Furnaces and Ovens are among major power consuming equipment in industries globally

Pune-based Kalyani Enterprises nowoffers a power saving solution for industrial furnaces. The company is a manufacturer of various types of heat treatment equipment since 1994, and an approved vendor of Sandvik Asia Pvt Ltd for revamping/reconditioning of old conventional brick-lined furnaces using their Fibrothal Heating Systems.

Among the jobs completed successfully in this area is the successful revamping of a 40-year-old Russian-make conventional brick-lined furnace at Hindustan Aeronautics Ltd, at Ojhar near Nashik, using the Fibrothal Heating System, resulting in saving of power to the tune of more than 40 per cent.

Here, by using the new energy-saving vacuum-formed Fibrothal Heating System, the total power of 280 kW was redesigned and brought down to 243 kW, a direct saving of 37 kW. The furnace was used for heat treatment of job-soaking time of 2 hours only, required for manufacturing various components for the Sukhoi 31 series aircraft for the Indian Air Force. In order to reach the desired temperature of 1000?C, it used to take 10 hours for the 2-hour job, which was brought down to 1 hour to achieve the required temperature, a reduction of 9 hours in the total required cycle time, resulting not only in power savings, but also increased output of heat treatment jobs.

A similar job was done at Sandvik Asia Ltd, Pune, and Premium Energy Transmission Systems, Pune, where energy savings of more than 30 per cent was achieved. Besides savings in power there was also no requirement of any other maintenance for the heating systems since 2006.

Earlier in both the organisations there were cases of regular breakdown (minimum twice a month as per their records) for repairs and replacement of heating elements, resulting in production loss. Here, too, the heat-up time was brought down from 4 hours to 1 hour.

Similarly, at the Pune Municipal Corporation (PMC) and the Pimpri-Chinchwad Municipal Corporation (PCMC), Kalyani Enterprises had the privilege of being the only organisation chosen to do the annual maintenance of the crematorium furnaces. Here again, the company executed some changes in design of the furnaces, resulting in the power savings to the tune of 10% to 15%.

In aluminium holding and melting cum holding furnaces, where direct application of vacuum-formed Fibrothal Heating System is not feasible, engineers at Kalyani Enterprises have used a combination of both refractory and vacuum formed boards, changing the type and design of heating elements, resulting in saving of power to the tune of 10 per cent to 15 per cent.

The company is also engaged in manufacturing electrical/gas/diesel fired furnaces, ovens, laboratory furnaces, aluminum melting cum holding furnaces, ageing furnaces, solutionising furnaces, heat treatment furnaces, high temperature furnaces, and furnaces as per customer-specific requirements.

The main focus is on saving of power, not only for the organisation, but also for the greater benefit of the society and the country. This saved power can be diverted to the rural areas where power cuts ranging from 12-16 hours, a day is routine even today.

The different organisations using Oil/Diesel can contribute by not emitting smoke and other gases into the atmosphere and also earn Carbon Credits for the same, using energy saving heating system. Kalyani Enterprises has the expertise and capabilities to redesign existing furnaces and work out the payback period by opting for the vacuum formed board heating system for saving power and increasing productivity.

(Kalyani Enterprises, Plot No: 4/29, Sector No: 10, PCNTDA, Adhar Industrial Co-op Premises, Opp Times of India, Bhosari, Pune 411 026, Tel: 020-66110856, 66142529-33. Fax: 91-20-66110855. Email: kalyanienter@ vsnl .net)