL EFFICIENT HEATING
SYSTEMS on Turn Key Basis
WE SERVE…
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Steel Plants
Transformers & Distribution [T&D] Industries
Automotive Industries
Foundries
Aluminum Industries
Pharmaceutical Industries
Cement Industries
Glass Industries
Ceramics & Refractory Industries
R&D ACTIVITIES
• Started in the year 1997
• Project sponsored by Gas Authority of India Limited (GAIL) and
Ministry of Science & Technology in partnership with Indian Institute of
Petroleum, Dehradun
• Developed gaseous film burner with savings of up to 16% compared to
conventional burners
• Innovated Gas Heating Elements which can retrofit any heating elements
(electric energized) application up to 550°C temperature
• Developed Burners for COKE OVEN & BLAST FURNACE GAS
• Developed Pilot Burners for Coke Oven/ Mixed Gas & LPG
Company Activity
• Fully integrated facilities for Engineering ,Design,
Manufacture and Assembling of
 Furnaces
 Waste Heat Recovery Systems
 RAD HEAT Gas Heating Elements
 Combustion Equipment
 Hot Air Generators
 Ovens
 Steel Melt shop Equipment's
FURNACES
• Design and manufacture furnaces on
turn key basis for the following
industries
Rolling Mills
Forging Plants
Heat Treatment Centers
Wire Drawing Plants
Aluminum Plant
Steel Plants
• Guaranteed fuel consumption of as
low as 33 ltr/ton for billet reheating
furnaces
DESIGN METHODOLOGY
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Capacity Rating
Material Handeling
Hearth Loading
Heat Loading & Zoning
Automation levels
Planning of Combustion System
Capacity Rating
• Is fixed after deliberation with the Client
• Depends on the size and mix of produce to be
preheated.
• The material of the billets play an important
part in finalizing capacity.
Material Handling
• Predominantly Preheating furnaces can be
divided into the following categories:
– Pusher Type
– Walking beam /Walking hearth
– Rotary hearth
• Considering the charge we plan the material
handling
HEARTH LOADING
• Based on the type of furnace hearth loading is
determined , with the focus on
– heat transfer ,
– Decarburization
– pattern of heating i.e Top Heating or Top and
Bottom heating
HEAT LOADING AND
ZONING
• Considering the design and capacity of the
furnace different types and sizes of burners are
recommended in the different zones of the
furnace.
• Types of Burners
– LAP Burners
– High Velocity/ Oxy Fuel
Automation In the Furnace
• In order to achieve greater efficiency in the furnace
and further increase production and reduce scale
losses the following automation in the furnace can be
carried out:
• Temperature Control
• Pressure Control
• Air/Fuel or Oxygen/Fuel Ratio Control
Oxy Fuel Technology
• Reduced Emissions
NOx emissions are reduced substantially with a oxy-fuel conversion.
• Improved Efficiency and Production
Improvement in fuel efficiency as compared with traditional air-fuel
furnaces. The energy savings partially offsets the cost of oxygen. There
scale formation also comes down to 0.3%
• Increased Furnace Refractory Life
Temperature homogeneity of the furnace increases thus minimizing the
chances of thermal shocks in the refractory
• Simplified Operation
With no recuperator, the furnace operation and maintenance are simplified
3D Images of the Proposed Furnace
3D Images of the Proposed Furnace
cont.….
3D Images of the Proposed Furnace
cont.…
3D Images of the Proposed Furnace
cont….
3D Images of the Proposed Furnace
cont.….
CFD OF FURNACE
RESULTS OF CFD
ANALYSIS
Case Study
INDIAN STEEL AND WIRE
PRODUCT (ISWP) , A Subsidy of
TATA STEEL
BACKGROUND OF ISWP
• The Furnace was initially designed by OFAG ,
Germany.
• The Furnace was designed to produce 30 to 32
Ton/hr
• The Furnace was based on Bull Nose Design.
PROBLEMS FACED BY
ISWP IN THE FURNACE
• Frequent failure of the Roof and Bullnose of
the Furnace
• High Fuel Consumption up to 42 ltr/ton
• Scale loss were as high as 1.5 %
• The furnace controls were present but not
operational
• The Furnace throughput was limiting the
production of steel
SUGGESTION MADE BY
ENCON
• Furnace Modification
– Redesigning the Bull nose design of the furnace by
Camel Hump
– Change in the design of the Roof Bricks and
Hangers.
SUGGESTION MADE BY
ENCON
• Combustion System
– The top firing LAP burners of the heating zone of
the furnace were replaced by High velocity burners
on the side wall
– The Soaking Zone burners were kept the same
SUGGESTION MADE BY
ENCON contd..
• Level 1 Automation
– Automatic temperature control
• This was achieved by placing 6 thermocouples in the
furnace, 3 Thermocouples were placed in the soaking
zone and 3 Thermocouples were placed in preheating
zone.
