In this study, along with technical and commercial feasibility study of 50 kg capacity plasma melt overflow (PMO) plant for Titanium and FeCrAl fibre production, we have performed lifecycle analysis (LCA) of the fibre produced through the PMO process. The high Capex of plasma torch and related operational cost make the selection of plasma torch as a thermal input of the Melt Overflow process (MO) commercially unfeasible. During the study, induction heating is found to be a technically, commercially and environmentally viable option of alternate heat source for the MO process. The Capex related to the IMO (Induction Melt Overflow) plant is 64% less compare to the PMO plant. IMO process consumes 89% less energy compare to PMO process and unlike PMO, the IMO process does not require continuous flow of gas (Argon 85%, Helium 15%). Only small amount of gas will be required to develop the inert atmosphere within the chamber. Hence the operational cost of the IMO process has also been significantly reduced compared to the PMO process.
For either of the cases, i.e. PMO or IMO, we will use the recycled content to produce Ti and FeCrAl fibre, the environmental performance of the product produced by these fibre will be better. Due to less energy and gas (Argon 85%, Helium 15%) consumption, the environmental performance of the IMO process is better compared to the PMO process which will also further enhance the environmental performance of the final product.
Titanium fibre networks will be used as a substrate for the SLI (Starting-lighting-ignition) battery electrodes with a thin film of lead and lead oxide coating that reduces the weight of the battery by more than 50%. With this approach, on an average almost 9.8 kg lead will be saved per SLI battery production. If we consider global picture for the use phase of the battery (for SLI application), over the whole life cycle of the battery (5 years), significant amount of fuel, emission and monetary saving will be realised from the increased fuel economy obtained from the reduced vehicle curb weight.
FeCrAl alloy substrate is a good candidate for the next generation of DPFs due to lower costs, superior filtration efficiency (more than 90%) and passive regeneration properties when compared to current cordierite or silicon carbide (SiC) particulate filters. With respect to the PMO process, IMO process will save more than 23 Gwh for Ti and FeCrAl fibre production to meet the projected demand in 2023.
