CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION...

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CASE STUDY – SUMMARY I. Oil & Natural Gas Corporation Limited (O.N.G.C.), Rajahmundry Asse Fuel -HSD II. Hindustan Petroleum Corporation Limited, (L.O.B.P.) Silvassa – Gujtat Fuel - FO III. Mahindra & Mahindra Ltd. (A.S.) Igatpuri – Maharashtra Fuel - LPG IV. R.M.I.Cycles Ltd., Rajpura, Punjab. Fuel - HSD V. Ranbaxy Laboratories Limited, Goa. Fuel - HSD VI. Excel Process Pvt.Ltd., Killa Pardi, Dist.Valsad-Gujarat Fuel - LPG VII. L & T John Deere Limited, Pune, Maharashtra Fuel - LPG VIII. Escotel Mobile Communications Ltd., Meerut, U.P. Fuel - LPG IX. Rich Kwality Products Ltd., Pune – Mahagashtra Fuel - LDO X. Garware- Wall Ropes Limited, Wai, Satara, Maharashtra Fuel - LDO XI. Bajaj Electricals Limited, Ranjangaon, Dist.Pune Maharshtra Fuel - LPG XII. Excel Insustries Limited, Roha, Maharastra Fuel - FO XIII. ITC Limited, Bhadrachalam, (A.P.) Fuel - FO XIV. ITW Signode India Limited, Rudraram Village, (A.P.) Fuel - LPG XV. Cadila pharmaceuticals Limited, Ankleshwar, Gujaarat Fuel - NG XVI. J.K.Pharma Chem Limited, Cudalore, Tamil Nadu Fuel - FO XVII. Hindustan Lever limited, Chimbal, Goa. Fuel - FO XVIII. Kirloskar Copeland Ltd., Karad & Atit, Dist. Satara- Maharashtra Fuel - FO XIX. Ford India. Maraimalainagar,Tamil Nadu. Fuel - HSD XX L & T Komatsu, Bangalore Fuel - LPG XXI Sterlite Industries (I) Ltd. Silvassa Fuel – FO XXII Badve Enggineering Limited, Aurangabad Fuel – LPG

Transcript of CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION...

Page 1: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

CASE STUDY – SUMMARY

I. Oil & Natural Gas Corporation Limited (O.N.G.C.), Rajahmundry Asse Fuel -HSD

II. Hindustan Petroleum Corporation Limited, (L.O.B.P.) Silvassa – Gujtat Fuel - FO

III. Mahindra & Mahindra Ltd. (A.S.) Igatpuri – Maharashtra Fuel - LPG

IV. R.M.I.Cycles Ltd., Rajpura, Punjab. Fuel - HSD

V. Ranbaxy Laboratories Limited, Goa. Fuel - HSD

VI. Excel Process Pvt.Ltd., Killa Pardi, Dist.Valsad-Gujarat Fuel - LPG

VII. L & T John Deere Limited, Pune, Maharashtra Fuel - LPG

VIII. Escotel Mobile Communications Ltd., Meerut, U.P. Fuel - LPG

IX. Rich Kwality Products Ltd., Pune – Mahagashtra Fuel - LDO

X. Garware- Wall Ropes Limited, Wai, Satara, Maharashtra Fuel - LDO

XI. Bajaj Electricals Limited, Ranjangaon, Dist.Pune Maharshtra Fuel - LPG

XII. Excel Insustries Limited, Roha, Maharastra Fuel - FO

XIII. ITC Limited, Bhadrachalam, (A.P.) Fuel - FO

XIV. ITW Signode India Limited, Rudraram Village, (A.P.) Fuel - LPG

XV. Cadila pharmaceuticals Limited, Ankleshwar, Gujaarat Fuel - NG

XVI. J.K.Pharma Chem Limited, Cudalore, Tamil Nadu Fuel - FO

XVII. Hindustan Lever limited, Chimbal, Goa. Fuel - FO

XVIII. Kirloskar Copeland Ltd., Karad & Atit, Dist. Satara- Maharashtra Fuel - FO

XIX. Ford India. Maraimalainagar,Tamil Nadu. Fuel - HSD

XX L & T Komatsu, Bangalore Fuel - LPG XXI Sterlite Industries (I) Ltd. Silvassa Fuel – FO XXII Badve Enggineering Limited, Aurangabad Fuel – LPG

Page 2: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

CASE STUDIES:

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY I: APPLICATION FOR D.G. SET (H.S.D.)

