Furnaces International June 2019

INDUSTRY NEWS

REFRACTORIES

MELTING TECHNOLOGY

ENERGY EFFICIENCY

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Contents

Editor: Nadine Bloxsome nadinebloxsome@quartzltd.com Tel: +44 (0) 1737 855115

Production Editor: Annie Baker

Sales/Advertisement production: Esme Horn esmehorn@quartzltd.com Tel: +44 (0) 1737 855136

Sales Manager: Nathan Jupp

Show preview 2 The Bright World of Metals 6 Otto Junker and Induga at GIFA/THERMPROCESS 2019 8 It’s time to connect

nathanjupp@quartzltd.com +44 (0) 1737 8555027

Manuel Martin Quereda manuelm@quartzltd.com +44 (0) 1737 855023

10

Projects and products

Industry 4.0 18 Defining technologies and setting trends in heat treatment 4.0 21 The amazing factory with 4.0 furnaces Q&A Furnace and Heat Treatment Technology 22 A new generation of networking

Subscriptions: Elizabeth Barford subscriptions@quartzltd.com

Energy efficiency 24 Does biogas co-firing in glass melting reduce CO2 emissions?

28 Efficient preheaters improve safety and energy consumption

Managing Director: Steve Diprose Chief Executive Officer: Paul Michael

Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000.

Email: furnaces@quartzltd.com www.furnaces-international.com

Furnaces International is published quarterly and distributed worldwide digitally

© Quartz Business Media Ltd, 2019

Furnaces International June 2019

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Comment

Welcome to this special, printed edition of Furnaces International, June 2019.

We usually only publish each issue online, but to celebrate the return of METEC/GIFA/ THERMPROCESS/NEWCAST, we have printed more than 1,000 copies to be distributed to visitors at the event.

Hopefully this is exactly where you are reading this column and wondering how you have missed such a fascinating, interesting and informative furnace industry magazine before!

Furnaces International covers industry news, technology Emission reduction 32 Primary measures to reduce the NOx concentration in waste gas

solutions and digital innovations across the furnace and

Integration 34 Refial expands capacity with new GHI equipment 36 Metalfino gets ready for an aluminium future 37 Aluminium recycling furnace for Fonderie Pandolfo

innovations and projects, as well as highlighting the most

heat treatment industry. We bring you all the latest product

talked about manufacturing topics and trends.

I have become so engrossed in this sector that along with

Optimisation 38 Furnace optimisation through in-house improvements Measurement 42 Accurate temperature measurement for the forging industry

a dedicated team, I am helping to launch a new, intimate meeting platform...

Furnace & Heat Treatment USA will take place in Miami, Florida on 17 - 19 November 2019. The event format is simple yet highly effective, providing a peer led education programme, pre-approved one-to-one research meetings with leading solution providers and a mix of informal networking opportunities.

More information can be found on page 22 I hope you’ll be able to join us!

Nadine Bloxsome. Editor, Furnaces International nadinebloxsome@quartzltd.com

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The Bright World of Metals GIFA, NEWCAST, METEC and THERMPROCESS: Theory and practice go hand in hand International conferences, symposiums and special shows enrich this trade fair quartet With 2,000 exhibitors and around 78,000 metalworking professionals expected to attend from around the world, Düsseldorf will once again become a hotspot for international foundry and metalwork technology from 25 to 29 June 2019. Under the slogan “The Bright World of Metals”, the trade fair quartet, comprising GIFA, NEWCAST, METEC and THERMPROCESS, covers the entire spectrum both in-depth and with a wide scope, ranging from foundry technology, casting products, metallurgy and thermal processing technology. But what would this international quadruple trade fair be without its extensive supporting programme for experts? The international conferences, symposiums and industry meetings are unique platforms for expertise, bringing theory and practice together and offering an amazing opportunity to network and exchange with other tradespeople.

The trio for success:

METEC & EMC & ESTAD METEC

and

its

accompanying

conferences, the EMC – European Metallurgical Conference and the ESTAD – European Steel Technology and Application Days, form an unbeatable trio. The ESTAD, held from 24 to 28 June, focuses on the raw material steel, along with its manufacturing, applications and

steel within the context of environmental engineering and energy. For steel manufacturers, suppliers and operators, this five-day conference is an absolute must. Ultimately, this English-speaking conference is split into five topic areas:

� Iron production � Steel production � Rolling and forging � Steel materials

and their applications, additive manufacturing techniques, surface technology � Environmental protection and energy The 4th ESTAD is organised, in tried-and-tested tradition, by the Steel Institute VDEh (Association of German Steel Manufacturers) in cooperation with its partners, the Austrian Society for Metallurgy and Metals and the Associazione Italiana di Metallurgia. More detailed information and tickets are available online at: www.metec- estad2019.com.

METEC isn’t the only institution that’s celebrating a decade in action - the EMC is also celebrating its tenth edition next year. The European Metallurgical Conference is the most important conference for non- ferrous metallurgy in Europe and starts two days before the METEC. Its main theme is the optimal

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use of resources and recycling to provide a sustainable solution. This exclusively English-speaking Conference is an invitation from the GDMB (Society of Metallurgists and Miners) and is oriented towards metal producers, equipment manufacturers and service providers, as well as universities and engineering firms.

Buy tickets and register from January 2019 via the following link: https://emc.gdmb. de/registration.

efficiency, with particular attention to CO2 and NOx emission reduction � Challenges posed by variation in gas quality, specifically when alternative fuels are fed in � Current and future requirements for thermally treated automotive materials � Heat treatment concepts in thermal processing technology � Industry 4.0 and implementing it in thermal processing technology

THERMPROCESS complete with symposium and special show

In addition to these speeches, renowned research institutes from the thermal processing technology sector will present their subject areas and current research work in the FOGI special show in Hall 10.

Theory and practice are also united at the two THERMPROCESS events, the FOGI special show, from FOGI, the Research Association for Industrial Furnace Engineering in the VDMA (Mechanical Engineering Industry Association) and the THERMPROCESS symposium from VDMA Metallurgy. The symposium illuminates topics that are current within thermal processing technology via a multitude of speeches from experts. The following topics form the main focus of this: � New combustion technology � Resource conservation and energy

GIFA & NEWCAST: A firecracker for the foundry industry The VDG (German Foundrymen’s Association) and the BDG (Confederation of German Foundry Industry) ignite a firecracker at GIFA and NEWCAST. The Foundry Meeting in Hall 13 (Stand D 04), which has been redesigned, serves as the main draw throughout the entire run of the trade fair with its different themed areas. In the “Technology in Casting”

area, BDG member companies present the entire range of foundry working materials. Marvel at cast components in “World of Castings”, which is right next-door. Alongside this, high-quality, exciting speeches will also be given on the five days of the trade fair at the BDG forum. Wednesday is dedicated to the foundries, which proffer information on the latest innovations in the foundry industry and outline practical solutions for daily foundry work and routines at the NEWCAST FORUM in Hall 13. On 26 June, the day will be topped off with the presentation of the NEWCAST Award for innovative cast parts. The two-day GIFA Forum bookends this event (it takes place on 25 and 27 June). Foundry suppliers present the latest trends and techniques here.

Two special shows, organised by the House of the Foundry Industry (Düsseldorf), provide clarification on two of the latest themes to crop up. One of these is the subject of digitalisation and its impact on the foundry industry, and the other is innovative solutions for preventing CO2 emissions. Here, the as yet untapped potential in waste heat

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utilisation, in particular, offers foundries significant opportunities to reduce energy costs and CO2 emissions.

