TO MODIFY THE SEALANT BAKING OVEN

DEFINITION
Oven is a device in which hot air is used for the baking of various parts
of the vehicles like cargo, cabin etc.

TYPES OF OVENS
1. Conveyorised Oven
2. Batch Type Oven

CONVEYORISED OVEN
In conveyorised oven the component to be baked is moving along the
conveyor inside the oven shell. This type of oven is very large in length as
compare to batch type oven. The length of conveyorised oven is based upon
baking schedule (means time for which component to be baked and speed of
conveyor)

BATCH OVEN
In batch type oven the component to be baked is pushed inside the
oven and outside from the oven manually or automatically. In this type of
oven component remains stationary inside the oven shell. This type of oven
is smaller in length compare to conveyorised oven.

CLASSIFICATION ACCORDING TO FIRING OF FUEL

DIRECT TYPE OVEN

In direct type of oven air, which is to be heated, is in direct contact
with the heating media this is further divided into three types

 LPG OVEN
 CNG OVEN
 ELECTRIC OVEN
 INDIRECT TYPE OVEN
In this type of oven air to be heated is not in contact with the heating
media. This type of oven is of two types

 Diesel Oven
 Thermic Fluid Oven

COMPONENTS OF OVEN
1. Burner
2. Heat Exchanger
3. Heater Box
4. Blower or Hot Air Circulation Fan
5. Induced Draught Fan
6. Ducts (external and internal)
7. Filter
8. Insulated Panels
9. Valves
10.Diesel Tank
11.Control Panel

DESCRIPTION OF PARTS

BURNER
With the help of burner diesel fuel is burned and heat produced
due to burning of fuel is flow through the pipes in heat exchanger, which
then used to heat up the air.

HEAT EXCHANGER

Heat exchanger is process equipment designed or the effective

transfer of heat energy between two fluids, a hot fluid and coolant.
CLASSIFICATION OF HEAT EXCHANGERS
Heat exchangers are classified according to

 Operating Principle
 Direct Contact
 Regenerator
 Recuperator
 Cross Arrangement

 Arrangement of Flow Path

 Cross Arrangement
 Parallel Flow
 Counter Flow

 Design and Certain Constructional Features

 Concentric Tubes: Two concentric pipes are used each

carrying one of fluid

 Shell and Tube: One of fluid is carried through a bundle of

tubes enclosed by a shell. The other fluid is forced through shell
and flow over outside surface of tubes.

 Multiple Shell and Tube Passes: The two fluids may flow
through the exchanger only once (single pass). By suitable design
the fluid within the tubes (tube sided fluid) can be made to
traverse back and forth from one end of shell to the other. Quite
often longitudinal baffles are provided within the shell which
causes fluid surrounded the tubes (shell sided fluid) to travel the
length of shell a no of times.
HEATER BOX

In the heater box heat exchanger is placed. Heater box doesn’t

let hot air to go outside from the heat exchanger because 200mm thick
insulated material (Rockwood Slab Resin) density 144 kg/m3 is on the
outer surface of heater box which prevents heat to flow outside from the
heat exchanger.

BLOWER OR HOT AIR CIRCULATION FAN

Blower or hot air circulation fan used the oven is of centrifugal
type. Blower is used to send the hot air inside the oven cabin hot air
comes from the heat exchanger go inside the cabin with the help of
blower. Blower also performs two more functions. It gives proper
velocity to the air so that heating effect of air can be maximum, to give
the adequate velocity to air inside the oven. There are minimum 3 air
changes per minute. Third important function performed by blower is to
send even distributed air inside the oven.

INDUCED DRAUGHT FAN

When the diesel is burned some carbon and flue gases are
produced which have to remove otherwise they will affect the working of
the oven. Id fan is belt driven and directly attached with the heat
exchanger.

DUCTS
A duct performs very important functions. Ducts are the
passages through which hot air go to oven shell and then recirculated to
the heat exchanger. Ducts are made up od 1/1.25mm g.i sheet. Ducts,
which are inside the oven, are known as internal ducting and ducts, which
are outside the oven, are known as external ducting.
FILTER
To send filtered air inside the oven air is filtered with the
help of filters. The mesh used in the filters are made up of ss. these filters
are inside the oven. These filters are 70 % efficient

INSULATED PANELS
Insulated panels are used to insulate the oven so that heat
inside the oven doesn’t come outside the ovens. They are filled with rock
wool having density of 140mm.

VALVES

Valves are used to control the temperature of the oven and

maintain the appropriate temperature inside the oven. Some of the valves
are given as below.