Client: Oil & Natural Gas Corporation Limited (O.N.G.C.), Rajahmundry Asset SYSTEM DETAILS:

Name of equipment : D.G. Set

Capacity : 1430 KVA

Make of the unit : Cummins

Type of fuel used : HSD

OBSERVATIONS:

Particulars Fuel

Consumed

Units

Generated

Units

generated/litre Hours Run % Change

Without Flux maxiox™ 5790 13900 2.40 120 hours

With Flux maxiox™ 3480 9200 2.64 100 hours + 10%

2.4

2.64

2.252.3

2.352.4

2.452.5

2.552.6

2.652.7

Bef

ore

Afte

r

Units Generated/litre

Fuel Efficiency

Page 3: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY II: APPLICATION FOR BOILER (FO)

Client: Hindustan Petroleum Corporation Limited (H.P.C.L.), Lube Oil Blending Plant, Silvassa SYSTEM DETAILS:

Name of equipment : Smoke Tube Boiler

Capacity : 6 TPH

Make of the unit : Thermax FM60

Type of fuel used : FO

OBSERVATIONS:

Particulars

(One Month Data

Compiled for

each case)

Fuel Consumed

per day (Monthly

Avg.)

Steam Generated

per day (Monthly

Avg.)

Steam generated/Fuel

consumption

% Difference

Before 679 3243 4.77

After 596 3062 5.13 + 7.5%

4.77

5.13

Bef

ore

Afte

r

Steam generated/Fuel consumption

Fuel Efficiency

Page 4: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.)

Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri.

SYSTEM DETAILS:

Name of equipment : Furnace (no. 14645)

Capacity : 540 kgs. melt

Make of the unit : Pioneer Margon (Fuel Furnaces Baroda)

Year of commissioning : 1988

Type of fuel used : LPG

OBSERVATIONS:

Period LPG Consumed (kgs.)

Castings Poured (kgs.)

Average Casting poured per kg. LPG

Percentage Savings

From 6.06.00 to 14.09.00 (Before Installation)

12350 23,592 1.91 9.47%

From 15.09.00 to 24.11.00 (After Installation)

19650 41,424 2.11

1.91

2.11

1.81.851.9

1.952

2.052.1

2.15

BeforeInstallation

AfterInstallation

Average Casting per kg. LPG

Page 5: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY IV: APPLICATION FOR BOILER (H.S.D.)

Client: R.M.I. Cycles Ltd.; Rajpura, Punjab.

SYSTEM DETAILS:

Name of equipment : Water tube Boiler

Capacity : 2 T/Hr.

Make of the unit : Nestler

Year of Commissioning : 1970

Operational details : 6 to 7 hours daily operation

Type of fuel used : HSD

Boiler : Fuel Consumption

98

99

100

101

102

103

104

105

106

107

108

26/08

/99

28/08

/99

31/08

/99

03/09

/99

06/09

/99

08/09

/99

17/09

/99

20/09

/99

22/09

/99

24/09

/99

27/09

/99

29/09

/99

01/10

/99

05/10

/99

07/10

/99

09/10

/99

12/10

/99

14/10

/99

16/10

/99

20/10

/99

22/10

/99

25/10

/99

27/10

/99

29/10

/99

01/11

/99

03/11

/99

05/11

/99

09/11

/99

11/11

/99

14/11

/99

16/11

/99

18/11

/99

20/11

/99

23/11

/99

Date

Fuel

Cos

umpt

ion

(litr

es/h

r.)

