Dhanaprakash Industrial Corporation

Kupwad, Sangli, Maharashtra

Vibraclaim, cooler classifier, dust collection systems.Vibraclaim, cooler classifier, dust collection ststems

Flaskless, Flask, Cement Sand, No BakeMoulds quickly uniformly dried.Online, Tunnel, Portable custom designedmodels.GasOilElectrical Heating.PLC Controlled.Mould strength unaffected.

The solution treated aluminium products are further subjected to precipitation Harding. Some products are directly aged. Sealed trolley Ovens are used with electrical / LPG heating system with forced draft recirculation for long time provides Ageing of the materials.

Cooling Is EQUALY Important as Heating

Submersible Agitator is a key equipment for Quenchant Tank Agitation in Heat Treatment process. The Airless agitation with 0.5-2.0 m/sec. velocity resulting in 800⁰ C/min hot job cooling rate achieves the required properties. The Submersible Agitators are any time removable equipment, not only agitates the quenchant but offers high thrust on hot jobs, due to which vapour blanketing is instantly broken (or do not allow) and heat is dissipated at tremendous rate. It is used for Water, Water Polymer and Oil Quenching Tanks very effectively.

The performance parameters of the submersible agitators are shown in the following table with the rated voltage of 415V and the frequency of 50Hz. However special agitators with 380V 60 Hz or other supply conditions are available on request.

Quenchant- Water, Oil, Polymer.

Cooling Rates- 800 c/min.

Velocity- 0.6 m/sec.

For no bake, shell sand.Complete automated gas fired plant.For no bake, shell sand.Complete automated gas fired plant.

We offer core driers. no bake, co2 sand, shell cores drying after painting. slat conveyor-tunnel, trolley-tunnel, overhead pallet etc. automated systems. core handling minimized. plc controlled. gasoilelectric heating.

Heat treatment furnaces

latest, strong, sturdy, plc/pc controlled heating quenching technology by dhanaprakash mn steel hardening, ss solution treatment, forging, quenching, tempering & normalising. Also available for pwht (post weld heat treatment) (n+q+t & q+t)

applications

• annealing
• normalising
• hardening
• solution treatment heating
• forge heating
• tempering
• aluminium solutionising
• stress relieving
• ductile iron full annealing
• adi (austempered ductile iron).

auto cycle control

• ramp, soak, cool . 8 steps profile
• 10, 20 profile memory
• multi inputmulti output (mimo)
• pid controlling action.
• plc based programmable controller.
• one burner, one thermocouple forms one pair as zone, thus multi zone control
• digital display for time temperature graph online with usb pen drive for data storage, wired lan pc connectivity for real time graph printing
• complete report generation by data logging & processing (scada).

firing

• high velocity short flame burner.
• direct on/offpulse firing effect.
• smokeless perfect combustion.

uniformity

• calibrated to api, ams, cq9, stm, asme, norsok
• national traceability (nabl)

the furnaces are calibrated for uniformity as per api 6a standard (the temperature difference between highest & lowest points at stabilised conditions should not be more than 13c.)

mechanization

• trolley - movement by geared motor with brake.
• door- movement by geared motor with brake, counter weighed,
• door lock unlock- innovative, pneumatically operated instant latching unlatching for perfect sealing.

construction

• strong rigid construction.
• heat resistant grade ci castings at door and frame, bogie and furnace interface eliminates warpage.
• railway rails for load bearing under temperature.
• triple sealing minimising heat losses.

insulation

• high temperature high density ceramic fibre monolithic anchored lining.
• self-supporting monolithic anchored extended door lining.

recuperator

• all fuel fired furnaces are equipped with recuperator to recover the heat from flue gases by preheating combustion air. By thumb rule a rise of 1500 c in combustion air 7.5% heat is recovered.

plc control

• large furnaces handle high value materials; it is essential to install plc for operation to avoid manual errors.
• plc checks each & every operation prior to loading of materials called booting to ensure air/gas/power etc. Are within the specifications & all the sensors are in working condition
• plc monitors each & every operation during auto cycle for supply conditions, flue temperatures burner operations any deviation is automatically notified audio visually & through scada.
• plc keeps event history for the record.

control panel

• aesthetically powder coated control panel.
• electrical switch gears for drives, burners.
• status indication and control.
• burner sequence controller and flame failure device.
• programmable start-up, burner, temperature controlling system.

• Completely indigenised components
• High pressure - no back pressure no smoke- ladle completely closed by lid
• Gas train for gas control
• Stainless steel lid with ceramic module lining
• Motorised/hydraulic up down, tilting, swinging motion
• High heat resistant burner
• Temperature measurement & control
• Nozzle, Electrode etc. easily cleaned
• Continuous flame monitoring
• Auto Ignition
• Fully automated unit
• PLC control (optional)

Innovations

• Ladle Drying and Preheating.
• Ladle Preheating Systems are custom designed and manufactured by Dhanaprakash.
• More than 250 installations in India and abroad.
• Any Ladle, Any Fuel, Any Position, Any Metal - PLC programmable systems.
• Quick, Smokeless, Energy Efficient.
• Recipient of G S Parkhe Award of MCCI in 1997.