At the first established European CAEF Forum, visitors can see presentations on successful flagship projects and countryspecific challenges in the countries, which are members of the CEAF on Friday 28 June.

manufacturing premier at the GIFA. Whether you work in pattern and die making, in core making or in direct metal printing, foundries and their suppliers can open up tons of unforeseen potential using additive manufacturing. Both of the events acknowledge this proven fact.

The “3D metal printing” trade conference focuses on the following hot topics on

26 June by giving technical lectures on them: � How foundries are profiting from 3D printing � Innovations in 3D metal printing � Digital process chain � Quality assurance � Looking deeper and further into the possibilities

The foundry industry:

Caught between tradition and modernity The VDG celebrates its 150th anniversary in 2019. In line with this, the BDG Forum on Saturday 29 June is completely devoted to the foundry industry’s development over the last 150 years. We will also look into the future to provide a contrast with this in the big Next Generation area (Hall 13, Stand C 38), which runs throughout the entire trade fair and focuses on the following aspects: - What can school pupils, apprentices and students expect to find in the foundries of the future? To answer this question, various projects will be presented in the exhibition space, for example how much casting is integrated into a car? We take a car apart to find out.

- What have the various universities and foundry institutes got to offer in the affiliated Institute Show?

- Where can you find training locations for foundry mechanics? More information on the entire program can be found online at www.bdguss.de from February 2019.

The Conference Leader and Moderator is Sebastian Bremen.

The Director of the Aachen Center for 3D Printing and Group Manager for Laser Powder Bed Fusion at the Fraunhofer Institute for Laser Technology (ILT).

The event organiser is Süddeutscher Verlag Veranstaltungen, and up-to-date information is available at: www.sv-veranstaltungen.de/de/event/3d-druck-metall.

Premiere: Conference & special show on additive manufacturing

The special show in Hall 13 and the trade conference on additive

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GIFA/THERMPROCESS 2019

Otto Junker and Induga at GIFA/THERMPROCESS 2019 MORE … Adding value with OTTO JUNKER, INDUGA and the THERMCON brand

Otto Junker and Induga will be exhibiting at GIFA/ THERMPROCESS 2019 in Düsseldorf from 25th to 29th June 2019. On the theme of MORE … the furnace specialists will be presenting highquality solutions at stand H41 in hall 10 to give users added value at multiple levels, especially in the spheres of

At GIFA / THERMPROCESS 2019, OTTO JUNKER will be informing visitors about individual solutions in the product range of induction-type melting and pouring systems, which the Group tailors specifically to the user’s processes.

Under the banner of MORE … and exemplified on an energy-saving mediumfrequency coreless induction furnace, OTTO JUNKER will be showcasing its Optical Coil Protection (OCP) system delivering direct in-crucible temperature measurements for more operating safety and reliability. In addition, operators can learn more about process control as achieved with Junker’s furnace control system JOKS or the MFT i4.0 mobile application. INDUGA is set to advise visitors on customer-specific solutions while also presenting the Puma Pro pouring system, which delivers more in terms of, e.g., pouring precision, productivity and process stability. Under the THERMCON brand, OTTO JUNKER offers gas-fired melting and pouring furnaces for aluminium. On the basis of a plant model, users can find out about the advantages of a productive system with pyrolysis technology for recycling contaminated aluminium scrap.

The matching furnace concept for every user In the segment of convection or induction-heated thermoprocessing equipment, OTTO JUNKER offers a comprehensive portfolio enabling

operators to obtain a furnace solution optimized to match the given application case and space availability.

In addition, the Group will inform visitors about the productivity and flexibility of its energy-saving systems and on how custom heating and quenching processes can increase the quality of aluminium or copper products. With offline versions of their process models, the Group’s furnace specialists empower users to develop suitable recipes and charge sequences.

Live Forum, service advice and individual appointments at GIFA Customer service personnel will likewise be on hand at stand H41 in hall10. This staff will be glad to advise visitors on available maintenance and upgrading options for existing equipment. For the Live Forum, the furnace specialists have assembled a compelling program of presentations and lectures. Held in English, these oral abstracts will familiarise visitors with the advantages of the relevant products and services.

News and information on the theme of MORE … and concerning the Live Forum will be available on following website: www.otto-junker-more.com or www. induga-more.com.

OTTO JUNKER and INDUGA are looking forward to attracting a strong visitor turnout at stand 10/H41.

In the run-up to the trade fair, prospective visitors can schedule an individual meeting with our specialists via these sites.

induction, convection and automation.

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GIFA 2019

It’s time to connect StrikoWestofen presents the connected foundry Ready for tomorrow's casting market: Industry 4.0 will once again be a key topic at this year's GIFA foundry trade fair from 25 to 29 June. This also applies to Norican Group's presence at the fair, which will feature its four technology brands StrikoWestofen, DISA, Italpresse Gauss and Wheelabrator. In Hall 11 (Booth A74-78), they will present the complete connected Norican foundry - powered by Norican Digital - on ca. 760 square meters from melting to surface finishing of the cast parts.

At GIFA, the world's leading trade fair for foundry technology, renowned suppliers will present proven solutions and pioneering innovations. Visitors to the Norican Group stand this year can look forward to a series of exciting solutions: The StrikoWestofen technology brand will be showcasing its innovations based on complete digital models and will also be giving technology insight presentations by its high-class experts.

Connected all along the line The StrikoWestofen exhibits range from the further optimized ProDos 3.3 dosing furnace control system via the “Smart Service Plan” with data glasses for realtime remote maintenance, an efficiency calculator for intelligent melting furnace solutions, through to digital models of the well-known StrikoMelter and Westomat melting and dosing furnaces. Visitors have the opportunity to experience the furnaces and their performance-enhancing options in a unique way. The digital presentation fits harmoniously into the orientation of the entire Norican Group: True to the motto “powered by Norican Digital”, all the Group's technology brands will be presenting their digitally connected systems.

Right and top right of the page: Industry 4.0 in the

GIFA 2019: Norican technology brand StrikoWestofen wants to present its innovations based on digital exhibits.

In addition, high-caliber experts will have their say with presentations at the booth. Graphics by StrikoWestofen.

For this reason, all new StrikoWestofen systems leave the production line Industry 4.0-ready – pre-equipped to collect and provide informative data. If customers opt for a cloud connection, even selectable machine and production data can be displayed clearly and in real time with the browser-based "Monitizer" app. The app has comprehensive user management and pre-installed widgets that give the customer full control over data access and the data displayed.

Comprehensive data analysis enables foundries to achieve improvements in productivity, quality and resource control. The “Monitizer Starter Kit” allows retrofitting to any production machine, regardless of the manufacturer.

At the stand, the possibilities of the “Monitizer” will be shown with live data from European foundries.

By networking its technology brands, Norican Group is focusing on good connectivity, because “Greater than the sum of its parts” is also the leitmotif of the full-range supplier.

Connectivity as the key to success Theodoor van der Hoeven will be discussing the opportunities and limits of industry 4.0 and the latest technologies

The sticker Industry 4.0 ready can be found on machines and plants of the Norican technology brands, which since April 2019 have been leaving the factory fully prepared with the gateway NoriGate for Industry 4.0 applications. With the “Monitizer” such applications can be used immediately.

Graphics by StrikoWestofen.

of the Industrial Internet of Things (IIoT), with a special focus on dosing accuracy, in his presentation at the GIFA Technical Forum. “Our trade fair motto is 'It's time to connect', says the Vice President Product Development at StrikoWestofen.

"This relates to machine connectivity, but also to our intention to enter into discussions with foundry specialists from all over the world. We look forward to the opportunity to exchange the latest technical knowledge and discuss new needs.”

aluminium foundry: The digital connectivity of the plants is to enable improvements in the areas of Productivity, Quality and Resource Control by means of comprehensive data analyses.

Graphics by Norican Group.

