Department of Science & Technology

Science for Equity, Empowerment & Development Division

Programme on Science & Technology Intervention in Traditional Craft

(STITC)

Organization of
1. Title, PI & Co-PI
Presentation

2. Location map, District and Villages Covered

/Beneficiaries
3 Project objective ; Action plan; Methodology
4. Baseline Data ( Gaps & Likely Intervention)
5. List of Deliverables; Local Community Involvement
6. Innovative Component / Novelty; Expected Benefits
7 Budget Major Equipments & Non-Recurring
Expenditures
8 Intervention
Linkages shape
with Organizations
& Experts
human interaction in tacit and collective
interaction of actors, within normative or cognitive patterns.

Multi-Pot Furnace
with
Hybrid Recuperator
An Attempt To Develop Efficient Thermal System

For

Firozabad Glass Craft Artisans

Investigators
Devendra Sah (CDGI)
Dr. Subrata Das (P.I)
Prof. Puneet Mangla (Co-P.I.)

Hindustan College of Science & Technology,

Farah, Mathura , UP 281122
In Collabration with
Center for the Development of Glass Industry (CDGI)
Firozabad - U.P.

Beneficiar
y
Glass Craft Artisans Community
District - Firozabad , UP
Population (2011 census)
603,797
4.5 Lakhs peoples in Glass
cluster.

Products
Low priced Bangles Chandeliers
Electric wares
Crystal ware
Scientific and lab wares Glass
beads.
Per Capital Glass Consumption
India
0.8 Kg
Indonesia
China
3.5 Kg
Malaysia
Thiland
5.2 Kg
US

2.5 Kg
12 Kg
30-35 Kg

ase Line Data

In-depth discussion
Technologist, CDGI, Firozabad

Devendra Sah ,

Sr. Glass

Deluxe Glass Industry, Prem

Glass, Sevak Glass, Firozabad
Highly energy intensive craft
Mr. Narayandas Gupta, Amit Gupta Pakai Bhatti Vikas Sahkari
Fuel cost 50% - of product cost & 75 % of the total energy.
Samiti, Firozabad
In previous 5 years, Muffle- 100 units dropped to just around ten.
Metallic Recuperator, cost 4-5 Lakhs, ture failure,
needs replacement in every two years.
Present Gas consumption/Day = 265 m3;
Costing 1700/day and
Effective utilization is about 35- 40 %.
GAPS
Dearth of heat recovery procedures.
Drastic need is cost effective improved technology (Sethi and Ghosh, 2008).
We Confine technology development roadmap ------Hybrid RECUPERATOR
To Improve energy efficiency & prevent pre-mature failure.

In an Indian plant a recuperation system is installed for Rs. 3 Lakhs,

Saved Rs 8,88,000 /year, ensued payback in 5 months (CII, 2012).

Project

Objectives

Revive consistent pre-mature failure of Metallic Recupurator.

Ensure Hybrid Recuperators implementation.

Energy economy opportunity.
Congeal competitiveness and financial situation.
Access to ingenious technological procedures.
Capacity building.
Competitiveness
Meet standard specifications,
Tackle unemployment issues.

Recuperators (whether Metallic or Ceramic) has

inherent limitations
Heat exchange between flue gases and the air through Radiation.
Tubes carry combustion air for preheating.
Gas side up to1550
Preheated air side to 815 C
Air preheat temperatures <700 C
During working hours ( ~1100oC
only.)
Underutilized
and/ or overheated during melting
hours (night) ~1340oC
Overheating
[flue gases
temperature leave the furnace]
Deficit thermal efficiency and/ or
reduced life.
Ceramic Recuperators
(usually Alumino-silicate refractory)
Colder end gets damaged due to

Base Line Data

cuperVideo 1
Video 2ators has
Video 3 inherent limitations
Metallic Recuperator,

4-5 Lakhs
Premature failure, every 2 years.

Air preheat temperatures <400 C

Ceramic Recuperators (usually Alumino-silicate refractory)
Deposition of alkali vapours FUSED
(sodium carbonate, borax)

Hybrid Recuperator
Ceramic Recuperator (3 Feets) before
Mettalic
Eliminate Flue Path Way ( 15 feets)
Uniform Temp.
optimum efficiency during working hours & melting
hours,
Enhance life of Recuperator (7- 8 Years)

A clearer view of recouping the heat FOR cost

control perspective

ceramic recuperator

metallic recuperator

Installation of a ceramic recuperator immediately before the

metallic recuperator
-----------------------------------------------------------will take care of high
temperature impact.
If purely
Ceramic recuperator is installed near to the furnace
(Hot End) &
Metallic at Colder end, deposition of alkali vapors take place on
metallic part, that can be easily cleaned.