* FLUX maxiox™ installed on 12/10/1999 Results: Fuel saving of around 25 liters per day

Page 6: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY V: APPLICATION FOR D.G. SET (H.S.D.)

Client: Ranbaxy Laboratories Limited, Goa.

SYSTEM DETAILS:

Name of equipment : D.G. Set

Capacity : 437.5 KVA

Make of the unit : Cummins

Year of commissioning : 1983

Operational details : crossed 7000 running hours

Type of fuel used : HSD

OBSERVATIONS:

Month April May June July August September October Increase in Efficiency

Fuel Efficiency

2.77 2.89 2.97 3.18 3.29 3.31 3.30 12%

FLUX maxiox™ installed on June 15, 2000

Increase in Fuel Efficiency

3.33.313.293.18

2.972.89

2.77

2.42.52.62.72.82.9

33.13.23.33.4

April May Jun Jul Aug Sept Oct

Month

Fuel

Effi

cien

cy

Page 7: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY VI: APPLICATION FOR OVEN (L.P.G.)

Client: M/s. Excel Process Pvt. Ltd., Killa Pardi, Dist. Valsad, Gujarat SYSTEM DETAILS: Name of equipment : Overhead Tubular Radiant Heater Max. inject gas pressure : 50 M Bar Make of the unit : Ambi-Rad (R) ARE 22 Unit, uk

Type of fuel used : LPG

OBSERVATIONS:

Period LPG Consumed (19.2 Kg. Cylinders)

Total Minutes

Per Cyl. LPG Consumption in minutes

Percentage Savings

From 22.11.00 to 10.12.00 (Before Installation)

5 5,766.0 1,153.2

From 25.12.00 to 21.01.001 (After Installation)

5 6,027.0 1,205.4 8.69%

From 21.12.00 to 24.12.00 (Before Installation)

1 1,167.0 1,167.0

From 21.01.01 to 25.01.001 (After Installation)

1 1,272.0 1,272.0 9.00%

1153.2

1167.0

1205.4

1272

0

500

1000

1500

2000

2500

minutes

before after

cylinder consumption (in minutes)

5 cylinders average data single cylinder data

single cylinder data 1167.0 12725 cylinders average data 1153.2 1205.4

22.11.00 21.01.01

19.2 19.2

Page 8: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY VII: APPLICATION FOR OVEN (L.P.G.)

Client: L&T John Deere Limited, Pune, Maharashtra SYSTEM DETAILS:

Name of equipment : PPS Colour Oven

Type of fuel used : LPG

OBSERVATIONS:

Particulars (One Month Data Compiled)

Time taken for the Temperature in the Oven to rise from 35 degrees C to 70 degrees C (hours)

% Difference

Before 0.35

After 0.28 20%

0.35

0.28

Bef

ore

Afte

r

time taken for fixed temperature increase

Time (hours)

Page 9: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY VIII: APPLICATION FOR D.G. SET (H.S.D.)

Client: Escotel Mobile Communications Ltd., Meerut, U.P.

SYSTEM DETAILS:

Name of equipment : D.G. Set

Capacity : 200 KVA

Make of the unit : Cummins

Type of fuel used : HSD

Model: NTA 743-G Mfg. Date: 7/10/96 Type: CPLX - 044

Engine No : 25218922 Inj. Timing: A 0.0415 ", 6 Cylinder type

Maximum Loading Permitted by DG set Manufacturer = 278 Amps

Flux Maxiox™ Installed on 27 January, 2003.