Concept

• Ladle completely covered by insulated Lid - No Heat Loss.
• Ladle bottom temperature is Higher than top.
• Auto Ignition, Fuel & Air on/off, temperature sensor for control.
• Instant preheating to 1000⁰C.
• Waste Heat Recuperator preheats Combustion Air.
• All ladles of foundry single Preheater.
• Motions, Air, Fuel supply automated with interlocks.
• Single fuel or Dual fuel.

Diesel, Gas, Dual fired, Radiant Burners for Industrial Application based on following concepts.Perfect combustion(100%).Appropriate combustion.Process - Combustion Physical Separation.Excess air Control.Fuel & Air OnOff.High Convection Turbulence, Churning of furnace Gases.Compatible to any PID, PLC, VLCC control system.Burner & Furnace match for each other.

We offers instant ladle pre heater. Completely indigenised components high pressure - no back pressure no smoke- ladle completly closed by lid gas train for gas control stainless steel lid with ceramic module lining motorisedhydraulic up down, tilting, swigining motion high heat resistant burner temprature measurment & control nozzle, electrode etc. Easily cleaned continous flame monitoring auto ignition fully automated unit plc control (optional).

Waste disposal management is essential for any enterprise. Through in-house r&d, and proficiency in combustion engineering, dhanaprakash industrial corporation have developed waste disposal systems for waste disposal management applications, including hazardous industrial, chemical and bio-medical waste. Bio medical waste incinerators are recommended for elimination of hazardous bio medical wastes. Bmw as per rules 1998- 10kg to 100 kg per hour. Mpcb approved waste disposal management is essential for any enterprise. Through in-house r&d, and proficiency in combustion engineering, dhanaprakash industrial corporation have developed waste disposal systems for waste disposal management applications, including hazardous industrial, chemical and bio-medical waste. Bio medical waste incinerators are recommended for elimination of hazardous bio medical wastes. Bmw as per rules 1998- 10kg to 100 kg per hour

• Exothermic sleeves baking is a critical operation.
• High moisture content allow heating at high temperature till it becomes dry. Then temperature is required to be reduced for baking.
• An automatic cycle control provides this feature with very good uniformity at optimum heating cost.
• Proven application.
• Replaces electrical heating.

We are offering pollution control equipment. Cupola exhaust gases quenched and cleaned, medium pressure ventury scrubber collects finest particulate matters. Treated flue conforms pollution norms

Rotary Calciner

Calcining is heating the material to a certain temp. for certain time and for a particular operation. Often calcining process for organic materials produces hazardous gases which cannot be left to atmosphere. Many times these gases have heating value and hence they are recirculated through a combustion chamber for heat recovery.

Indirect calcinerProducts pass through a tube , which is heated from outside , both , products of combustion and liberated gases are sucked by pollution control equipment to make them dischargeable In this system calcination under atmospheric control is possible.Heating media can be electrical gas oil fired.

Direct firedMaterial and combustion devices are normally in the same side as a concurrent system some time counter current .Both products of combustion and gases are treated in pollution control system.

• Waste disposal management is essential for any enterprise.
• Through in-house R&D, and proficiency in combustion engineering, Dhanaprakash Industrial Corporation have developed waste disposal systems for waste disposal management applications, including hazardous industrial, chemical and bio-medical waste.
• Solid wastes are recommended to be calcined- rotary calciner is recommended for many applications.

Down Draft Incinerator

• Down draft incinerator with pollution control device.
• Gas quencher, Ventury scrubber, Mist separator, ID fan, Solid, Liquid, Gaseous feeds accepted.
• Emissions as per Indian and International Pollution control norms.
• Residue in glass state.
• Maximum temperature 1050C.
• Fully automatic operation.
• Fuel - Diesel, Natural Gas.

Calcining is heating the material to a certain temp. for certain time and for a particular operation. Often calcining process for organic materials produces hazardous gases which cannot be left to atmosphere. Many times these gases have heating value and hence they are recirculated through a combustion chamber for heat recovery.

Indirect calcinerProducts pass through a tube , which is heated from outside , both , products of combustion and liberated gases are sucked by pollution control equipment to make them dischargeable In this system calcination under atmospheric control is possible.Heating media can be electrical gas oil fired.

Direct firedMaterial and combustion devices are normally in the same side as a concurrent system some time counter current. Both products of combustion and gases are treated in pollution control system.

• Waste disposal management is essential for any enterprise.
• Through in-house R&D, and proficiency in combustion engineering, Dhanaprakash Industrial Corporation have developed waste disposal systems for waste disposal management applications, including hazardous industrial, chemical and bio-medical waste.
• Solid wastes are recommended to be calcined- rotary calciner is recommended for many applications.

