Lisa Engineering converted their existing oil-burning hot mix system to LPG to reduce pollution and increase efficiency. Their 60-ton system previously used furnace oil at a cost of Rs. 1,050,000 per month. After converting to LPG, their fuel consumption decreased to 3.5 kg/hr and their monthly fuel costs reduced to Rs. 2,625,000, saving Rs. 525,000 per month. The conversion included installing an LPG pipeline and tank system along with associated safety and pressure regulation equipment.

1. FUEL CONVERSION
Oil to Gas Fuel ( Hot Mix Case Study )

2. INTRODUCTION
Converting your Existing Oil-Burning furnace ,Ovens
or Boilers ,Hot Water Generator, Thermic Fluid
Heater ,Hot Mix Plant to LPG ( Liquefied
Petroleum Gas ).
Conversion System Consist .
 LOT Gas Bank System
 Safety Equipment ( Detection Sensors ).
 Secondary Pipeline with Complete Fittings
 Second Stage Pressure Regulatory Station
 Gas Fired Burner System . .

3. WHY LPG ?
 Efficiency: LPG’s energy content (Calorific Value)
is the highest amongst other conventional fuels. A
very high proportion of the energy content is
converted into usable heat. LPG offer clean and
efficient combustion and the equipment used for
combustion of these gases like burners etc. have
significantly no maintenance costs. Due to
complete combustion, Gas does not leave deposits
on heat exchange surfaces, thereby providing
higher efficiency of combustion and heat transfer
compared to Diesel or Furnace Oil.

4. WHY LPG ?
 Environmental Friendly: LPG have the lowest
greenhouse gas emissions than any other
conventional fuels. Combustion of both gases
produces no smoke generation, no sulphur
emissions, no poisonous gases, no soot and no
unburnt carbon particles. And when it comes to
carbon dioxide emissions from both the gases, they
are the cleanest fuels available today.

5. WHY LPG ?
 Convenience & Safety:LPG are extremely safe
fuels if handled in the right way. Both gases are
very easy and convenient to use for a wide range of
applications across several industries. The number
of known applications for gases around the world
totals to over 2000. Since Gas is stored in a
pressurized vessel and utilized vide a closed loop
pipeline system, there is no scope for pilferage.

6. WHY LPG ?
 Accessibility: While LPG is easily accessible and
available in different sizes of portable cylinders,
Natural Gas has even better accessibility where the
Natural Gas pipeline connection is available right at
your premises gate for use. Housekeeping is
excellent since unlike Diesel and Furnace Oil, Gas
does not stain floors and create noxious fumes.
This is especially critical for food industries such as
Dairies, Chocolate and Biscuit manufacturers and
Hotels.

7. WHY LPG?
 Commercial Viability: Compared to liquid and
conventional fuels, LPG are the most commercially
viable fuels when fuel efficiency and maintenance
costs are taken into consideration.

8. WHY LPG ?
 Least Carbon Dioxide Emissions
 The Greenhouse Gas footprint of Gas is relatively
small compared to other fuels in terms of total
emissions and emissions per unit of energy
consumed. Gas has the lowest on-site emission
rate of the major energy sources, with the exception
of natural gas. In terms of life-cycle greenhouse gas
emissions, Gas produces significantly lower
emissions than gasoline, diesel, and electricity on a
per Btu basis.

9. CARBON DIOXIDE EMISSIONS

10. COMPARING VARIOUS FUELS
10
FUEL CONVERSATION CHART
PRODUCT LPG Electricity HSD LDO FO Kerosene LSHS PNG COAL
Unit 1 KG 1 KWH 1 LTR 1 LTR 1 KG 1 LTR 1 LTR 1 SCM 1 KG
GCV in kcal/kg 11800 860 10700 10700 10280 10420 9670 13300 5550
Density of Fuel N/A N/A 0.82 0.84 0.93 0.85 0.93 0.7 1.5
Fuel Efficiency % 90 100 85 88 60 80 80 90 20
Effective CV PER
UNIT
10620 860 7458 7909 6168 7086 7914 8379 1110
Rate (NCR)* 50 10 65 50 40 50 45 48 8
Equivalent LPG
Kg Required for
unit
1 0.081 0.707 0.745 0.581 0.677 0.680 0.790 0.105
Saving in % as
on Date
0 60% 46% 28% 25% 33% 25% 18% 34%
Results N/A POSITIVE POSITIVE POSITIVE POSITIVE POSITIVE POSITIVE POSITIVE POSITIVE
Neutral point of
LPG Cost
123 93 70 70 75 65 60 75

11. SAFETY & AVAILABILITY
 LP gas are actually quite safe in comparison with
Other fuels. LPG has a high ignition temperature,
About 450-510 C compared to about 177- 329 C
for Gasoline's. This makes it less likely to ignite
Spontaneously.
 LPG is handled in closed, leak-proof cylinders /
Tanks ensuring that there are no spillages and
other Handling losses.
 LPG is available in various systems VOT, LOT &
Bulk installations for Commercial & industrial
Consumers.