Interested GIFA visitors will experience all the new StrikoWestofen technologies and lectures at the Norican Group stand in Hall 11, Stand A74-78.

8 Furnaces International June 2019

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Projects/Products

CAN-ENG TO DELIVER NEW SYSTEM CAN-ENG Furnaces International Limited has been selected to deliver a New Aluminum High Integrity Thin Walled Casting Heat Treating System Can-Eng Furnaces has been chosen to design and commission a high-capacity, heat-treatment system for a Tier 1 Global Automotive Manufacturing Company.

The new system provides T-6 and T-7 processing capabilities for lightweight aluminum High Pressure Die Casting

(HPDC) automotive components.

Features of the system include Can-Eng’s proven Lean Manufacturing robotically integrated part handling system, individual part processing features that deliver predictable metallurgical and part dimensional properties, Precision Air Quenching (PAQTM) Technology, Level 2 automation system for the managing of individual component parameter traceability, system diagnostics and CQI9 reporting. The system is scheduled for Commissioning Q1, 2020 and will support a next model generation Luxury SUV being released in 2021.

CAN-ENG Furnaces International is a global provider of state-of-theart thermal processing systems for ferrous and non-ferrous metals and is a significant supplier to the automotive community through direct and tier supply. For further information, please contact Tim Donofrio - Vice President, Sales at tdonofrio@can-eng.com. CANENG Furnaces International Limited is an ISO 9001:2015 certified company with its head office and manufacturing facility located in Niagara Falls, ON, Canada.

For additional information contact www.can-eng.com

GE TO INSTALL NO X GE to install NOx reduction technology across 10GW of power plants in India India’s NTPC has awarded a contract to GE Power India (GEPIL) to supply and install low nitrogen oxide (NOx) combustion system for 10GW of thermal power plants across the country.

Under the Rs1.42bn ($20m), GE will be responsible for in-combustion system modification of the boiler by staging the combustion air in the furnace to reduce the generation of fuel and thermal NOX during the combustion process.

GE said that the combustion modification technology will help reduce NOx emissions by 30 - 40% from the coal-fired boilers up to a level of less than 400 mg/Nm3 at 6% oxygen (O2) content in flue gas on dry gas basis at Induced Draft (ID) Fan outlet.

The contract supports India’s emissions reduction goals and marks the largest scale NOx reduction installation across NTPC-operated thermal fleet in the country.

GE South Asia Clean Combustion Leader Lalit Sankrani said: “We are truly delighted to have received this prestigious order from NTPC which is reflective of the commitment of GE towards helping the country address the critical issue of emission from the coal power plants.

“With more than 150 GW of coalfired plants operating at sub-critical level, India is the world’s second largest NOx emitter, contributing close to 30% of annual NOx emissions of the country’s industrial sector.”

Chinese architectural firm CCTN Design has developed an ambitious regeneration project aimed to convert a disused blast furnace in Beijing into a vibrant museum and cultural center.

When completed in 2019, the project will be the first regeneration of a disused steel factory in China.

The blast furnace is part of a large industrial complex operated by state-owned Chinese steel company Shougang Group, whose operations were relocated outside Beijing before the 2008 Olympics, thus making the metallurgical plant a disused one.

Then, Shougang decided to transform a part of the old plant, namely one of its three blast furnaces together with its cooling pond, into a cultural complex, commissioning CCTN to design it.

To cope with such a complex scheme,

GILLESPIE AGREEMENT Gillespie & Powers Inc. has entered into an agreement with Matalco to supply one (1) 115,000 Lb. Tilting Melting Furnace, One (1) 115,000 Lb. Tilting Holding Furnace, Three (3) 120,000 Lb. Batch Homogenizing Ovens and Two (2) 120,000 Lb. Batch Coolers with Charging Car and related equipment in support of their business expansion in Wisconsin Rapids, Wisconsin. This equipment will be operational by June 1, 2020.

Gillespie & Powers Inc. is honored to be working with Matalco in their continued development of their business.

Gillespie & Powers is a 5th Generation family owned design, build, supplier of specialised furnaces supporting the metals processing industry.

For additional information contact info@gillespiepowers.com imarsh@gillespiepowers.com

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Projects/Products

CCTN REGENERATION PROJECT the Chinese architectural firm conceived a very ingenious solution which combines the restorations and adaptive reuse of the huge blast furnace with the creation of new spaces for exhibitions of art, multicultural programs, and visitor facilities.

While the huge blast furnace and its building will be carefully restored to showcase the 100-year-long industrial past of the site; six of the old furnace’s service platforms will be converted into exhibition, education and performance spaces.

Adjacent to the blast furnace, CCTN designed four earth-covered buildings which will contain various functions including a temporary exhibition hall, a restaurant, and a shop.

Finally, an “underwater” circular pavilion, 60 meters / 197 feet across, will be built in the middle of the cooling

pond. Accommodating an art exhibition gallery, the pavilion will be connected to the furnace building by a 150-meter-long (492-foot-long) pier.

The regeneration project also includes a park with trails, boardwalks, and public plazas.

MMK PLANS TO RECONSTRUCT ITS BLAST FURNACE NO. 2 NEXT YEAR Magnitogorsk Iron and Steel Works (MMK) plans to begin the reconstruction of blast furnace No. 2 in 2020, in line with its modernisation plans. MMK plans to radically modernise the unit, significantly reducing its environmental impact.

The historically-significant blast furnace No. 2 was commissioned in the summer of 1932, a few months after the launch of the plant. Currently, it produces around 3,800 tonnes of pig iron per day.

As part of the modernisation process, MMK plans to dismantle and completely replace all parts of the old furnace, as well as to replace the cooling system.

Equipment for the new cooling system will be supplied by the Luxembourg company Paul Wurth, which has been selected following the results of a tender which required the cooling systems presented to have horizontal cooling elements. Following its reconstruction, the new furnace will have non-lintel design. Paul Wurth will supply horizontal box coolers, highly-heat-conductive graphite blast-furnace brickwork and ramming compound. The package also includes a complete set of equipment for a stand-alone hydraulic power unit with heat exchangers and an accompanying

closed-loop cooling system for chemically purified water. The installation process will be supervised on-site both during the pre-installation period and during the period between installation and the startdate of the furnace’s operation.

The casting beds will also be redesigned.

The main technological equipment required for the production of pig iron and slag will be replaced by modern hydraulic equipment manufactured by Dneprohydromach. Similar equipment has already been installed on four MMK blast furnaces. Changes will affect the main transportation flumes, which will be equipped with convective cooling and will increase in size, facilitating the separation of pig iron from slag.

The lining of transportation flumes will be made from refractory concrete. In addition, the flumes will also be equipped with an aspiration system air-duct. Gaspurifying equipment will also be supplied

by Dneprohydromach in the form of aspiration systems for casting beds. As a result of this aspiration installation which has a suction capacity of 850,000 cubic meters per hour, the emission of pollutants into the atmosphere will be significantly reduced, improving working

conditions for our metallurgists. At the moment, the site designated for the construction of the aspiration casting bed is being prepared. The construction of the new blast furnace will have no effect on MMK’s overall steel production or on the quantity of finalised products as its reduced blast furnace production capacity will be compensated by increasing the capacity of the electricfurnace workshop.

MMK’s blast furnace no. 2 was commissioned in June 1932. It was named Komsomolka to commemorate the achievement of hundreds of Komsomol members who worked on the construction of the plant. Since then, the blast furnace has been repeatedly updated - most recently in 2000, when it was rebuilt almost from scratch. The capacity of the current blast furnace is 1,380 cubic meters. In 2010, a bellless top charging mechanism provided

by Paul Wurth was installed on blast furnace no. 2.