Period Units Diesel Units % Generated used Generated improvement (KWH) (Litres) Per litre 06 Jan to 27 Jan, 2003 9367.70 3100.00 3.02 28 Jan to 24 Feb, 2003 6632.52 2070.00 3.20 5.625 % 25 Feb to 24 Mar, 2003 6545.26 1943.00 3.37 10.38 %

3.02

3.2

3.37

2.9

3

3.1

3.2

3.3

3.4

3.5

Effic

ienc

y

Before After (Jan-Feb)

After (Feb-Mar)

Efficiency of D.G. Set

Page 10: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY IX: APPLICATION FOR BOILER (LDO)

Client: Rich Kwality Products Ltd., Pune SYSTEM DETAILS:

Name of equipment : Boiler

Capacity : 300 kg./hr.

Working Pressure : 8 kg/cm2

Make of the unit : Thermax

Type of fuel used : LDO

OBSERVATIONS:

Particulars Before Installation

of Flux maxiox™

After Installation

of Flux maxiox™ % Difference

LDO Firing Rate 19 litres/hour 18 litres/hour

5.2% Steam Pressure 8 kg/sq.cm. 8 kg/sq.cm.

Steam Temperature 1720 C 1720 C

Steam Output 300 kg/hour 300 kg/hour

19

18

17

18

19

20

Fuel

Con

sum

ed

Before After

Fuel Consumption(litres/hour)

Page 11: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY X: APPLICATION FOR D.G. SET (L.D.O.)

Client: Garware-Wall Ropes Limited, Wai, Satara, Maharashtra SYSTEM DETAILS:

Name of equipment : D.G. Set

Capacity : 750 KVA

Make of the unit : Cummins

Type of fuel used : LDO

OBSERVATIONS:

WITHOUT Flux maxiox™: 3.65 KWH/Litre Date KWH/Litre Date KWH/Litre Date KWH/Litre 15/11/2002 3.68 20/11/2002 3.69 25/11/2002 3.64 16/11/2002 3.60 21/11/2002 3.60 26/11/2002 3.65 17/11/2002 3.59 22/11/2002 3.74 27/11/2002 3.66 18/11/2002 3.64 23/11/2002 3.69 28/11/2002 3.65 19/11/2002 3.65 24/11/2002 3.65 29/11/2002 3.67

WITH Flux maxiox™: 3.85 KWH/Litre Date KWH/Litre Date KWH/Litre Date KWH/Litre 16/03/2003 3.85 20/03/2003 3.85 24/03/2003 3.86 17/03/2003 3.85 21/03/2003 3.85 25/03/2003 3.85 18/03/2003 3.86 22/03/2003 3.86 26/03/2003 3.85 19/03/2003 3.86 23/03/2003 3.85 27/03/2003 3.85

Percentage Improvement: 5.19%

Efficiency of D.G. Set

3.5

3.6

3.7

3.8

3.9

15/11/2002 21/11/2002 27/11/2002 17/03/2003 23/03/2003 29/03/2003

Date

Effic

ienc

y

Page 12: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XI: APPLICATION FOR GALVANIZING FURNACE (L.P.G.)

Client: Bajaj Electricals Limited, Ranjangaon, Dist. Pune FURNACE DETAILS: Name : Galvanizing Furnace Make : Gimaco, Italy Total Running Hours : 15,000 Fuel Used : L.P.G. Avg. Fuel Consumption : 350 kg/hour Avg. production Output : 1500 MT/month

Study 1: This study is to observe the time taken to raise the temperature of the furnace from 430 0C to 450 0C both with and without the Flux maxiox™. Following are the standing observations:

Parameter Without Flux maxiox™ With Flux maxiox™

Time Temperature Time Temperature

Time taken to raise the temperature of the furnace from 430 0C to 450 0C

1.38 430 7.05 430

2.03 435 7.33 435

2.26 440 7.48 440

2.48 445 8.21 450

3.11 450

Actual Time Taken 93 mins. 20 0C 76 mins. 20 0C Thus from the above data, there is a saving of 18.27% in the heating time of the furnace.

93

76

WithoutFlux

maxiox

With Fluxmaxiox

Time (mins.)