1. Valve Globe
2. Valve Needle

DIESEL TANK

Diesel tank is used for the continuously supply of diesel to the

burner. The capacity of the diesel tank is 990lit .to increase the capacity
of diesel Tank Company has to take license from government because
maximum capacity of diesel tank allowed by the movement is 990lit

CONTROL PLANEL
Control panel is fully automatic and electronic device on
which there is on/off switch of id fan, hac fan, and oven tip switch.
Temperature inside the oven is also displayed on the control panel. Inside
the oven there is eight sensors, which sense the tempeature, the
tempeature sensed by these sensors, are also displayed on the control
panel.
NEED OF MODIFICATION
1. Earlier indirect Thermic fluid oven was used for the baking of cargo
but the temperature of air that was obtain by burning Thermic fluid
was not enough for the baking of new large size cargo.
2. Existing oven shell was smaller in size compare to the size of new
cargo.
Old length of oven = 4400mm
New length of oven = 5600mm

MODIFICATIONS IN OVEN
1. Thermic fluid fuel is replaced by diesel to get required temperature
2. Oven shell size changes
Length=6164mm
Width =3200mm
Height=3600mm
3. Hot air circulation fan capacity changes
4. Heat load changes

Calculations For The Hot Air Circulation Fan

Capacity
Length of oven, L=6164mm
Height of oven, H=3200mm
Width of oven, W=3600mm
Volume of air inside the oven, V =volume of oven
=L x W x H
= 6164 x 3200 x 3600
=71 m
No of air changes per minute = 4
Volume of air entering per minute = 71 x 4m3/min
=284 m3/min
Volume of air entering per hour=284 x 60m3hr
=17040m3hr
Thus capacity of hot air circulation fan should >=17040m3hr
According to capacity of fan we will choose motor use o run the fan from
the chart
CALCULATIONS FOR HEAT LOAD
Input Required For The Heat Calculations
 Material for construction of oven (ms), heater (ms) box, ducting
(1.25mmg.i sheet)
 Mass of material which is coming into contact of hot air
 Oven temperature = 170 c
 Room temperature= 5 c (min)
 Specific heat of material = 0.12 kcal/kg/c
 Oven initial heat up time =30min

Area of oven = 2 (LxW + WxH + HxL)

=2 (6164x3600 + 3600x3200 + 3200x6164)
=106870400 mm2
=106.87m2
Area of heater box = 2 (2750x1980 + 1980x1545 + 1545x2750)
=25.5057m2
Area of external ducting =10.194 m2 (given)
Area of internal ducting =25m2 (given)

Mass of empty oven =Volume x Density

=Area x Width (wall) x Density
Density of oven material (ms) = 7.86g/cc

Therefore mass of empty oven =106.87x1.25x7.86

=1049.998kg
Mass of heater box = 25.5057 x 1.25x7.86
=250.586kg
Mass of external ducting = 10.194 x 1.25 x 7.86
= 100.156 kg
Mass of internal ducting = 25 x 1.25 x 7.86
=245.625 kg

Total mass = 1049.998+250.586+100.156

=1646.3 kg
Mass of heat exchanger = 655.86 kg
Mass of blowers = 102.318 kg
Mass of filter supported structure = 20kg
Total mass of material that comes into contact with hot air, m
=1646.3+655.86+102.318+20
=2424.478 kg

Heat required to heat this mass = m x cpx (toven-troom)

Specific heat of air cp= 0.12kcal/kg/c

H1=2424.478x0.12x (165-5)
=46549.98kcal

Heat required to heat the air inside the oven and system = mass of air x cp x
(toven-troom)

Mass of air = volume of total system x density

= 71 x 1.29
=91.59 kg

Heat h2= 91.59x.24x (165-5)

= 3846.78 kcal
Under the theoretical conditions, heat required to heat up the oven
= 46549.98+3846.78
= 50396.76kcal

If this oven is to be heated in 1 hr then heating rate will be = 50396.76

kcal/hr
But we have to heat this oven in 30 min (0.5 hr) hence heating rate will be
=50396.76/0.5
=100793.52kcal/hr

This heat load we have calculate under theoretical conditions but in practical
there will be losses through the system which are taking place continuously
irrespective of whether component is inside or not

THESE LOSSES ARE

 Ventilation losses
 Convection losses
VENTILLATION LOSSES

In order to continuously replace the solvent fumes getting

collected inside oven, we add certain fresh air inside the oven and equal
quantity of air is exhausted through solvent exhaust duct. Although this is
required only when the paint baking is going on, for safety purpose and to
avoid explosion inside the oven, this air is exhaust continuously irrespective
of component inside oven