For additional information contact www.eng.mmk.ru

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Projects/Products

MONOMETER MELTING & REFINING ROTARY FURNACES

Specification copper ingot production from Monometer Rotary Furnace

A new Monometer copper melting rotary furnace is scheduled to be installed in Africa this Autumn. Facilities at the plant will equip the installation to meet European standards for emissions abatement, and the furnace technology will enable the client to cast specification ingot from all grades of scrap while melting with low-cost reclaimed oil.

The furnace will be one from the Monometer range of economical units with capacity between 1 and 2 tonnes designed for thermal and metallurgical

efficiency where smaller batch production is preferred.

Monometer equipment in the UK continues to provide foundries with the competitive versatility to produce a range of specification product from all grades of scrap material. For example, the popular Monometer 5 to 7 tonne capacity rotary furnace cycles in around 3 hours 30 minutes with a lining life in the region of 220 heats. Alloys commonly produced range from LG1, LG2 through to the higher grades CT1 and the phosphor bronzes. Further products and high purity copper is obtainable from the furnace’s Monometer refining technology.

For refining, the furnace is equipped with programmable gas diffusion refining technology, and variable chemistry main burner. The variable flame chemistry is designed also to protect the molten bath from oxidation, so to allow effective protection with minimal slag volume production and in the absence of any slag covering.

Various rotary melting processes have incorporated Monometer refining equipment, including iron, copper

and lead, performing significantly above traditional methods in terms of increased yield, thermal efficiency and furnace productivity.

For example, in copper refining from Birch-Cliff to high purity copper, a 6-tonne capacity Monometer tilting rotary furnace will typically cycle in 4 - 6 hours; 3 tonnes of scrap iron may be melted, alloyed and tapped in under 120 minutes, and 10 tonnes lead battery scrap may be processed through the furnace in under 5 hours. Monometer designs and supply includes the furnace charging system, gas diffusion technology for the refining process, slag systems, oxy-fuel burner system, and exhaust filter complete with settler, as well as the fluxing agents injector, and consumable spare parts.

Monometer offers comprehensive onsite support, ranging from turnkey management or installation support, to short training packages targeting metallurgical training or general furnace performance. All Monometer clients benefit from being kept up to date with the latest equipment software updates and full engineering on site support.

TRIMET PUTS RECYCLING FURNACE INTO OPERATION With a capacity of around 40 tons, the new furnace will be replacing two of the three existing systems. The TRIMET Executive Board, headed by Chairman Philipp Schlüter, Plant Manager Jens Meinecke and the employees of TRIMET’s Gelsenkirchen plant ceremoniously put the new system into operation this Friday.

“Around 90 percent of the aluminium in circulation is recycled, and the total quantity of recycled light metal continues to increase as a result of increasing demand. So it is only logical for us to consistently invest in expanding our capacities and modernizing our plants,” said Philipp Schlüter, Chairman of the Executive Board of TRIMET Aluminium SE. The new rotary furnace significantly increases remelting capacities at the

For additional information

TRIMET plant in Gelsenkirchen. Along with its installation, the infrastructure and exhaust system of the secondary smelter were modernised and expanded.

“The employees have put their heart and soul into the planning and remodeling with a great deal of flexibility. We are proud of this, because only in this way could everything be carried out smoothly without interrupting operations. At the same time, we are all happy that we can now concentrate fully on remelting aluminium scrap into high-quality products,” said Jens Meinecke, head of TRIMET’s Gelsenkirchen plant.

The furnace has a self-controlling burner system that switches between oxygen and air during the production

of the fuel mixture, depending on requirements. This not only significantly reduces energy consumption, it also increases the proportion of recycled metal.

In addition, the furnace is equipped with intelligent charging technology, which enables faster filling and can process larger quantities of material per smelting process.

At the TRIMET plant in Gelsenkirchen, around 100 employees produce standard alloys and customer-specific special alloys from recycled aluminium. Most of the scrap comes from customers in the region. The aluminium recycled without any loss of quality is often delivered to them for further processing in vehicle construction applications or in the electrical and machine-building industry.

contact www.trimet.eu

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Projects/Products

SMS GROUP TO MODERNISE GAS CLEANING SYSTEMS AT POSCO GWANGYANG SMS group in cooperation with AERIX Co., Ltd., South Korea, has been commissioned to modernize the gas cleaning systems of the three BOF (Blast Oxygen Furnace) converters at the integrated steel mill of POSCO in Gwangyang, South Korea.

Within the scope of a production increase in the converter shop, the gas cleaning systems will be adapted to deal with the higher process gas volumes.

Primary gas cleaning is performed by means of easy-to-maintain dry electrostatic precipitators (ESP) which will be extended accordingly.

This will enable the gas cleaning systems to treat higher process gas volumes while, at the same time, their cleaning capacity is improved. The gas cleaning systems will each be designed for a capacity rating of more than 108,000 Nm³ per hour (dry).

The scope of supply of SMS group comprises all basic engineering services and the supply of electrodes.

The first and second electrostatic precipitators have already been extended, and the completion certificate for the first stage was issued to SMS group immediately after successful commissioning. Extension of the third and last ESP is scheduled for the end of 2019.

POSCO (formerly Pohang Iron and Steel Company), a South Korean company based in Pohang, is the world’s fourth largest steelmaker. At present, POSCO

operates two integrated steel mills in Pohang and Gwangyang.

SMS group is a group of companies internationally active in plant construction and mechanical engineering for the steel and nonferrous metals industry.

It has some 14,000 employees who generate worldwide sales of about EUR 3 billion. The sole owner of the holding company SMS GmbH is the Familie Weiss Foundation.

For additional information contact www.sms-group.com

HARPER INTERNATIONAL LAUNCHES AN ON-LINE CLEANING FEATURE FOR FURNACE IN US Harper International has launched an on-line clean feature for its HighTemperature (HT) furnace system in the Buffalo, US. It will incorporate numerous enhancements to the entrance throat section, including on-line cleaning capabilities.

Rebecca Stephenson, Applications Engineer at Harper International said: “Continuous uniformity across the tow band throughout the entire campaign has never been more achievable than with Harper’s innovative HT online cleaning system.

“Increased fibre quality throughout the whole production campaign is now possible with this solution for removing debris that negatively impacts the velocity uniformity within the HT furnace throat.”

Left untended, debris and filament

build-up impedes and disrupts smooth gas flow in a Carbon Fibre HT Furnace, resulting in non-uniform properties across the tow band.

The debris needs to be removed periodically during the operation of a fibre production line.

Traditional cleaning techniques require reduction of HT furnace temperatures in order to gain access for cleaning, resulting in reduced furnace run times.

Harper’s new on-line cleaning system, located in the entrance section, enables cleaning while the furnace is hot, resulting in increased HT Furnace runtime.

In order to prevent exposure of the HT Furnace to an air atmosphere, the on-line cleaning feature is self-contained and sealed with an incorporated nitrogen purge.

Additionally, Harper’s on-line cleaning system includes sight-ports that permit the operator to see into the process chamber in order to assess the level and location of the debris.

Utilising the on-line cleaning feature offers Harper HT furnace users improved fibre thermal uniformity and increased furnace utilisation.

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04/06/2019 12:09:17

Projects/Products

SOLAR PLANT TO PRODUCE HYDROGEN FUEL FOR GLASSMAKING FURNACES As part of a partnership with Development Centre RC eNeM Ltd., a solar powered plant has been installed

by GEN-I at Steklarna Hrastnik.

The glass manufacturer will use the generated electricity for the production of hydrogen. This sustainable investment will serve to pursue the company’s longterm vision of reducing environmental impacts and ensuring a responsible attitude towards the environment, employees, and the people living in the company’s surroundings.