Time taken to raise the temperature of the furnace from 430 0C to 450 0C

Page 13: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

Study 2:

This study is to observe the flue gas temperature while raising the temperature of the furnace from

430 0C to 450 0C both with and without the Flux maxiox™. Following are the standing observations:

Parameter Without Flux maxiox™ With Flux maxiox™ Flue Gas Temperature Difference

Furnace Temp. (0C)

Flue Gas Temp.

(0C)

Furnace Temp. (0C)

Flue Gas Temp.

(0C) Flue gas temperature while raising the temperature of the furnace from 430 0C to 450 0C

430 443 430 456 + 13 0C

435 478 435 489 + 11 0C

440 493 440 503 + 10 0C

450 512 450 522 + 10 0C

Thus from the above data, there is an increase of at least 10 0C in the flue gas temperature which

indicates the efficacy of the Flux maxiox™ in increasing the heat output of the L.P.G. being

consumed. This exhaust heat when utilized could lead to a further saving in L.P.G.

443456

478489 493

503 512522

425

445

465

485

505

525

Flue

Gas

Tem

pera

ture

430 C 435 C 440 C 450 C

Furnace Temperature

Flue Gas Temperature

Page 14: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XII: APPLICATION FOR BOILER (FO)

Client: Excel Industries Limited, Roha, Maharashtra SYSTEM DETAILS:

Name of equipment : Smoke Tube Boiler

Capacity : 10 TPH

Make of the unit : Nestler

Pressure Rating : 15 kg/cm2

Type of fuel used : FO

OBSERVATIONS:

Particulars

(One Month Data

Compiled for

each case)

Fuel Consumed

per day (Monthly

Avg.)

Steam Generated

per day (Monthly

Avg.)

Steam generated/Fuel

consumption

% Difference

Before 11,141.26 1,48,246.66 13.30

After 10,722.12 1,47,975.00 13.80 + 3.76%

13.3

13.8

Before After

Steam generated/Fuel consumption

Fuel Efficiency

Page 15: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XIII: APPLICATION FOR FURNACE (FO)

Client : ITC Limited, Bhadrachalam (Paperboards & Specialty Papers Division) Sarapaka Village, Bhadrachalam, Khammam District, AP, Pin–507 128 Energy Manager : Mr. N. Alagiri (Technical Cell) Tel : (08746) 242331 to 340, Fax : (08746) 242460, Email : [email protected] SYSTEM DETAILS:

Name of equipment : Lime Kiln Furnace Type of fuel used : FO

OBSERVATIONS:

Specific FO consumption before installation (Lit/ton) 185

Specific FO consumption after installation (Lit/ton) 176

Savings achieved (Lit/ton) 9

Reduction in FO consumption (%) 4.86

Average Lime Sludge Processed per day (MT) 147

No. of Working Days (days) 330

Cost of FO (Rs./Litre) 12.00

Estimated Saving per Annum (Rs.) 52,39,080.00

185

176

Before After

Specific FO consumption (Lit/ton)

Page 16: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XIV: APPLICATION FOR FURNACE (LPG)

Client : ITW Signode India Limited Rudraram Village, Sangareddy Taluk , Medak District-503329 (AP) Contact Person: Mr. D. Sateesh, Head-Electrical Maintenance, Tel.: 09848845180 SYSTEM DETAILS:

Name of equipment : Lead Melting Furnace for Heat Treatment Unit Type of fuel used : LPG

OBSERVATIONS:

Status Period LPG Consumption (Kgs)

Net Production (MT)

LPG (Kg./MT)

WITH Flux maxiox™

April 2004 21563 1764 12.22

May 2004 26267 2097 12.53 01-10 June 2004 6257 516 12.13

54087 4377 12.36

WITHOUT Flux maxiox™

11-30 June 2004 17521 1305 13.43 01-20 July 2004 15322 1091 14.04

32843 2396 13.71

WITH Flux maxiox™

21-31 July 2004 9102 708 12.86

01-16 Aug 2004 14930 1266 11.79

24032 1974 12.17

Avg. LPG Consumption 210 MT/Annum

Cost of LPG 24.00 Rs./kg

Savings in LPG 11.18 % 23.47 MT/Annum

Saving per Annum 5,63,472.00 Rs.

