CLEAN TECHNOLOGY INITIATIVE

IN
SMEs CLUSTER

BY:
A. K. ASTHANA
Director
National Cleaner Production Center, India
 Firozabad Glass Industry
ABOUT THE CLUSTER

• Firozabad city has 400

glass manufacturing
units situated 250 km
from New Delhi and
40 km from Taj Mahal
• Previously units were using coal, Which emits lots
of air pollution effecting the color of White Marble
of Taj Mahal.

• To protect the monument, all the units have been

asked to switch over to Compressed Natural Gas
(CNG).
 BANGLE MANUFACTURING PROCESS
Sand
Cutlets Batch Preparation
Chemicals
5.2-5.3 tons/batch
CNG
Pot Furnace Flue gases -10000C
2300-2500 1350-14000C
Sm3/batch

Preheating furnace
600-700 Sm3/day (Sekkai Bhatti) Flue gases 6500C
for 10 hours 10000C

CNG
Each furnace consumes Belan Furnace Gas consumption depends upon no. of
around 10Sm3/hr CNG Furnaces

CNG Tapai Furnace

 FOCUS AREA-I

• Glass Melting Pot Furnace:-

1. No. of Furnaces – 200 nos operating continuously

2. Average Glass Melting per day – 5.3 tons
3. Average Natural Gas Consumption per–2200 Sm3/Furnace
4. No. of Working day in a year – 300
5. Furnace Temperature – 1380-14000C
6. Flue Gas Temperature – 10000C (Average)
7. Annual CNG Consumption – 132 million Sm3
8. Cost of CNG/year – 26.4 million US $ (0.2 $/Sm3)
9. GHG Emission – 310,068 tons/yr
Existing System
Chimney

Natural
BURNER
Draft

Flue Gas Temp. – 900-1000 0C

 HOT AIR
Recuperative Waste Heat Recovery System (380C-400) 0C
COLD AIR
300C

BURNER (900-1000)0C

Combustion Air Temperature = 380-400 0C

Natural Gas Savings = 20-22%
Investment = 12000 US$
Annual Gas Savings = 132000 Sm3
Monetary Savings = 26400 US $
Simple Pay Back Period = 5.5 Months
 Advantages Of Waste heat Recovery in
Pot Furnace
• The combustion air can be preheated to a higher
temperature

• As the combustion air temperature is high more fuel

economy can be achieved

• Cycle time for melting and refining will be reduced.

 Disadvantages Of Recuperative Waste Heat
recovery system in Pot Furnace
• Being in small scale industry, the initial capital
investment is high.
• Entrepreneurs feel that furnace operates under natural
draft and carryover of glass will deposit on recuperative
tubes affecting the draft condition. It is also a general
feeling that excessive positive pressure inside the
furnace will reduce the pot life.
• For cleaning of heat transfer area the flue duct is to be
cooled down and mechanical cleaning is required. In
order to clean the tubes a by pass arrangement for flue
gases is required
Modified Waste Heat Recovery System
Cold Air at 30 OC
Hot Air at 222 OC

6” Dia

BURNER

900 -1000OC

Stainless Steel Tube (13 Meter)

Techno-Economies
Gas Consumption = 2200Sm3/day
Gas Savings = 10% (Approx.)
Annual Gas Savings = 2200 x 0.1 x 300 x 0.2
= 13200 US$
Investment =2000 US $
Simple Pay Back = 1.8 month
heat Transfer Area = 6 m2
 COLD AIR
HOT AIR

Area – 2 Pipes 4” Diameter & 13 meter length = 8 m2

- 3 Pipes, 4” Diameter & 13 meter length = 12 m2
 Advantages Of Modified Waste Heat
Recovery System
• It is low cost and simple to construct the device.
• Need not required to close the furnace for longer
duration.
• Easy for cleaning carry over material and the
deposits can be cleaned even during the
operating time.
• Not affecting the draft condition.
 FOCUS AREA-II
• Pre-Heating Furnaces

1. No. of Furnaces – 200 nos operating 10hrs/day

2. Glass processing per day – 5.3 tons
3. Natural Gas Consumption per day – 700 Sm3/Furnace
4. No. of working days in a year – 300
5. Furnace Temperature – 900-10000C
6. Flue Gas Temperature – 6500C
7. Annual CNG Consumption – 42 million Sm3
8. Cost of CNG – 8.4 million US$ (0.2 $ / Sm3)
9. GHG emission – 98,658 tons/yr
 PRE HEATING FURNACE (SIKKAI BHATTI)
– EXISTING SYSTEM

Hot Exhaust Gases Hot Exhaust Gases

600 – 650 oC

Combustion Air at
300C
 MODIFIED SYSTEM OF PREHEATING FURNACE
COLD AIR IN
HOT AIR OUT

10 INCHES

8 INCHES

Pre Heated Air for

Combustion

6 INCHES
 FOCUS AREA –III
Waste Heat Recovery From Gas Generators
̇ All the units at Firozabad Glass Industry cluster has captive
power generation from natural gas operated generators. It is
estimated that there are nearly 300 generators in the cluster
and average flue gas temperature is in the vicinity of 5200C.
̇ As most of the generators are operating during production
process, it is proposed to recover the waste heat for
preheating combustion air which is used for natural gas
combustion. The areas where the hot combustion air can be
used are given below:
¬ In bangle manufacturing units the preheated combustion
air can be used for pot furnace, Sikkai Bhatti and Tapai
Bhatti
¬ In regenerative tank melting furnace the secondary air can
be preheated.
 Exhaust Flue Gas
(Cold)
0.4 meter

2.0 Inch

Cold Air
20 Inch
0.5 meter
2.5 Inch

1.5 meter

6.5 Inch
0.6 meter

Hot Flue Gas

Hot Air

Gate
Valve 5
Inch