• The air to fuel ratio was governed by a combination
valve.
• The Furnace was divided into 6 zones three in soaking
zone and three in Preheating zone.
RESULTS ACHIEVED BY
THE RETROFIT
• Fuel consumption has come down to
32.6ltr/Ton of steel produced.
• Scaling is down to 1%
• There has been no failure in the furnace for the
last 1 year the furnace has been operational.
• The furnace is constantly producing steel at the
rate of 35 Ton/hr.
CASE STUDY -2
Revamping of Furnace at
TATA SSL, BOISAR
PROBLEMS FACED BY
SSL IN THE FURNACE
• High Fuel Consumption up to 47 ltr/ton
• Improper Soaking of the Billets
– High Power Consumption by the Mill
– Frequent break down of the Mill
• The Furnace was only producing 36 Ton against the
designed capacity of 45 ton
MODIFICATIONS MADE BY
ENCON
• Heat Load calculation were done and
accordingly the combustion equipment's were
changed
» Burners
» Blowers
» Recuperators
• Air and Oil pipeline were redesigned and
modified accordingly.
MODIFICATIONS MADE BY
ENCON contd..
• Complete refractory lining was done again
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Walls
Roof
Hearth
Water Cooled skid
RESULTS ACHIEVED
• Increase in production by 16-25% from 36
tons/hr to 42-45 tons/hr.
• Fuel consumption reduced by 23-30% from 47
ltrs/ton to 33-36 ltrs/ton.
• Electrical Power consumption reduced by
about 8%.
• Reduction in breakdowns due to better quality
heated billets
DIVINE ALLOY, RANCHI
25 TON/HR BRHF
Furnace Design
• Designed a Top and Bottom fired furnace with water
cooled skids and PID based control.
• The furnace is designed for firing Mixed Gas (Blast
Furnace Gas and Producer Gas). The gas will be
either enriched with Oxygen or supplementary firing
of furnace oil will be done.
• All the combustion equipments are being supplied by
us.
ELEVATION OF THE
FURNACE
BURNERS
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Oil Burners
Gas Burners
Dual Firing Burning Systems
High Velocity Burners
(OIL/GAS)
• Pilot Burner for Coke Oven
Gas/ LPG/NG
• Coke Oven & Blast Furnace
Burner
RECUPERATORS
• Recuperators with flue temperatures of
up to 950oC
• Preheat temperature of combustion air
as high as 450oC
• Guaranteed savings of 15-20% and a
minimum life of 3 years for ENCON
Recuperators
Jupiter- Encon Oxy-Fuel
Technology
1. is a patented process for the combustion of fossil fuels with pure
oxygen
2. uses an undiluted high flame temperature, but keeps the same
process temperatures
3. combusts at or near stoichiometric
4. retrofitted using the same furnace design and refractories
Conventional Combustion v/s
Oxy-Fuel
Higher Flame temperature
Traditional Combustion
– Air fuel fired 21% oxygen, 79% nitrogen
– 3 to 5% excess air
Relatively Low Flame Temperature
No change in furnace design and materials
Readily Available Nitrogen to Create NOX.
Nitrogen Increases the combustion volumes
Does not affect Inclusions/impurities in the
re-melted aluminum
78% Potent heat escapes through Stack.
Possibility of variable processes
No change in versatility of the usage
OVENS BY ENCON
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3D DESIGNING & CFD.
In House CFD Modulation.
Energized by GAS HEATING ELEMENT.
Minimal Heat Loses .
MODULAR TYPE
Ceramic Fiber INSULATION
Proper Air CIRCULATION with minimum electric
consumption.
• TEMPERATURE UNIFORMITY
• ENERGY CONSERVATION
» 50% IN COST ( Approximately)
» 20%– 30% IN CO2 EMISSIONS
OVENS FOR
TRNASFORMER
INDUSTRY
CORE DRYING
OVENS FOR
FOUNDARY
LADLE HEATING SYSTEM
• Ladle capacities up to 300 ton/hr.
• Pioneered the unique concept of
recuperative ladle preheating system
with guaranteed fuel consumption as low
as 1.2 ltr/ton.
• Saves 20 – 60%
• Energized by LDO/LPG/HFO/COG/OXY
FUEL
LAUNDER HEATING SYSTEM
• Short and High momentum flame length
achieved through high velocity burners.
• Energized by LDO/LPG/HFO/COG/
OXY FUEL
TUNDISH HEATING SYSTEM
RAD-HEAT GAS HEATING ELEMENTS
• Retrofitted in many applications which use Electrical
Heaters, Thermic fluid up to a temperature of 550 oC
• Savings from 30% - 70%
‘BEST TECHNOLOGY'
award from NSIC
'EXCELLENCE IN TECHNOLOGY'
award from CII -SIDBI
Designing
• ENCON believes in continuously Up –gradation &
updating our standards and setting new standards in the
industry.