12.36

13.71

12.17

With Without With

LPG (KG/MT)

Page 17: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XV: APPLICATION FOR BOILER (NG)

Client: Cadila Pharmaceuticals Limited, Ankleshwar, Gujarat SYSTEM DETAILS:

Name of equipment : Smoke Tube Boiler

Capacity : 3 TPH

Make of the unit : IAEC

Pressure Rating : 9 kg/cm2

Type of fuel used : Natural Gas (Gujarat Gas Ltd.)

OBSERVATIONS:

Status

Gas Consumed

(NM3)

Steam Generated

(MT) NG (NM3/MT) % Difference

Before (July 2004) 1,20,139 1,460.54 82.25

After (Aug 2004) 1,27,703 1,711.55 74.61 9.29%

Avg. NG Consumption 16,79,000 NM3/Annum

Cost of NG 8.96 Rs./ NM3

Savings in NG 9.29 % 1,55,979 NM3/Annum

Saving per Annum 14,00,000 Rs. approx.

82.25

74.61

Before After

NG Consumed (NM3/MT)

Page 18: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XVI: APPLICATION FOR BOILER (FO)

Client: J.K. PharmaChem Limited, Cuddalore, Tamil Nadu

SYSTEM DETAILS:

Name of equipment : Water Tube Boiler

Make : Thermax

Capacity : 30 TPH

Pressure Rating : 12 kg/cm2

Type of fuel used : FO

OBSERVATIONS:

Status

FO Consumed

(KL)

Steam Generated

(MT)

SFC

(Lit/MT) % Difference

Without Flux maxiox™ 16.43 217.73 75.46

With Flux maxiox™ 15.86 215.84 73.48 2.6%

Avg. FO Consumption 7300 KL/Annum

Cost of FO 15 Rs./Litre

Savings in FO 2.6 % 189.80 KL/Annum

Saving per Annum 28,47,000.00 Rs.

75.46

73.48

Without With

SFC(Lit./MT)

Page 19: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XVII: APPLICATION FOR BOILER ( FO )

Client: Hindustan Lever Ltd. Chimbel, Goa OBSERVAYIONS : Make : IAEC Steam Boiler

Year of Make : 2001

Boiler Nos. : IPSG 325/IPSG 326

Type : IFO 40

Fuel Used : Furnace Oil (FO)

Capacity : 4 TPH

Working Pressure : 11.5 kg/cm2

Heating Surface : 96 cm2

Saturation Temp : 189 deg.C

Month

Fuel Consumed per day

(Monthly Avg.) litres

Steam Generated per day

(Monthly Avg.) kgs.

Steam generated/Fuel

consumption

December 2003 8872.14 118296.61 13.3

January 2004 8787.98 116441.38 13.2

February 2004 8134.17 111535.00 13.7

13.313.2

13.7

Dec 03 Jan 04 Feb 04

Installation Date 29.01.2004

Fuel Efficiency

Page 20: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XVIII: APPLICATION FOR THERMIC FLUID HEATER (FO)

Client: Kirloskar Copeland Limited, Atit, Dist. Satara, Maharashtra

SYSTEM DETAILS:

Name of equipment : Thermic Fluid Heater

Capacity : 6 lac kcal/hour- 4 nos.;

2 lac kcal/hour- 4 nos.