(whether Metallic or Ceramic

A clearer view of recouping the

ceramic recuperator
heat

Assessment of waste
heat recovery
Q = heat
content in
kCal
V = the flow
rate of the
substance in
m3/hr
= density
of the flue gas
in kg/m3
Cp = the
specific heat
of the
substance in
kCal/kg oC
T = the
temperature
difference in
oC
Cp (Specific
heat of flue
gas) = 0.24
kCal/kg/oC

The amount of recoverable heat can be calculated as:

Q = V x Cp x T x

Heat Saving Calculation

m=

1000 kg/hr

Cp
T
=

= 1 kCal/kg C
= (75 20) C = 55 C
Heat Recovery Factor = 58% or 0.58

Q
=

= 10000 x 5000 kg/yr = 50000000 kg/year

= 50000000 x 1 x 55 x 0.58
1595000000 kCal/year

GCV Natural Gas = 10,200 kCal/kg

Equivalent GAS Savings = 159500000 / 10200 = 156372 L
Cost of GAS = 22 /L

Monetary Savings = 54730 /Annum

Action
Plan
Community Engagement

Capacity Building

Convergent Technology

Methodolo
gy
Participatory & Appreciative Inquiry Based
ACTION RESEARCH

OPERATIONAL
PREPARATION
Workshops
MECHNAISM
(Initiation
Phase)

Brainstorm
Session

TARGET
SETTING

ACTION PLAN

IMPLEMENTATI
ON

MONITORING
& REPORTING

Assessment
Design
Critical
Review
Fabrication,
Demonstratio
n
Debugging

Drafting
Report
Capacity

Deliverable
Process development
s

Prototype of Hybrid Recuperator for Multi- Pot Furnace.

Prototype of Modified Muffle Furnace.

Documentation

PROJECT Reports - 1

Journal Papers
- 1

Conference Paper - 1

Articles
- 1 (Type - Communication)

Technology Manuals 1

Brochure
- 1 (Hybrid Recuperator)

Training Module Software for Technological Capacity Building

Software/Mobile App (Furnace maintenance & operating
procedures)

Community Involvement
Workshop-1

Brainstorming Session with Labor/Workers in Firozabad Glass Cluster

Workshop-2

Meeting Session with Supervisors/Managers in Glass Cluster

Workshop-3
Workshop-4
Agencies

Session with Unit Owners , CDGI, FCGI,

Brainstorming Session with Experts from Academia, Industries, Government

NOVELT
Y
Augmentation of income.
Hybrid Recuperator
Community engagement
Convergent technologies
Apprciative Inquiry

xpected Benifits to Community

Cost-reduction,
Access to technical knowledge
Facilitation of Pilot Plant
Mobilize initiative to replicate effective technology.
Value addition to Govt. Policy Initiative

NOVELTY
Improve quality of life and augmentation of
income.

Community engagement
Convergent technologies
Appreciative Inquiry
Sustainable Action Plan (SAP)

Research
inspires
sustainable and inclusive
ected
Benifits
to Community

growth via
Cost-reduction,
Access to technical knowledge
Facility created can be used by local
units/Researchers.
Mobilize initiative to replicate energy
efficient &
cost-

MAJOR ITEMS /
EQUIPEMENT
Gas Fired ,Day Tank, Multi-Pot Furnace
Melting capacity ~800 Kg.
Metallic Recuperator
Ceramic Recuperator
Low-pressure
Blower
Vortex flow
burners
with motor
meters

SS 310/ SS
304 Tubes

BUDGET OF
EXPENDITURE
CD
GI

Sl.
No

Item Head

Non-recurring (Capital
Items)
Permanent Equipment

1st Year 2nd Year

5000 20,80,000

Sub total (capital items)

B.

Recurring Items (General)

1.

Manpower

2.

Consumables

3.

Contingencies

4.

Travel

5.

Overhead
Sub total (General)

Total cost of the project

(A+B)

3rd Total (Rs.)

Yea
r
20,85,000
20,85,000
99750

99750
1,80,000

1,80,000

6,18,736

6,18,736
8,98,486

29,98,48

BUDGET OF
EXPENDITURE

HCST

Sl. Item Head

No
A
Non-recurring (Capital
Items)
Permanent Equipment

1st Year

2nd Year

3rd Year Total (Rs.)

1,55,00
0

Sub total (capital items)

1,55,000

B.

Recurring Items (General)

1.

Manpower

3,69,000

3,69,000

2.

Consumables

1,61,000

2,00,000

3.
4.
5.

Contingencies
Travel
Overhead
Sub total (General)

Total cost of the project

(A+B)

1,55,000

30,000
30,000

30,000
30,000
NA

3,69,00
0
1,97,00
0
30,000
30,000

11,07,600
5,58,000
90,000
90,000
18,45,600

20,00,600

NON-RECURRING
EXPENDITURES
CDGI

Capital Items

1st Year

Multi-Pot Furnace
With Hybrid
Recuperator

2nd Year

3rd Year Total (Rs.)

20,85,000

20,85,000

HCST
Capital Items
Modified
Muffle Furnace

1st Year

2nd Year

3rd Year

Total
(Rs.)
1,75,000 1,75,00
0

LINKAG
E
Center for the Development of Glass
Industry, Firozabad - 283 203
Deluxe Glass Industry
Glass Expert
Firozabad Glass Chamber of
Commerce and Industry
Glass Expert

Shri. Devendra Sah

Shri. Harshit Agarwal
Shri. R.N. Bhargva

Amit Gupta
Dr. Ashsih Agarwal

STANDING TIE-UP
Pakai Bhatti Vikas Sahkari Samiti,
Firozabad

Mr. Narayandas
Gupta

Sevak Glass
Mr. Sachin Gupta

SCHEDULE OF
ACTIVITIES
Activity/Time
Field Visit &
Survey,
Literature
review

Workshops
Documenting
findings and
suitable
solutions
Critical
Review
Erection,Trail
& Demo
Modified
Muffle
Furnace
Erection,Trail
& Demo
Workshop &
Project

2 4 6

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