• This is not possible without the backing of proper
design team and software’s to support them.
• We are among the very few in the country to use 3D
software for designing of all our products. We are
using SOLIDWORKS designing software.
LIST OF MACHINERY
SL.NO
TYPE OF MACHINES
MAKE
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Shearing M/C
Bending M/C
Lathe M/C
Rolling M/C
Radial Drilling M/C
Bench Drill M/C
Power Hecksaw M/C
Welding SET(INVERTER TYPE)
Welding Set (RECTIFIRE)
Welding Set (TWO PHASE)
Welding set (3 PHASE)
Mig Welding M/C
Hammer drill M/C
Angle Grinder
NIMOGA
NIMOGA
AMT DELHI, TURNWELL
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Angle Grinder
Angle Grinder
Hand Drill Machine
Comperessor
Genset
Hydra Crane
Hand Press
Weighing M/C
Pipe Cutting M/C
Magnet Drill M/C
Gas Cutter SET[ESSAB]
Pug Cutting M/C
Testing Furnace
Testing Oven
Plasma cutting m/c
Electrode Heating oven
Channel Straightening
PIPE Cutting M/C
33
CNC Plasma/Gas Cutting m/c
HM
BANSAL,WELDER,SUNSHINE
MATADOR
JMT
MATADOR,ARMAC.
DEWALT
BOSCH
CAPACITY
1-6 MM
1-6 MM
6FT,9 FT,10FT
UPTO 16 MM
UPTO 50 MM
UPTO 12MM
14"
400 AMP
400 AMP
400 AMP
400 AMP
400 AMP
AG-7
BOSCH (NEW)
BOSCH
BOSCH
ATLAS COPCO,MOTHERSON
MAHINDRA
ESCORTS
AG-5
AG-4
12 MM
MOTOR CAP-7.5 HP, 5HP
82.5 KW
8/15 TON
ACU WEIGH
DEWALT
NEUTRON
ESSAB
ESSAB
ENCON
ENCON
MATADOR
ESSAB
0-100KG,0-1000 KG
UPTO 4"
UPTO 50MM
UPTO-20MM
UPTO-20MM
UNIQE MACHINE
Hypertherm Max Pro 200
1 TO 25 MM of SS& 300 MM
of MS
AVAILABLE
QTY
1
1
3
1
2
1
1
3
5
2
4
4
1
12
10
1
5
1
1
2
2
2
1
1
3
1
1
1
1
8
1
1
1
Machinery Photo
FACTORY
• Total Land Available 10,120 SQMT
• Total Covered Area 4600 SQMT
• Office area 285 SQMT, 145 SQMT on ground
floor & 140 SQMT on First floor
• Shed Area 2,620 SQMT
• Paint Booth 100 SQMT
• Sand Blasting Booth 64 SQMT
WORKSHOP PHOTOS
BOOTH FOR
Sand Blasting & Painting
STORE
SOME OF OUR ESTEEMED
CLIENTS
Aarti Steel Ltd.
ABB Limited
Areva T & D India Ltd.
Bajaj Auto Ltd.
B.H.E.L.
Bhilai Steel Plant
Bhushan Steels Ltd.
Cummins India Ltd.
Danielli India Ltd.
DCM Engineering Ltd.
Electrotherm (I) Ltd.
Emirates Steel Co. LLC
Escorts Ltd.
Exide Industries Ltd.
Godrej & Boyce Mfg. Co.
Ispat Inds. Ltd.
ISWP, Ltd.
Jindal Strips Ltd.
Jindal Stainless Ltd.
JSW Steel Ltd.
Kajaria Ceramics Ltd.
Kirloskar Ferrous Inds.
L G Electronics Ltd.
Lloyds Steel Industries
Mahavir Aluminium
Mahindra and Mahindra
Mehru Electricals
Mukand Ltd.
NALCO
Orient Abrasives Ltd.
Orient Fans
Polycab Cables Inds.
Power Solutions Ltd.
RHI Clasil Ltd.
Rourkela Steel Plant
SAIL
Samtel Color Ltd.
Shriram Pistons & Rings
Shah Alloys Ltd.
Siemens VAI Metal
Simplex Castings Ltd.
Skipper Electricals
Tata Motors Ltd.
Tata Refractories Ltd.
Tata Steels Ltd.
Usha Martin Industries
Viraj Profiles Ltd.
Visa Steel Ltd.
Visakhapatnam Steel Plant
Welspun Steel Ltd.
Whirlpool India Ltd.
THANK YOU!
“ Adopt eco-friendly technologies that your children can be
proud of ”
Vishve Bandhu Mahendra