The latest and energy-efficient methods, technological procedures, and solutions that reduce environmental impacts were therefore one of the essential strategic orientations in the decision of which technology would be employed in the production of glass at Hrastnik. “Last year, we began developing an innovative technology with our partner RCeNeM which aims to reduce the consumption of natural gas as an energy source for the melting of glass, which will in turn significantly reduce the CO2 footprint in the environment. The installation of the solar power plant is an important step towards the realisation of this technology,” emphasised Peter Čas,

General Director of Steklarna Hrastnik.

The factory will thus substitute a portion of the fossil fuels with hydrogen, which generates minimum carbon emissions.

Hydrogen will be produced with the help of the solar power plant, which was designed in conjunction with GEN-I. This will help reduce the carbon footprint on the pilot plant by an additional 10%. “We have already managed to reduce CO2 emissions by 30% at the Tableware unit, and by 10% at the Packaging unit. Such sustainable operations are in line with the strategy that is also pursued by our demanding customers in the premium and super premium segments which also expect the same from their partners. We can realise this goal only through constant investment into innovative technologies, which this solar power plant certainly is,” said Peter Čas about the environmental impact reduction strategy of Steklarna Hrastnik.

As their development is geared towards carbon-free energy which goes beyond the traditional competitive energy supply, GEN-I was the right partner for the installation of the solar power plant that worked closely with Steklarna Hrastnik to make the glassworks a leader in this field in Slovenia. “GEN-I wishes to facilitate an effective green transition and carbon footprint reduction to its partners, which is why it has developed numerous energy management services.

Today, solar self-supply is a realistic and economically viable option for corporate energy consumers. Solar power plants are the first step that we can take in this direction. It is certainly an investment

that each of us can afford, be it a single-family home, a multi-apartment building, or a commercial building.

The installation of a solar power plant today means gaining access to one’s own energy source that has long-term financial benefits for us, the planet, and future generations,” emphasised the President of the Management Board of GEN-I, Dr. Robert Golob.

The installation of a solar power plant is part of the OPERH2 project which is co-financed by the Republic of Slovenia and the EU from the European Regional Development Fund (ERDF).

The development of the mentioned innovative technology is in its pilot stage, whereby RCeNeM is currently constructing the hydrogen production plant. “It is a facility where electrolysis and the energy from the solar power plant will be used to generate high purity hydrogen that will then be used on a pilot glassmaking furnace to reduce the CO2 footprint. We are thus introducing biocomponents into the fuel used to melt glass,” said Tilen Sever, researcher at RCeNeM, about the joint project with Steklarna Hrastnik.

The pilot installation phase will presumably be completed in July of this year when the solar power plant is to be connected to the pilot plant. This will be followed by the experimental development phase aimed at the practical confirmation of the new glass melting solution employing hydrogen and the formulation of guidelines for the transfer of the technology to large glassmaking furnaces.

For additional information contact www.gen-i.si/en

L&L SPECIAL FURNACE SUPPLIES TO CERAMICS COMPANY L&L Special Furnace has shipped a floor-standing furnace to a high tech ceramics company in the Northeastern United States.

The furnace will be used for glass components along with fiber optics, research and development. It will also be used to fill in on various thermal projects and development.

The work zone in the furnace is 24” wide by 16” high by 32” deep, with a temperature gradient of ±20°F at

1,100°F using two zones of temperature control with biasing to balance any temperature gradients.

The control instrument is a Eurotherm EPC3004 programme control that has 10 individual programmes with up to 10 segments for each. The furnace also has over-temperature protection with manual reset and backup safety contactors.

There is a NEMA12 panel and fused disconnect. Solid-state relays are used

to fire the resistance coils. An audible and visual stack light is included to show current furnace status and inform the operator of any alarm conditions.

An atmosphere-sealed case allows the furnace to be operated under a protective atmosphere blanket. This option gives the operator the ability to displace the oxygen in the chamber with either nitrogen or argon to provide a virtually oxygen-free environment.

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Projects/Products

U.S. STEEL RESTARTS FAIRFIELD FURNACE U.S. Steel is resuming a $215 million construction project on what it is calling a ‘technologically advanced’ electric arc furnace steelmaking project in Fairfield.

The project, which shut down in Dec. 2015 due to unfavorable market conditions, will add about 150 full-time employees, the company said. It will include modernisation of the existing rounds caster.

David Burritt, President and CEO of Glass Service, said: “Thanks to the President’s strong trade actions and improved market conditions, support from the United Steelworkers and incentives from the State of Alabama and the Jefferson County Commission, we are excited to add EAF capabilities to our company’s footprint and provide sustainable tubular solutions for our customers.”

The furnace will have an annual capacity of 1.6 million tonnes. Construction is expected to begin immediately and the furnace is projected to begin producing steel rounds in the second half of next year.

Currently, the Fairfield operation has

an annual capacity of approximately 720,000 tonnes of seamless tubular products, made mainly for the energy industry.

Mr Burritt, in a statement, gave credit to the Trump Administration for its action on steel trade. Trump set a 25 percent tax on all imported steel and 10 percent tax on aluminum last year.

The expansion at U.S. Steel’s Tubular Operations had originally been announced in March 2015 before its cancellation later this year.

Incentive totals were not immediately available.

Last year, Brent Sansing, plant manager for U.S. Steel’s Fairfield Works tubular production, said in a forum that unfair trade practices had been one of the factors that led to the postponement of the electric arc furnace project.

Mr Sansing said: “In tubular operations alone, over 2,000 employees were laid off and over 50 percent of our tubular facilities were closed. This is the context in which President Trump’s action should be measured.”

As The Wall Street Journal stated, electric furnaces, which make steel from melted scrap metal instead of iron ore, can operate with fewer workers and are easier to stop and restart than traditional blast furnaces that must operate continuously to avoid damage.

U.S. Steel has made several announcements over the last year following the tariff imposition. The company restarted two St. Louis blast furnaces last year, and last week announced it would restart a Texas mill that has been idle since 2016, adding 140 jobs.

CHINA MIIT PROMOTES ELECTRIC ARC FURNACES IN STEELMAKING China’s Ministry of Industry and Information Technology (MIIT) has stated that it will encourage steel producers to use EAFs. EAFs generate less pollution than traditional blast furnaces and involve the melting of steel scrap, as opposed to the processing of iron ore.

MIIT said: “We will strictly forbid any

new steel capacity to be launched ... and make sure all out-dated steel capacity is eliminated and prevented from reopening.”

The country has recently upped its volume of EAF capacity approvals, which should result in new facilities coming into play from 2018 onwards.

The move is in line with China’s anti-

pollution campaign, with the ministry also noting that it would continue to cut existing steel capacity and ban the launch of new steelmaking facilities in 2018.

It already reduced steel capacity by 50 million tonnes per annum last year and aims to cut up to 150Mtpa of capacity before 2020.

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04/06/2019 12:09:18

Projects/Products

PRIMETALS TECHNOLOGIES TO SUPPLY EAF QUANTUM Primetals Technologies has received an order from Chinese steelmaker Wuzhou Yongda Special Steel Co., Ltd. (Wuzhou Yongda) to supply an EAF Quantum electric arc furnace and a ladle furnace for a greenfield project in Wuzhou city, in Guangxi Zhuang Autonomous Region.

This marks the tenth EAF Quantum for China. The EAF Quantum furnace is designed to handle scrap steel of very varied composition and quality. The electrical energy requirement of the electric arc furnace is extremely low because the scrap is preheated. This reduces both the operating costs and the

CO2 emissions. The twin ladle furnace sets the desired steel grades and the correct casting temperature. The new furnaces are scheduled to be commissioned in early 2020.

