1. 1© Copyright, Confidential, Tata Motors Ltd
Tata Lucknow Waste Heat Recovery Project
 Tata Lucknow has 3 no of Durr Ovens ED Oven, TC Oven 1 & TC Oven 2.
 Heat recovery unit will be installed in ED Oven, TC Oven 1 & TC 2 Oven
 Total Heat Recovery from Hot flue gas from oven Exhaust is approximately=
 Waste heat of Oven will be used to raise the temp of water used in PT CED line from 85o
C to 95 o
C
 Total project cost = Rs 1.06 cr.
 Return on investment 10 months
 Propane savings 75 kg/hr with annual savings of Rs 2.2 cr (propane price Rs 72 per kg)
Project Highlights
828100 Kcal/hr

2. 2© Copyright, Confidential, Tata Motors Ltd
TC-2 Oven
TC-1 Oven
ED Oven
Hot Water Generator 1
KOD
Hot Water
Rinse
Degrease Activation Phosphating
Hot Water Generator 2
PT Tanks
Hot Water
Supply (85°c) to
PT tanks
Return Water from PT tanks
(75°c) to Heat Exchanger
then Hot Water Generator
Exhaust to
atmosphere 100°c
Exhaust to
atmosphere 100°c
Exhaust to
atmosphere 100°c
• With Heat Recovery Units (HRU’s)
Tata Lucknow Waste Heat Recovery Project
HRU
HRU
HRU
Hot Water at
100°c
Heat Exchanger
Return Cold
water
Hot Water Generator will not run as oven exhaust heat will be sufficient to maintain the PT tanks temperatures
Total Heat Recovered
318500 Kcal/hr-ED
Total Heat Recovered
254800 Kcal/hr-TC2
Total Heat Recovered
254800 Kcal/hr –TC1

3. 3© Copyright, Confidential, Tata Motors Ltd
HRU
HRU
TC-2 Oven (5.6mtr)
TC-1 Oven (5.6 mtr)
ED Oven (5.6 mtr)
Boiler 1
Boiler 2
Return water from PTED at 75'c
Supply water to
PTED at 90'c
Hot water at 85'c
Cold water at 75'c
Heat Exchanger
Pipings at
16 mtr
Boiler at 0mtr
HRU
Location of HRU with piping's at 5.6 mtr in TML Lko Paint Shop

4. 4© Copyright, Confidential, Tata Motors Ltd
Calculation sheet – Heat Recovery system

5. 5© Copyright, Confidential, Tata Motors Ltd
Installation of Heat Exchanger With diverter valve Assy- E.D. Oven
Shell & Tube
Heat Exchanger
Motorized
Actuated
Diverter valve
Stainless Steel
Ducting
Flow Meter
Hot Water O/P
Cold water I/P
Pressure
Indicator
Resistance
temperature
detectors
DP Water Switch
Flue Gas Back
Pressure Switch
Allen Bradley
PLC panel
Control Logic
L71

6. 6© Copyright, Confidential, Tata Motors Ltd
Heat Recovery from ED Oven
TOTAL Savings from 3 Systems = 828100 Kcal /Hr.
Propane Savings of approx. 75 Kg/ Hr.
Total Project Cost= Rupees 1.06 cr

7. 7© Copyright, Confidential, Tata Motors Ltd
Propane Gas consumption Trend
Start of ED & Top coat
Heat Recovery System
( partially ) without
Insulation