Weight of air that need to be exhausted = {(component area/hr) x (solvent

mass/m2)}/0.008
=160x0.05/0.008
=1000kg/hr

Therefore heat loss through this air,

H3=1000x0.24x (165-5)
=42000kcal/hr

Convection losses,
= Surface area of the system x heat transfer
coefficient x (oven skin temp. –room temp) + 15000 kcal/hr
=167.37x6x10+15000
=25042.2 kcal/hr

Total heat load (heating rate) required to heat up the empty oven
=100793.5+42000+25042.2 kcal/hr
=167835.72 kcal/hr
Technical Specification for Modification
of Sealant Baking Oven
Type of Oven

Indirect HSD fired (existing heat source to be remove)

Component Details
Component Dimensions Thickness Weight Surface
L W H of Sheet (kgs) Area
(mm)
Cargo 5600 2200 2200 1.2-1.6 1000 SQM
Cargo with 5600 2200 2575
Trolley
1.2-1.6 1250 70

Batch Type

One cargo will processed at a time in one batch.

Process Temperature
Process Process Time Temperature
≤ 30 min for proper all
160°c to 170°c Air &
Water dying sealant & around baking, 10 min
140°c EMT (Effective
primer baking for cargo heat up + 20 min hold
Mean Temperature)
up
Performance & Commissioning Parameters
Description Specification
Air temp variation inside the oven
+/-5 Deg C
(all area)
Oven skin temp (all seasons for
± 10° c above ambient (max)
extended portion)
Blower noise level ≤ 85 DB
Temp checking initial Will the help of temp time graph
Baking Schedule 10 min for heat up, 20 min for
holding
Initial heat up time (at start of shift) 30 min for (+5 deg c ambient)
Quality of hot air w.r.t dust level & Dust arrestance down to 05 microns
pressure pressure = 65 mm water gauge at
blower
Air changes Minimum 03 air changes / mins

List of Standard Bought Out Items

Items Make/ specifications
Blower NADI / Flank Wood
Electric Motor Siemens Insulation (Class H)
HSD Burner Benton B50 With Motorized Damper
And Servo Motor
Temp Controller Radix
Circulation Filter (a) At Fresh Air Duct G-4 (EU6 /
F6)-EFF 70%
(b) Inside the Oven G-4 (EU6 / F6)-
EFF 70%
Panel, Floor Air Circulation Ducting Minimum 150 mm thick rock wool
Insulation slab resin bonded of density 144
kg/m³ with wire mesh for oven and
200 mm thick for heater box
Side Panel 1.20 mm G.I Sheet
Hot Air Supply And Return Duct 1.20 mm G.I Sheet
Canopy 1.20 mm G.I Sheet and Dust Along
Structure 3 mm MS Sheet
Flue Gas Duct
Valves
Dry Storage Tank Including
Platform Level Indicator And
Controller With Ladder
Heat Exchanger
Painting Inside Surface
Painting Outside Surface
Hot Air Circulation Blower
3 mm MS Sheet
Audco
Capacity 990 LTRS
Material of construction should be
(BE SS 304)
MS surface 2 coater of Aluminum
Paint (Heat Resistance)
1. MS surface 1 coat of Zinc
Chromatic Primer, 2 coats of
Synthetic Air Drying Enamel
2. G.I Surface 1 coat of ETCH
Primer, 2 coat of Synthetic air
drying Enamel
Centrifugal with casing V belt Drive
by motor at 1440 RPM and should
Withstand 250°c

Ambient Condition
Max Summer Temp 45° c
Max winter Temp 5°c to 10°c consider for heat load
calculation
Description Specification Requirement
Fuel HSD HSD 10,000 Kcal/Hr Approx. 40 Lt /hr
Electric Power 3 PH, 440 Volt Ac 50 165 Kw / 20 + 2 Hp
Hz Approx

Construction of the oven

The existing box / batch type oven is floor mounted having entry & exit
doors. The oven is constructed from MS/GI sheet insulated panels
supported on an MS sheet framework. The oven panels are double walled
and fabricated from MS/GI sheet with rock wool insulation 144 KG/M
+≥. The panels are design to have a very small amount of through metal to
minimize heat loss.
Hot Air Circulation

The existing thermic fluid indirect heating system will be replaced by new
heating system comprises of HSD fired burner with air to air heat exchange
and heat transfer by convection. The hot air disturbance system comprises of
a hot air circulation fan, which forces air through the heat exchanger,
internal external ducts are mounted on a self supported structure. The
recirculation ducts at the roof of the oven suck the hot air back to HSD fan
damper/shutter are provided for controlling the air supply.

Solvent Exhaust

HAC fan outlet will be used to exhaust the solvent fume. The capacity of
HAC fan will ensure preventation of solvent fume condensation and will
provide adequate ventilation to the system. Filtered fresh air intake with
adjustable damper will be provided to compensate the exhaust.