Mr. Arindam Roy, Managing Director, FGK Thermal a leading manufacturer of kilns speaks to Indian Minerals about increasing the efficiency of tunnel kilns.
IM: What are the key cutting edge technologies that you offer?
AR: At the outset, if you want to know about FGK Thermal, the discussion cannot start without mentioning Mr. Anup Kumar Dasgupta who founded FGK in 1978 and left us for heavenly abode in 2022, then Chairman ( Emiratus) . Myself Arindam Roy ( Managing Director) of FGK Thermal is trying to make a constant effort to carry forward his legacy. Our cutting edge technologies include Single Operator Per Shift Fully Automated High Temperature Tunnel Kiln with Dryer, Shuttle Kiln for all types of Refractories; Tempering Kiln for Unburnt Basic Refractory, Snorkel, PCPF Kiln, Dryers, Black Refractory Kiln, Dryer and last but not the least Preheating Furnace, Rebake Tunnel Kiln for Graphite Electrodes.
IM: Where does India stand in kiln manufacturing technology vis-à-vis China or Europe?
AR: India is now the 5th largest manufacturing nation in the world, surpassing traditional industrial powerhouses like UK, France and South Korea. India stands just behind China, US, Germany and Japan. Due to MAKE IN INDIA policy we can surpass them by 2032; thanks to Honourable Prime Minister of India & his team. Today we are facing some issues but this will yield huge benefits in near future. Almost all global refractory companies now have their plants in India. Why? Because they can see the future writing is on the wall. FGK Thermal is making Industrial Kiln, Furnace & Dryers indigenously at par European companies if not better at 40% less cost with identical performance. FGK Thermal Kilns cost are similar to Chinese manufacturers with much better performance. Our USP is life time free after sales service. This is a big statement. You can verify the same with any major refractory companies in India.
IM: Do you use modelling tools in kiln design?
AR: Yes Definitely. We make 3D Models of our Kiln and share with our customers for their better understanding & feedback. We have also developed some software of our own for refractory lining selection & surface temperature calculation.
IM: What steps do you suggest to recover exhaust / waste heat from the heating /cooling zone?
AR: Please be noted that Exhaust Flue contains SOX, NOX, CO, CO2. Waste heat is pure hot air. If you are running a batch kiln, recover upto 48% exhaust flue through recuperator and use them as preheated combustion air which will account for 5-10% fuel savings depending on designs. If you are running a continuous kiln, recover 78% waste heat depending on designs, use them as preheated combustion air which will account for 15% – 20% fuel savings apart from its additional usage like Dryers, Tempering Kiln, Oil Tank Heating etc.
IM: Please inform our readers about flue gas treatment systems offered by your kilns.
AR: Nowadays FGKT does not make Kilns with Producer Gas or Petcoke as a fuel. In continuation to trailing replies, please note that we are using ABS (After Burning System) if the fuel is Oil or the product is abrasive. If Fuel is Natural Gas or LPG, we design the chimney accordingly as product of combustion of NG or LPG is CO2 + Steam.
IM:. Can you provide reference plants operating with your tunnel kiln?
AR: Reference List is huge as we have made more than 100 Kilns & Dryers. But I need to mention specifically that today whatever FGKT has achieved in the last 48 years, the credit
mainly goes to Tata Refractories Limited (now TRL Krosaki Refractories Limited), ACC Refractories (now Calderys India Refractories Limited), IFGL Refractories Limited because they gave us the opportunity to develop our products indigenously.
IM: What energy savings have been achieved in some past installations?
AR: We have achieved upto 40% fuel savings in PCPF Dryers, 20% fuel savings in Tunnel Kiln with acknowledgement for the same with certificate(s).
IM: For tunnel kiln operators in the ceramics and refractories industry, what would be your advice to boost tunnel kiln efficiency?
AR: My quick points:
- Green Energy – Use Gas except Producer Gas. 100% combustible. Better Temperature Uniformity. High Yield.
- If not – at least use LSHS. Any heavy oil is not 100% combustible whatever you implement. Result is high fuel consumption and unburnt fuel getting released in atmosphere resulting in pollution with SOX, NOX, CO
- Use Waste Heat Recovery System
- Use good quality refractory to insulate your kiln to minimise your heat loss
- Insulate Ducts, Joints; Openings with LRB MWM; CFB
- Last but not the least; design your kiln suitable to product, temperature output so that for high temperature kilns, burning zone should have enough space for radiation apart from convectional heating.
IM: Thank you very much.
AR: You’re welcome