12. INDUSTRIES (LPG USED )
 Hotel & hospitality: Boiling, Stewing, Frying,
Grilling, Toasting, Broiling, Roasting, Baking, etc
 Food Processing: Tea Drying, Biscuit baking,
Bread baking, Cocoa Bean roasting, Coffee
roasting, Chicory roasting, cornflakes, Tea drying &
many more Where drying, roasting & frying is
required
 Building And Construction: Bitumen Heating,
Asphalt heating ( Concrete Mixing), sand curing &
many More where Heating must be required.

13. INDUSTRIES (LPG USED )
 Agriculture: Bird scaring, Chicken breeders,
Poultry , Grain drying, Cereal drying, Rice drying,
Tobacco Curing & Many more where heating/
drying Is required.
 Glass & Ceramic Industries: Mould heating,
Glass furnaces, Glass melting, Glass forming, Fire
Polishing, Annealing Chambers, Tile Decorating,
Tile Glazing Etc.

14. INDUSTRIES (LPG USED )
 Industrial Processes: Aluminum melting,
Aluminum-Billet heating, Steam boiler, Space and
Process Heating, Melting, Preheating, Hardening,
Tempering, Grain drying, Cutting, Welding, Powder
Coatings, Powder manufacturing, Lead melting,
Soap Manufacturing, Paint drying, Food
processing , Hot Water generation, Shrink-
wrapping, Industrial ovens, Galvanizing,
Degreasing, Print drying, Incinerators. Pulp drying,
Radiant heating of Paper

16. CASE STUDY
LISA ENGINEERING PVT LTD
 With the Supreme Court of India and the National
Green Tribunal, mandating the prohibition of pet
coke and furnace oil as an industrial fuel, industries
have been on their toes ever since to change over.
Lisa Engineering Pvt Ltd ( Greater Noida ) has
set an excellent example by opting for a cleaner
source of energy by converting the traditionally
used FO to LPG.

About Lisa Engineering Pvt. Ltd. :-
 Established in 2017 , Activity - Road Construction .

17. CASE STUDY
LISA ENGINEERING PVT LTD
 Lisa Engineers Pvt Ltd are manufacturing
coated road stone as per demands the combination
of a number of aggregates, sand and a filler (such
as stone dust), in the correct proportions, heated,
and finally coated with a binder, usually bitumen
based or, in some cases, tar, although tar was
removed from BS4987 in 2001 and is not referred
to in BSEN 13108/1 . The temperature of the
finished product must be sufficient to be workable
after transport to the final destination. A
temperature in the range of 100 - 200 degrees
Celsius is normal

18. CASE STUDY
LISA ENGINEERING PVT LTD
 Before Conversion:
 Lisa Engineering had been using a 60-ton capacity
HOT Mix System with FO being the source of heat.
 FO being a polluting fuel, rendered the air unfit for
breathing especially to the workers at the plant.
 The cost and energy content of FO in contrast with
LPG was far too inefficient for the company.

19. CASE STUDY
LISA ENGINEERING PVT LTD

21. FUEL CONSUMPTION DATA ( AS GIVEN )
 Fuel = FO
 Capacity = 60 TPH
 Make = Apollo ( Drum Mix )
 Fuel Consumption = 5 kg/Ton ( As Given &
Recorded)
 Daily Average Production – 500 Ton .
 Max Consumption per day = 2500 Kg
 Cost of Fuel per Unit = Rs 42 kg
 Fuel Cost per day =2500 x 42 = Rs 1,05,000
 Fuel Cost per month = Rs 31,50,000.

22. FUEL CONSUMPTION ( AS RECORDED)
 After Converting on LPG
 Average Fuel consumption = 3.5 Kg/hr (As
Recorded )
 Average Cost of LPG per Unit = Rs 50 kg .
 Cost of Fuel per day = Rs 87,500 .
 Cost of Fuel per month = Rs 26,25,000.
 Saving per Month = Rs 5,25,000.

23. DRUM MIX SETUP

24. BITUMIN TANKS ( 30KL)
PRV STATION 2
PRV STATION 1
LPG PIPELINE
HEATERLESS VAPORISOR

25. LOT MANIFOLD SYSTEM ( HIPPO)
LOT MANIFOLD SYSTEM (47.5KG ) LOT MANIFOLD SYSTEM (47.5KG )
HEATER VAPORISOR (150 KG ) DO & DONT BOARD

26. PR STATION

27. ELECTRICAL VAPORIZER

29. THANKS FOR THE WATCHING
M/S Naveen Gas Service ( Saraswat Group)
(An ISO 9001 -2015 & CE Certified Company)
KH-1188,Street-12,Kapashera New Delhi-110037.
Ph: +91 9810537355, 9971492390,7303397678
Email: Naveengasservice@gmail.com
Info@saraswatgroup.com
For More Details Please visit Site
 Web: www.naveengasservice.com
 www.Saraswatgroup.com