Typical Aluminium Chips contain magnetic Iron Material which sticks to chips due to Oil and Water used during machining.; Hence Chips are required to be dried to make it free from oil and moisture, which is then passed over a highly sensitive Magnet with vibrating screen.

• Initial Fe Content-0-50%.
• Final Fe Content-0.5%.
• Typical Batch-200 Kg.
• Continuous rotary dryer & magnetic separation.
• Refractory Lined Rotary Drier.
• Fully Automatic Gas/Oil Burner Controlled.
• Vibrating Feeder for receiving and discharging of dried chips.
• Highly Sensitive Magnetic Drum for separation.
• Automated System.

Ideal for Aluminium foundry with Machine shop.

Combustion Devices

High Velocity Burner for Furnaces

Replaces Electrical Heating for Cost Saving & Quality Enhancement

• Churning.
• Circulating.
• Thrusting.
• Penetrating.
• Pulsating.
• Driving.
• Fully Automatic.
• Fuel- HSD/ Kerosene/ LPG/NG /Bio CNG
• Complete combustion, smokeless, high velocity short flame.
• Compatible to on/off, PID, Multi Input, Multi Output PLC controller.
• Offers excellent uniformity as per API 6 A standard.

Applications- All high temperature automatic furnaces, heat treatment furnaces, Pot furnaces, wire annealing etc.

InnovationsDiesel, Gas, Dual fired, Radiant Burners for Industrial Application based on following concepts.

Concept

• Perfect combustion (100%).
• Appropriate combustion.
• Process - Combustion Physical Separation.
• Excess air Control.
• Fuel & Air On/Off.
• High Convection Turbulence, Churning of furnace Gases.
• Compatible to any PID, PLC, VLCC control system.
• Burner & Furnace match for each other.

Combustion Automation

• Each Burner has Burner Sequence Controller for operation.
• Flame Sensor.
• Separate Burner Control Panel.

Temperature control Automation & Recording

• Compatible to PID, PLC, Micro controllers.
• Std. 8 step Ramp Soak Profile & 10 Profile memory or more.
• Complete Safety - PLC control.
• Paperless Graph on HMI, PC Connectivity.

Applications

Heat Treatment- Electrical Bogie Hearth, Tempering, Normalizing, Hardening- Tempering, Atmosphere controlled, Blueing, Burnout, Wire Annealing.

Aluminium Industry- Holding, Solution Treatment, Ageing, Ovens, Flash Annealing, Collapsible Al Product ProcessingAl-Cu-Brass, Billet Heating, Wire Annealing.

Ceramic Glass- Enamelling, Glass, Lustre.

Surface Coating- Copper Wire enamelling, Teflon Coating, Powder Coating, Paint Baking, Stator Enamel Baking, Submerged Tank Heating, Resin Coated sand mixers.

Ovens- Foundry Core baking, food products, granule drying.

Achievements

• More than 2000 Burners in operation,
• More than 200 Retrofit Applications,
• Installations using these Burners 150 Heat Treatment Furnaces,
• 200+ Ladle Preheaters.
• 200+ Other Foundry/Forging Equipments,
• 2 Nos. 100MT Heat Treatment Furnaces.

CommitmentCommitted to Customer - Satisfaction driven performance package of concept to commissioning

MECHANICAL SAND RECLAMATION SYSTEM

• Chemically bonded foundry sand after metal pouring can be partially or fully reclaimed for reuse.
• Mechanical sand reclamation.
• Thermal sand reclamation.

After knockouts Sand lumps are fed to a lump reducer Vibraclaim where due to vibratory gyratory motion lumps abraded with each other to release the original sand grain.
The abraded sand grains and fines are then fed to classifier, where mixture is fluidized to remove fines.If sand lumps are hot water cooled tubes are used to cool the sand.Dust collection system collects all fines which are disposed off.Above system is used for mechanical reclamation system. for small foundries.

THERMAL SAND RECLAMATION

• Chemically bonded foundry sand after metal npouring can be partially or fully reclaimed for reuse.
• Mechanical sand reclamation.
• Thermal sand reclamation.

When sand to metal ratio is high and total quantity of sand replenishment goes high thermal sand reclamation is used to eliminate the waste sand and stop buying new sand thus double environment impact.

The thermal reclamation starts with mechanical reclamation. The mechanically reclaimed sand is pass through calciner to burn off the chemicals to get reclaimed sand which is better than new sand.

This technology is suitable for:

• Nobake sand
• Cold core sand
• Shell sand

We are offering incinerator.electronic waste is eliminated in rotary calciners, precious metals collected, pollutants treated in venturi scrubber and vented off in 30m high chimney.capacity - 50 - 200 kghr shredded waste of pcb, and other electronic parts, primary cumbustion - 850 50c.secondary chamber - 10500c 1 sec. Res. Time.fuel - gas, diesel, electricity.turbo technology - waste offers heat for burning itself partially.pollution control equipments venturi scrubber, quencher demister, id fan in stainless steel.emissions - as per national ambient air quality norms.