SCALE LOSSES AND FUEL LOSSES are the biggest causes of concern for all re-heating furnace owners, particularly in these recession–hit times.

Scaling Loss:

On an average, Indian scale loss is 1.5% to 3.5%. However, not many people are aware that the average International scale loss is 0.2% to 0.8%. It is possible to limit scale losses and match international standards. A rough estimate is that a scale loss of 1% in a daily production of 100 MT of rolled steel will cause a loss of Rs.36000/- per day i.e. Rs.108 lacs per annum.

Fuel Loss:

Indian consumption of fuel per MT of steel rolled is anywhere between 38 to 55 litres, which is, again, way above the International average consumption of Furnace oil 25 litres/MT.

A reduction in fuel consumption by even 10% would effect savings of upto Rs. 11700/- per day or approximately Rs. 35 LACS per year (at an average consumption of 45 litres / MT and at a production level of 100 MT per day and taking the cost of Furnace Oil to be approximately Rs. 26/ Litre).

Scale losses and increased fuel consumption are caused mainly due to too much excess air in the furnace due to incorrect air: fuel ratio, causing the excess oxygen to oxidize the job in the re-heating furnace and sensible heat being carried away from the furnace requiring more fuel to be pumped in.
Re-heating plants across India are thus losing lacs and lacs of Rupees every year. What is the solution.

1. "OXYCOMP-G" - FYKAYS ONLINE OXYGEN ANALYSER
The OXYCOMP - G works on the well–proven Zirconia sensor principle which enables detection of Oxygen in the furnace from PPM level to 100%. 
The OXYCOMP-G has been specifically developed to monitor the amount of excess oxygen in the re-heating furnace gases. Once this is known, the user can control the amount of fuel injected. 

For example, if the Oxygen percentage is too high (say 5%), the instrument will give an indication on the remote display and the air injected into the furnace will have to be reduced by the user. This will obviously reduce fuel consumption as well as scaling losses. 
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The basic components of Fykays OXYCOMP-G system are as follows:

Oxygen Probe: The Zirconia Oxygen probe which senses the Oxygen in the furnace atmosphere
Probe heating Furnace + Controller: A small auxiliary furnace which is installed on the side wall of the re-heating furnace in which the Oxygen probe is installed. This furnace temperature is controlled with the help of a PID controller.
The Oxygen Analyzer
The reference air system
The electronic purging apparatus
The remote display: The signaling panel with Hi/Lo alarm

Once the Oxygen content in the furnace atmosphere is indicated by the instrument, the fuel can be controlled manually. If desired, the output from this system can be used to automate the control of fuel injection into the furnace with the use of control valves. 

2. OXYCOMP G-II FYKAYS OXYGEN ANALYZER AND CONTROLLER

Recognizing the industry requirement for automated control, we developed the OXYCOMP G-II. Essentially, it is also built around the well proven Zirconia technique and enables precise detection and control of Oxygen over a wide range. 

In addition, this version of OXYCOMP G-II utilizes an equally well proven technology namely Variable Frequency Drive (VFD) to regulate the speed of the main air blower so as to reduce the air intake into the furnace so as to contain the excess free Oxygen, instead of having to depend on the furnace fireman.