Make of the unit : Thermax

Type of fuel used : FO

OBSERVATIONS: (Trial Field Study)

Particulars Before Installation After Installation Fuel Saved

T.F. Oil Circulation Pressure 4 kg/cm2 4 kg/cm2

3 litres/hour

T.F. Oil Outlet Temperature 230 deg C 230 deg C

T.F. Oil Return Temperature 200 deg C 200 deg C

Stack Temperature 250 deg C 250 deg C

Fuel inlet Pressure to Burner 16 kg/cm2 14 kg/cm2

Fuel Firing Rate 75 litres/hour 72 litres/hour

Combustion Efficiency 84.3% 84.5%

Avg. FO Consumption 960 KL/Annum

Cost of FO 15 Rs./Litre

Savings in FO 3.25 % 31.2 KL/Annum

Saving per Annum 4,68,000.00 Rs.

75

72

60

70

80

Fuel

Con

sum

ed

Before After

Fuel Consumption(litres/hour)

Page 21: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XIX: APPLICATION FOR OVEN (HSD)

Client: Ford India Limited, Maraimalainagar, T.N. SYSTEM DETAILS:

Name of equipment : Top Coat Oven 1, Zone 1 (Dark Radiation)

Type of fuel used : HSD

OBSERVATIONS:

Particulars Time taken for the Oven to heat up from ambient to preset temp. of 220 degrees C (mins)

Reduction in heating up time (mins.)

% Saving

Without Flux maxiox™ 34.34 6.51 18.96%

With Flux maxiox™ 27.83

* Since HSD firing rate in burner is fixed lit/min, hence saving in time is directly proportional to saving in HSD consumed.

34.3427.83

05

10152025303540

Time (mins.)

WithoutFlux

maxiox™

With Flux

maxiox™

Time taken for Oven to heat up to 220 deg C

Page 22: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XX: APPLICATION FOR OVEN (L.P.G.)

Client: L&T Komatsu, Bangalore

SYSTEM DETAILS:

.# Paint Baking Oven is used for finish baking the polyurethane paint for PC 200,300 & 71.

# LPG pressure 1 bar, consumption varies between 5400 Kgs to 6000 Kgs / Month.

# Temperature maintained inside the oven is 80 degree centigrade.

#Date Of Installation : Septembr 2005

OBSERVATIONS

Time Period Total Production in

Tons

Total LPG

Consumption in Kgs.

LPG Consumption

per Ton

Aug04-Aug05 17791 69690 3.92

Sept05-Jul06 21236 61000 2.87

LPG consumption without Flux maxiox™ for 21236 tons @ 3.92 Kgs/Ton ; 83245 Kgs

Actual LPG consumption recorded with Flux maxiox™ : 61000 Kgs

Savings of LPG as on July 2006 : 22245 Kgs

Cost of saved LPG until July 2006 @ Rs.30 / Kg : 667350 Rs.

PRESENTATIN BY MR. U.K.SINGH TO THE L&T MANAGEMENT)N 17th AUGUST 2006

……………………submitted to flux by Mr. U.K.Sing , Works Manager September 2006

Page 23: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XXI : APPLICATION FOR FURNACE

CLIENT: STERILITE INDUSTRIES (INDIA) LIMITED, SILVASA

Contact Person : Mr. Satish Rahinj, Tel No.0260 6612340 SYSTEM DETAILS:

Name of equipment : Copper Melting Furnace Make of the unit : ASARCO-CHINA

Capacity : 3 TPH Type of fuel use : LPG

Avg. Fuel Consumption : 7 Tones / Day. Avg. Production : 230 Tons/Day

Date Of Installation : July 6. 2009 Flux maxiox™ 82 : 10 Nos.

OBSERVATIONS:

Status

LPG

Consumption /

Ton .(Avg.)

