Background

The diamond industry is one of the most energy intensive industries of Gujarat. The process technology employed for diamond processing is obsolete and highly in efficient and, therefore, energy accounts for a sizable share in the total cost of production. Electric hotplates, electric motors and lighting form the major load of any diamond-processing unit. There are about 2 lac diamond hotplates and equal number of diamond lathes motor (8 lac lathes) being used by the diamond industry in Gujarat alone.

Gujarat Energy Development Agency executed a project for demonstrating efficient technology during the year 1999-2000 & 2000-01, for promoting use of efficient diamond hotplates developed by Savalia Research Centre, Ahmedabad. In all about 22000 in-efficient hotplates have been replaced with efficient hotplates during this period. It is estimated that total load reduction in connected load of 45 to 50% (7 mW) and annual energy saving of 27 million unit of electricity would be achieved from this replacement project. (Assuming 200-days/annum uses).

ENERGY EFFICIENT DIAMOND LATHE

Savalia Research Centre, Ahmedabad has developed an improved design of a LATHE used by the diamond process industry for rough grinding of diamond. The lathe designed and developed by SRC is about 70-80% more efficient as compared to the lathe arrangement that is presently popular in the diamond industry. The power rating newly developed mono-block lathe motor is just 35 watts. The motor employed in the conventional lathe arrangement is 0.5 HP (370 watts approx.).

While the conventional arrangement has one ½ HP motor coupled to four lathes using fast-loose belt-pulley drive the new improved lathe is directly driven single user device. Hence it has various advantages over the conventional system. Schematic diagram of old and new system given in Annexure I.

• Consumes less power - uses 30 watt 3ø motor.
• Easy ON/OFF switch designed for trouble-free one million operations.
• Small, simple & safe to use.
• Vibration & noise-free.
• Low maintenance.
• Self-lubricating.
• Long duty performance and life.

The improved lathe has been lab tested by Electrical Research & Development Association, Vadodara and found to be conforming to specification as claimed by SRC.

Energy Saving Potential

The improved lathe will serve the same purpose and ensure better performance with 80 % less energy as compared to the conventional arrangement. The connected load would reduce by about 65% and energy saving of 0.66 units per lathe/day (assuming 3 hours daily) is estimated, i.e. about 132 units per lathe per annum (assuming 200 days per year). (Assuming @ Rs. 4 per unit)

Primary study of the improved lathe reveal that the device has an excellent potential for energy saving (more than 80%) like the Energy Efficient Diamond Hot promoted by GEDA during the last two years.

Payback Period

The cost of the mono-block diamond lathe would be Rs. 3000.00 approximately and on the basis of the annual energy saving the payback period would be around 5 years.