Gujarat Heavy Chemicals Ltd (India)

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Visit Report to M/s.Gujarat Heavy Chemicals Ltd.

Nemeli Road, Tiruporur, Kanchipuram Dist. 603 110. Tamilnadu, India

Date : 19/06/2003.

Product used for drying = Salt

Source used for drying = Thermic Fluid

Name of the fuel used = Furnace oil

Fuel used per hour = 100 litres ( as per report)

Fuel used per hour = 135 - 150 litres (as per personal enquiry)

Fuel used per day = 2400 litres

Fuel used per year = 640 kilo litres

Approximate cost of Fuel = Rs.13.25/litres

Method of drying = FBD (Fluidised Bed Drying)

Capacity of drier = 15 tonnes

Initial moisture of the product = 4.5%

Final moisture of the product = 0.13%

Annual production = around 75,000 mt

Capacity of heating system = 15 lakh Kcals/hr.

Total shifts = 3 shifts (24 hr.)

Tilting angle of factory = 11o SE (south towards east)

Total blowers used for drying = 2 Nos.

Main Heating Blower = 1 no Exhaust Blower = 1 no

Main Heating Blower specification

Blower power = 75 HP

Measured Current & Voltage = 72.5A, 420V

Volume flow of the main blower (measured at blower suction side)

Circumference of the pipe = 1.63m (diameter of the pipe = 0.52m)

Cross sectional area of the pipe = 0.212m2

Average velocity of the air = 22.85 m/s

Volume flow of the air = 17,500 CMH

Blower suction pressure = 57 mm of H2O

Volume flow measured at blower delivery side

Cold air delivery for cooling chamber

Delivery pressure at cold air passage = 635 mm of H2O

Circumference of the pipe = 1.63m (diameter of the pipe = 0.52m)

Cross sectional area of the pipe = 0.212m2

Average velocity of the air = 5.1 m/s

Volume flow of the air = 4,000 CMH

Net volume flow of the air used for drying = [17,500 - 4,000 CMH] = 13,500 CMH

Drier inlet temperature = 2100C

Delivery pressure near thermic fluid = 596 mm of H2O heat exchanger side

Exhaust Blower Specification

Blower Power = 75 HP

Measured Current & Voltage = 57A, 420V

Thermax boiler Specification

Blower Power = 15 HP

Measured Current & Voltage = 8.7A, 420V

Thermic fluid inlet temperature = 2200C Thermic fluid outlet temperature = 270oC

Volume flow of the Exhaust blower (measured at blower suction side)

Circumference of the pipe = 1m (diameter of the pipe = 0.32m)

Cross sectional area of the pipe = 0.08m2

Average velocity of the air = 7.7 m/s

Volume flow of the air = 2,250 CMH

Blower suction pressure = 12 mm of H2O

Energy Balance for Hot Air Generation

Net volume flow of air heated from 35oC - 2100C = 13,500 CMH

Total energy required / hour

= (13,500 x 0.898*)kg. x 1 kJ x (210 – 35)

= 21,21,525 kJ

= 5,07,542 kilo cal.

Density of air at a temperature 1250C - average of 350C & 2100C

Solar Energy Contribution to heat the air from 350C - 1050C

Energy delivery = (13,500 x 0.999*)kg. x 1 kJ x (105 – 35) = 9,44,055 kJ = 2,25,850 kilo cal.

Density of air at a temperature 700C - average of 350C & 1050C

The percentage of energy savings through solar heating = 44.4%

Fuel Savings (assuming 100 litres/hr)

The average fuel savings per day = 100 litres x 0.444 x 7 hr. = 311 litres

The average fuel savings per year = 311 litres x 300 days = 93,300 litres

Fuel savings cost per year = Rs12,12,900/-

Assuming 135 litres/hr The average fuel savings per day = 135 litres x 0.444 x 7 hr. = 420 litres

The average fuel savings per year = 420 litres x 300 days = 1,26,000 litres

Fuel savings cost per year = Rs16,38,000/-

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