Savings

Savings in

LPG @

Savings in Indian

Rupees. Considering

LPG @ 35Rs/Kg

Before Installation of

Flux maxiox™ 33.21

0.288 Tones / Day

10,080 Rs. / Day

After Installation of

Flux maxiox™ 31.84

+ 4.12%

8.64 Tones / Month

3,02400 Rs. / Month

Fuel Efficiency

31

31.5

32

32.5

33

33.5

Before July-2009

After Aug-2009

Rat

io

Series1

……………………………………………… @ Reported and Confirmed : September-2009

Page 24: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

FLUX maxiox™ (β-Series): For Industrial Fuel Utility

CASE STUDY XXII: APPLICATION FOR BOILER

Client: M/s. Badve Enggineering Limited. Unit – V ,Narayanpur, ( Near Walunj, Aurangabad –

Pune Highway Taluka : Gangapur, District : Aurangabad – 431 133 (Maharastra, India)

Contact Person : Mr. S.U.Shelke. (Manager Plant Maintains) Cell .No. :9881150859

SYSTEM DETAILS:

Name of equipment : Boiler

Capacity : 10000 K cal

Make of the unit : Aquatherm (Thermax) MFG 2005

Model :ATH – 10 mod/80

Type of fuel used : LPG / N. GAS.

OBSERVATIONS:

Sr. No. Discription UOM QTY Trial Period A Before maxiox installation Hanger Produced No 42671 Fr. 01.09.09 to 14.09.09 LPG consumed Kg 12555.03 LPG consumed per Hanger Kg/Hgr 0.303 B After maxiox installed Hanger Produced No 41462 Fr. 15.09.09 to 27.09.09 LPG consumed Kg 11947.88 LPG consumed per Hanger Kg/Hgr 0.280

Savings

LPG consumed per Hanger Kg / Hgr 0.023 Cost of LPG / Hanger Rs / Hgr 0.73 % Saving Kg / Hgr 7.53

………………………………………………………. @ Reported and Confirmed : May 2010

Page 25: CASE STUDY – SUMMARY maxiox (β-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri. SYSTEM

WHY DO DIFFERENT FUELS LEAD TO VARIABLE RESULTS IN SAVINGS? Hydrocarbon fuels consist of long chain molecules, the length of which increases in the following order: CNG/ LNG (Compressed/ Liquified Natural Gas ): usually around 70-90% methane (CH4) with 10-20% ethane, 2-8% propanes, and decreasing quantities of the higher HCs up to pentane. LPG (Liquefied Petroleum Gas): predominantly propane (C3H8) with iso-butane and n-butane. Petrol: major constituents iso-octane (C8H18), hexane, heptane upto C12. Diesel: major component is Cetane (n-hexadecane) (C16H34). Thus the hydrocarbon chain length, complexity and fuel density increases in the order of CNG/LNG<LPG<Petrol<Diesel<HSD<LDO<FO<RFO As the hydrocarbon chain length increases, the formation of macromolecular associations leading to large pseudo-molecules also increases and the chains get all the more entangled. Thus it becomes more and more difficult to separate or open up these macromolecules by way of excitation due to our device as we go up the series. Hence, the more complex the molecule or longer the hydrocarbon chain, lesser is the effect of our device on it and consequently lesser are the savings in fuel. To substantiate this theory by way of results, field study results for our products encompassing the FLUX technology show definite savings around 30-40% for CNG/LNG, 20-30% for LPG, 15-20% in Petrol, 12-15% in Diesel, 7% in HSD, 5% in LDO and 3% in FO/RFO. The savings in fuel vary as per the complexity of the hydrocarbon fuel. Several parameters such as line pressure, flow rate, MOC of fuel pipe affect these savings. For gaseous fuels used in industrial applications such as LPG and LNG, savings vary as per the flow rate. The savings range between 7-10% for flow rate around 250 nm3, 5% for a flow rate of 500 nm3 and 3% for a flow rate of 750 nm3. SALIENT FEATURES: Following are the advantages of installing the Flux maxiox™ (β-series)

• Increases BTU output • Increases thermal efficiency of the fuel • Eliminates use of fuel additives • Reduces maintenance on the fuel si de • Reduces carbon buildup • Increases the combustion efficiency, reducing the fuel consumption • Reduces stack emission levels • Leads to a cleaner environment • Online installation • Zero-Maintenance • No external power required

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