Gas Oven for Core Drying: ROI (March 2015)

Absolute cost impact cosidering quotations

recieved and estimation
A Investment
Quotation-Main euipment with installation and commissioning for
2,530,000 Rs
oven

Piping material
Quotation for Gas pipe line (Approx 650 Metrs) from Heat Treatment
available from old
Metering unit to foundry core shop (Miscullenious Material & Labour 500,000 Rs
LPG Yard will be
charges)
used

Civil activity required for roof exhaust pipe and miscullenious core oven
150,000
foundation work

Miscullenious Fabrication work for relayout and existing Core trolly wheels
300,000
modification (FML scope)

Total-Landed 3,480,000 Rs
B Annual Saving (Rs.)
1 Infra head & Hot air ovens electrical consumption
current load / day 1,800 Kw
Rate of elecricity per day @ 9 Rs 16,200
Rate of elecricity per month @ 9 Rs 421,200
Rate of elecricity per year @ 9 Rs 5,054,400

c Gas consumption
PNG consumption 11.76 SCM

Cost of png per day @ 47 Rs / SCM 11,842

Monthly consumption 307,880
Yearly Gas consumption 3,694,554

E Annual Saving (Rs.) 1,359,846

F Return On Investment in Years 2.6

 PNG Fired Core Oven Unit ( First Tier)
Temperature Requierment

a)    Maximum temperature required (Designed) 200 Deg. C

1 b)    Operating temperature 150 to 180 Deg. C.

c) Temperature variation allowed + / - 10 Deg. C.

Primarily PNG Fired

d) Heating Fuel
With Alternate backup of Electrical Heating

Core Data

a)    Total weight of the core (30 Kgs X 2) = 60 Kgs

Two Core Assemblies on One plywood

b)    Shape & Size of the core
Total (L 790 X W 750 X H 155) MM

Silica Shell sand

2
c) Material of Core (Silica sand Coated with resin Binders,
Thermo set binders)

c)    Initial moisture content in the core & 1) Required for Core gum setting after assembly
Application 2) Required for Drying of water base refractory wash (2% Maxm)

d)    Final moisture content in the core No Moisture recomonded Practically

e) Temperature of the core at exit 130 to 150 Deg. C.

f)Requirement of assemblies to be fitted in one
16x2 (Total weight = 960 kgs)
set up
Oven Size & Conveyor requirment

Width : 790 mm
a) Clear Inside size of the Oven Heigth: 410 mm
Length: Based on cycle requirment (Maxm 6000 MM)

b) Conveyer working Height 900 mm from Shop Ground level

3 At Loading Side Minm 2 mtrs Extra than Oven Length

c) Conveyer Length
At Unloading side Minm 1 mtrs Extra than Oven Length

d)     Throughput / Output 900 Kgs / Hour

Motorised Roller conveyer,
e)    Type of conveyor required
Variable speed of 100 to 200 MM / min
f) Total Heating Cycle 50 to 60 Minutes (Input to Output Time of cores)