Wuzhou Yongda is a privately owned steelmaker operating in the Guangxi Zhuang Autonomous Region in Southern China. The company produces steel rods, coiled rebar and coiled wire. The EAF Quantum and the twin ladle furnace are part of a greenfield project for the production of stainless steels. For the new EAF Quantum electric arc furnace and the twin ladle furnace, Primetals Technologies

For additional information contact

will supply the complete mechanical and electrical process equipment and the automation technology. This includes the automated scrap yard management, the automated charging process, automation of the oxygen injection and sand refilling, as well as the Level 2 automation which makes the plant ready for Industry 4.0. A basic data package for dedusting equipment is also part of the order.

The EAF Quantum developed by Primetals Technologies combines proven elements of shaft furnace technology with an innovative scrap charging process, an efficient preheating system, a new tilting concept for the lower shell, and an optimised tapping system.

This all adds up to very short melting cycles. The electricity consumption is considerably lower than that of a conventional electric arc furnace.

Together with the lower consumption of electrodes and oxygen, this gives an overall advantage in the specific conversion cost of around 20 percent.

In comparison to conventional electric arc furnaces, total CO2 emissions can also be reduced by up to 30 percent per metric ton of crude steel. An integrated dedusting system with modern automatic off gas control fulfills all environmental requirements.

www.primetals.com

O-I TO INVEST €60 MILLION IN GIRONCOURT PLANT Owens-Illinois (O-I) will invest more than $60 million to expand its plant in Gironcourt, France.

Plans include building a new furnace for a total of three furnaces at the plant when the expansion project is completed in early 2020.

The expansion at Gironcourt (pictured) will focus on the growing premium beer segment, which is highly differentiated and uses unique bottle shapes to build strong, premium brand equity.

O-I CEO, Andres Lopez, said: “Our customers recognise that glass brings brand building capabilities. It delivers what consumers want - premium, healthy and sustainable packaging.”

“The expansion at Gironcourt is an important part of O-I’s investment strategy to support the growing demand for glass in premium segments.”

This expansion supporting organic growth follows the recent transaction to

acquire nearly 50% interest in Empresas Comegua, a manufacturer of glass containers for the Central American and

Caribbean markets.

This inorganic growth investment connects the company’s footprint across the Americas - extending from Canada to Argentina.

O-I is also driving innovation in the glass segment evidenced by the development of MAGMA, a breakthrough initiative to reimagine glassmaking with transformational technology and new processes.

O-I also recently launched O-I: Expressions, a direct-to-glass digital printing technology offering customization at speed, value and flexible volumes.

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04/06/2019 12:09:26

Following on from the success of its phase one development, USA-based Big River Steel has commissioned German plant builder SMS group to supply mechanical equipment, electrical and automation systems and digitalisation expertise for phase two expansion of the Osceola, Arkansas steel plant.

According to SMS group, since commissioning the new mill back in 2017, Big River Steel has been busy producing high-quality steels, including tube grade sheet for pipeline construction, silicon steels for a wide variety of energy and electric motor applications, and advanced high strength steels for the US automotive industry.

Expansion of the Osceola site will increase the plant’s annual output to about 3Mt of steel.

Once phase two expansion is completed, the plant will have two electric arc furnaces and two twin-ladle furnaces. An additional gas cleaning system, claims SMS group, will ensure compliance with strict environmental legislation. A second tunnel furnace and a further downcoiler will be added to the CSP plant, which produces up to 1,930mm wide coils, making it one of the widest in the world. The hot coil produced in the CSP plant is processed into high-grade cold strip in the downstream-coupled pickling line/tandem cold mill. There will also be an additional coiler for the plant’s continuous galvanising line (CGL).

SMS group will supply mechanical equipment for all the newly installed plants in addition to the X-Pact electrical and automation systems, including level 3.

The SMS group company MET/ Con’s product quality analyser (PQA) will also play an important role in the development of Big River’s phase two development as it will form the central

SMS GROUP COMMISSIONED FOR BIG RIVER PHASE TWO

For further information, log on to www.sms-group.com module of the process automation system. The PQA monitors, documents and assures product quality down to the finished cold strip along the complete production process. “It uses stored rules defined on the basis of expert knowledge to assess coil quality in a semi-automatic procedure and, based on these assessments, takes ‘ship’ or ‘block’ decisions for the downstream processing of the strip or its dispatch,” SMS group explained.

According to the company, the system sends instructions for action to the operators while production continues in order to make them aware of any onset of irregularities within the production process and suggest countermeasures to be taken. “This allows the operators to predictively intervene in the process before an incident becomes a problem, dramatically reducing the occurrence of failures along the production process which otherwise might have resulted in poor quality and downtimes,” SMS group explained, adding that, in the long run, the system provides higher yield while

increasing the product quality.

SMS group’s technical service operation, which includes spare part management services, plays a central role in the BRS expansion project.

David Stickler, CEO of Big River Steel, commented: “I have purchased several technologically advanced steel production facilities from SMS over the past 20 years and I am fully confident that SMS group will again deliver a high quality mill that sets the standard in terms of product capability, energy efficiency and environmental sustainability.”

At SMS group, Burkhard Dahmen, chairman of the managing board, said that SMS group had worked very closely with management and staff of BRS. “We have succeeded in digitalising a highly complex steel plant in a way that meets the targets of stable and resource-saving production,” he said. “We are very pleased about Big River Steel’s decision to also award us the order for the next expansion stage of the steel plant and to continue on their proven successful way with SMS group as their partner.”

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04/06/2019 12:09:27

Industry 4.0

Defining technologies and setting trends in heat treatment 4.0 Dictated mainly by market demand, SECO/WARWICK, one of the top 5 heat processing system manufacturers, has developed equipment of unparalleled quality and value with solutions suitable for today’s needs tailored to the Industry 4.0 era.

SECO/WARWICK will showcase its award-winning solutions meeting the requirements of the most demanding sectors and various system advancements at this year’s biggest industry event – Thermprocess in Dusseldorf, Germany.

Intelligent solutions tailored to the era of Industry 4.0 Industry 4.0 is a global phenonemon that will fundamentally transform the competitive landscape and bring about fundamental changes in the heat treatment sector. SECO/WARWICK is a pioneer in technological solutions that enable customers not only to compete in their markets, but also to gain an advantage, thanks to time-saving process cycles, energy efficiency, environmentally friendly solutions and high-quality products.

The power of data analysis Augmented reality (AR) and algorithms supporting the decision-making process. Predictive maintenance systems enabling detection of potential failures before they occur. Remote repairs and training leading to substantial time and cost savings. These are just some of the benefits of implementing the latest SECO/ WARWICK’s technological solutions.

The Shift to Predictive is Worthwhile Making the shift from traditional maintenance to predictive maintenance might take some time, but the benefits are numerous. SECO/WARWICK has designed an advanced set of tools to seamlessly move our customers into the next generation of maintenance best practices. One of them -SECO/ PREDICTIVE is an original system for

supporting maintenance processes, using Industry 4.0 and IoT solutions, minimising unplanned downtime and failures, increasing the availability of equipment.

“SECO/PREDICTIVE is based on the Microsoft Azure cloud – and is available in mobile versions. The platform collects data from intelligent sensors and saves them in the SECO/WARWICK cloud.

Powered with a large amount of data – fed into the system from other devices – the system analyses the obtained information and on the basis of advanced learning algorithms, it monitors the equipment on an ongoing basis and manages the product’s life cycle, ensuring optimal operation. The solution includes a remote access and notification system along with a report and analysis function,” explained Sławomir Wachowski, Automation Department Director at SECO/WARWICK.

Seeing more. Seeing further.

The use of the latest technologies allows SECO/WARWICK to provide customers with significant benefits, adding to

their business’s competitive advantage.

SECO/WARWICK is known for its brave implementations, breaking the rules, going beyond the obvious and standard thinking, and finally - offering unique solutions worldwide.

