Energy Audit in Industries

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Tyre & Rubber

In the tyre industry, raw material accounts for nearly 70% of the cost of manufacture. Hence, for this industry, the efficient use of utilities becomes even more pressing, if they to be competitive.

Fuel used for generating steam is around 40% of the total utility cost. Major area of steam consumption is for rubber preparation. Curing process consumes almost 70- 75% of total steam. Hence, the potential for making these areas energy efficient is considerable.


By partnering with tyre companies across the country we have been successful at reducing the avg SFC across the industry and have also now set ourselves a new benchmark to beat. Forbes Marshall- CII joint studies reveal differences in fuel consumption per ton of finished tyre within the industry, i.e. Specific Fuel consumption – SFC (FO Kg/Ton Finished Tyre)

                            

 

We have partnered a wide diversity in Tyre and Rubber plants, Radial/OTR, Solid Rubber, Cycle/Scooter, Rubber Products, etc.  We have also rendered our services for autoclaves.


Case Study

A tyre plant in Maharashtra was able to reduce its Specific Fuel consumption from 284 to 254 kg petcoke/MT tyre savings 2040 kgs of pet coke each day!

The plant implemented the following recommendations

  • Recovering condensate & flash steam
  • Rectification of trap installation, right selection of traps on platen/dome presses
  • Distribution and utilization of steam at the right pressure
  • Arresting steam leaks.
  • Implementation of ash re-burning system.


The prime reasons for difference in SFC across plants were:

1. Efficiency of steam generation


Avg Direct efficiency: 67%
Avg Indirect efficiency: 75%

        

 

Reasons for gap:

1. Fluctuating steam demand as number of presses online varies.
2. Average steam consumption is about 50% of total boiler capacity.

 

2. Optimized steam distribution and utilization


1. Effective steam trapping (selection, sizing & installation) improves batch timings and curing.
2. Proper pressure temperature and dryness fraction of steam ensure lower SFC.
3. Use of indirect steam over direct steam for hot water generation leads to better SFC.

3. Recovering condensate and flash steam

          


Reasons for gap


1. In most plants flash steam is not recovered.
2. Feedwater temperature varies between 40-900C
3. Condensate recovery using electrical pump leads to loss of useful heat as electrical pumps cannot pump condensate at high temperatures.
4. Condensate recovery by trap pressure leads to back pressure on equipments and thus trap malfunctioning. Importantly it also impacts product quality.