As one of the first in the world, the company reached for the technology of augmented reality.

This is how the SECO/LENS application was created, which, based on the holographic Microsoft - HoloLens, introduces a new dimension of heavy industry, making it possible to see more and benefit more.

How? SECO/LENS can add a 3D model of metal heat treatment equipment to its actual image, enabling monitoring, diagnostics, remote repair and planning the most optimal layout of the production line in the hall. SECO/LENS will allow for a very accurate visualization of SECO/ WARWICK solutions, as well as for conducting training on the operation of the equipment without the need for expensive and time-consuming travels.

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Industry 4.0

0 METEC/GIFA Show announcement

Defining technologies “From the very beginning, the company philosophy was based on the product and technology development to meet high expectations of our customers. Since then, SECO/WARWICK has delivered more than 4000 solutions to customers in 70 countries. Our advanced heat treatment systems, extensive experience and innovative approach gives our partners a competitive advantage in the industry, which makes SECO/WARWICK a supplier of choice, ranked among the 5 top biggest industry players,” said Katarzyna Sawka, SECO/WARWICK Group Marketing Director.

Customer challenges and requirements map out new development paths – SECO/ WARWICK R&D projects, laboratories and global science crew work on solutions that are the most efficient in supporting its customer-partners. The company selects or creates new technologies, performs computer simulations and tests and offers products and services matched to the customer’s need to stay at the forefront of a fast evolving landscape in manufacturing – to be successful, one need to remain creative not only in product development, but also in providing support services.

Want to see more?

Best to see for yourself SECO/WARWICK Group experts will be present at the upcoming June’s Thermprocess, the biggest industry event, which will be held in Dusseldorf, Germany (booth 9C26).

The company invites all producers who want to see for themselves what Industry 4.0 really means, and how the Group utilises the latest technologies so that various industries can capitalize with their world-class, state-of-the-art heat treatment solutions.

ience counts !

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Temperature Profiling and TUS solutions For all your Automotive, Aerospace and General Heat Treatment Application needs Comprehensive

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Thermprocess Show Düsseldorf, 25-29 June

PhoenixTM LLC USA info@phoenixtm.com

Hall 9 Booth C59

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Furnaces International brings readers a selection of technical features focusing on all aspects of the international furnaces market, as well as industry news, events, and regular columns from the British Industrial Furnace Constructors Association (BIFCA).

Published quarterly in a digital format, Furnaces International magazine is sent straight to the inbox of over 50,000 professionals from across the aluminium, steel, and glass industries.

SIGN UP TO RECEIVE YOUR FREE COPY

Contact us now: Nadine Bloxsome

Nathan Jupp

Esme Horn

Manuel Martinquereda

Editor

Sales Manager

International Sales Executive

+44 1737 855115

+44 (0) 1737 855027

Glass & Primary Metals Department Co-ordinator

nadinebloxsome@ quartzltd.com

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ManuelM@ quartzltd.com

+44 (0) 1737 855023

BUSINESS MEDIA

WWW.FURNACES-INTERNATIONAL.COM Untitled-3 1

05/09/2018 13:37

Industry 4.0

The amazing factory with 4.0 furnaces

By Claudio Goldbach, Termina Solutions AGILITY!! This has been the greatest feature of successful companies. And it is the main role of the so-called Industry 4.0: accelerate information analysis so that processes can be adapted quickly.

The faster an organisation adapts to an EVENT, the greater the profits. Events can be operational as a machine breakdown or strategic, with new demands that create changes for the manufactured goods or services provided. I often say that a business, which does not adapt quickly to new demands, will soon have no problems. It is not that demand will disappear, but the business will.

To be practical, let’s dive in the world of thermal processes. Several thermal treatment furnaces have their thermal energy produced by heating elements.

An inevitable and inherent EVENT of these processes is the rupture of heating elements. As they usually have a serial connection, the so-called “burnout” of one element ends up impacting another one. Therefore, an area in the furnace will be without heat. However, the control system compensates this lack of heat, increasing power in other heating elements. In other words, the temperature indicated by the thermocouple, which measures the average temperature of the specific area, is not influenced.

Nevertheless, in this scenario we have some heaters that are off, and others being overwhelmed. Notice that, until now, the heater burnout has not been identified, since the controlled variable is the area temperature. Then, the load closer to the specific area lacking heat may not reach the treatment temperature, therefore, the desired physical feature may not be achieved. The least troublesome scenario would be for quality control to identify these parts and reject them. The worst scenario, which happens frequently, is delivering the item to the market and causing larger damages. Analysing the scenario in which the quality control identifies the problem in the load, we would have the follow timeline: Figure 1 shows that between the “heating element burnout “ and the identification of the load quality problem, a considerable amount of time goes by,

and it is called “perception time”. Only after identifying the problem is that the assessment of the root cause starts. A part of the load without its desired physical feature may have several potential causes and many loads may be treated in the same faulty equipment, while the root cause is being assessed.

Having identified the root cause, decision time starts. Here, I believe that the decision is done quickly because the damage this event is causing in the operation is clear and evident. Once the decision has been made, action time starts, that is, time for exchanging the heating element. A spare part may not be in stock, then, the deadline is some days or weeks.

Meanwhile, palliative solutions can be considered, such as increasing treatment time or repositioning heating elements.

Anyway, damage has been done. This is so common that it is considered as part of operation, an inefficiency that has been incorporated to the system.

This is when Industry 4.0 takes action!

Sensors are installed in each heating elements and they track its operation in real time. When a heating element “burns”, the computational algorithm recognises the event, decides to extend the process time and modifies the treatment curve it is performing, since it understands that this action ensures that every load reaches their required physical features, without production losses. The harm is then restricted only to treatment delay. It is important to emphasise that as we drastically reduced the overall time,

the adapting value is very relevant.

In addition to this action, the smart furnace sends maintenance alerts via SMS and email, warning about the need to change the heating element, once the longer treatment is complete. With the integrated systems, the purchasing department will receive the “burnout” information and, depending on the organisational maturity, even the heating element manufacturer will be notified.

While there is no heating element exchange, every process will be extended to guarantee the production, even with less productivity.

All technologies to obtain these benefits are already available, with low implementation costs. In other words, this can be today’s factory.

In a near future, through a sensor and an algorithm that is being improved by TERMICA Solutions, the heating element “burnout” will allow it to be changed before its rupture, avoiding or minimising drastically current productivity losses.

It will lead us to smarter processes, reducing the waste and increasing environmental and economical sustainability of industrial operations.

The machines will be doing what they are good at and human beings will be doing much more relevant activities, developing their endless strengths. Long live the Revolution!

Contact: chg@termica.solutions

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04/06/2019 12:16:33

Q&A: Furnace & Heat Treatment Technology

A new generation of networking Nadine Bloxsome* spoke to Tim Bryant** about the introduction of Furnace & Heat Treatment Technology USA, a new event aimed at bringing the industry together. more relaxed atmosphere.

Ultimately, Delegates are spending time with peers in an information rich environment supported by high levels of organisation, 5 star accommodation and fine food.

This actually makes an intense couple of days feel strangely relaxed.

Q. What is the aim for Furnace & Heat Treatment Technology USA? A. In short, to deliver a progressive event experience to a senior audience in an exclusive environment.

Senior decision makers are busy people and, from our experience of delivering this tailored event format in other markets, the opportunity to condense relevant information that could otherwise take months to collate into just 1.5 days makes for a highly efficient use of time and future decision making intelligence.

Our aim is to become the go-to source of information, ideas, collaboration and connections for senior players in this industry.

Q. What can Delegates expect?

A. Firstly, relevance. To be able to deliver relevant information, the event model is in turn based on information.

All attendees are asked to contribute detailed information about their business, key challenges and upcoming projects at registration. This allows us to build an individual itinerary of relevant educational content and solution provider research meetings for each person. Itineraries are approved pre-event leading to a clear on-site schedule. The schedule includes various networking activities which provide a further opportunity for dialogue in a

Q. How does it differ from other events in this sector?

A. Most events are important, providing the opportunity for live interaction to compliment digital interaction.

Our main points of difference are the exclusivity and pre-event organisation.

This is an opportunity for a senior audience to hear from experts and benchmark with their peer group which creates a great platform for ideas and future thinking.

Other points of difference include the curation and environment as described earlier, and the visual simplicity. For example, Exhibitors are a vital aspect of the event because they are the innovators in the supply chain, but, rather than having an expo hall of exhibits, this aspect of the event is discrete and designed for direct dialogue with Delegates who have a pre-established interest in their products and solutions.

Q. What are the main topics that will be covered?

A. Following the theme of stimulation through information, the education programme offers a mix of future thinking, critical considerations and case study context.

Top line topics include The Furnace of the Future, Emerging Technologies, Dealing with Data, Furnace Automation, Upgrades & Retrofitting, Safety Fundamentals, Cyber Security and CO2 efficiencies.

The call for papers is open, so if you are reading this and you would like to contribute, please go online and submit the Call for Papers form.

Q. How important is a networking event like this for the industry?

A. As organisers, we can only work hard to set the scene, but when we receive feedback from senior Delegates telling about how their caution to take time out of the office was dispelled by the absolute value of the experience, this type of event becomes important. “An opportunity for us to raise the bar” is one of my favourite quotes and tells us that we are doing a good job.

Q. What opportunities are there for furnace manufacturers and suppliers to be involved?

A. We have a variety of all-inclusive Exhibitor meeting packages available, all of which involve direct dialogue through 25 minute meetings with decision makers face to face as well as attending the event networking functions.

Delegates come with the intention of spending 25% of their event time researching solutions that are relevant to their projects which makes the event a very tailored and cost efficient marketing opportunity.

Q. When and where?

A. 17-19 November at the luxurious JW Marriot Turnberry Resort & Spa just outside Miami.

Miami airport is a North American hub as well as being good for South and Central American travel connections. It is also a good opportunity for early winter warmth.

The venue has excellent conference facilities in addition to being home to two fantastic PGA golf courses. So, for those who would like to enjoy a round before or after the event, we have negotiated discounted green fees, which we will happily co-ordinate for you.

There is also the opportunity for meeting rooms to be arranged for delegates to use the event for a team catch up or general use of the venue facilities for those who would like to make more of their stay. Spouses are welcome!

*Editor, Furnaces International **Event Director, Furnace & Heat Treatment Technology www.furnace-summit-usa.com

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Information, Research, Relationships Furnace & Heat Treatment Technology USA brings together industry experts, senior decision makers and leading industry solution providers to collaborate for progress.

The event format is highly effective, providing a peer led education programme, face-to-face research meetings and a variety of informal networking opportunities.

Turnberry Resort & Spa Miami, Florida 17-19 November, 2019

Our invitation only approach allows us to provide a high value and time efficient event experience To confirm your place, visit: www.furnace-summit-usa.com The Furnace & Heat Treatment Technology Summit series is organised by Quartz Ridge Events, RIDGE EVENTS

a division of Quartz Business Media, and specialising in organising senior level, itinerary led events.

Energy Efficiency

Does biogas co-firing in glass Jörg Leicher*, Anne Giese*, Klaus Görner,* and Bernhard Fleischmann** investigate the use of biogas firing in glass furnaces and report the results of a trial at Verallia’s Bad Wurzach plant in Germany.

Climate change has been identified as one of the major challenges of today and the future, with anthropogenic CO2 emissions being one of the driving forces for a global rise in temperatures.

Man-made CO2 emissions are closely related to the use of fossil energy sources such as coal, oil and natural gas across all sectors, from power generation to domestic heating and industrial manufacturing processes.

The fact that energy consumption is set to increase globally exacerbates the issue.

CO2 emissions are also a challenge for the glass industry with its energy-intensive manufacturing processes.

There is an increased pressure to reduce the industry’s CO2 footprint, both from authorities and customers [1].

About 70 - 80% of the end energy used in the German glass industry is provided by natural gas. At the same time, the glass industry accounts for about 2% of total national gas consumption.

The melting furnaces are particularly relevant here since they are responsible for the highest fuel consumption in the manufacturing process. In principle, there are several options to reduce CO2 emissions from the melting process: The first way is to increase the efficiency of the melting furnace, and thus reduce fuel consumption and hence CO2 emissions.

This is the traditional approach, and the glass industry has been successful at this in recent decades [2], [3].

There are economical and physical

Thermocouple type B Thermocouple type K Probe device Lambda sensor Flue gas probe head

Figure 1. Mobile combustion test rig at a biogas plant (left hand side) and sample insertion into the furnace (right hand side)

limits, however, as efficiency cannot be increased indefinitely.

The second option is to go ‘all-electric’, i.e. to replace gas-fired heating with electric heating systems. Huge strides have been made to make this technology more attractive [4], [5]. From a CO2 perspective, electric heating only makes sense if the electricity is actually produced by ‘green’ technologies such as solar panels or wind turbines.

While the share of ‘green’ electricity is on the rise in Germany, the majority of power is still produced by conventional power plants, based on coal, natural gas or nuclear power.

Similar situations can be found all around the globe. So switching from gas-fired heating to electrical heating would not necessarily reduce overall CO2 emissions, but could simply shift them from the furnace to the power plant.

In essence, the highly efficient and clean combustion of natural gas inside the furnace would be replaced by the far less efficient and clean combustion of coal in the power plant.

There are also technological challenges in designing high-pull fully electric furnaces, and finally, electricity is much more expensive than natural gas.

The third option would be to substitute natural gas with a CO2-neutral fuel such as biogas, either completely or at least partially. Biogas is considered to be CO2neutral as the plants which provide the feedstock remove CO2 from the atmosphere when they grow.

Thus, the net CO2 emissions of biogas combustion are zero.

This switch from a fossil to a regenerative fuel would be less disruptive to manufacturing processes than a complete system change from gas-fired to electric heating.

There are questions though: how does biogas affect process performance in terms of efficiency or pollutant emissions such as NOx? Do trace components in the biogas affect refractory materials and thus furnace lifetime?

Most importantly, is there any influence on glass quality?

Biogas and glass melting It is important in the context of this article to distinguish between biogas and biomethane. Biogas is a combustible gas produced by fermenting biomass.

This biomass may be energy crops such as corn, specifically grown to serve as biomass feedstock, or it may be biowaste.

Depending on the feedstock, the biogas composition may vary, but typical biogases contain 50-70 vol.-% methane.

The rest is mostly CO2, and often low concentrations of O2 and N2.

Trace components of species such as siloxanes, ammonia or H2S as well as alkaline and earth alkaline salts may be found. The calorific values of these biogases usually range between 20 to 30 MJ/m3 (@ 25°C/0°C).

Biogas is usually roughly de-sulphurised before it is put to further use.

Biomethane is biogas that has been

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Energy Efficiency

melting reduce CO2 emissions?

Temperature [°C]

100% natural gas Section A

70% natural gas 30% biogas, by energy 100% biogas

2000 1800

50% biogas

1600

30% biogas

1400 1200

20% biogas

1000 800

10% biogas

600 400 220 25

Natural gas 0

20 40 60 80 100 120 140 160 180 mass flog CO2/mass flow CO2 for natural gas combustion [%]

CO2 from natural gas combustion

CO2 from biogas combustion

200

inert CO2 from biogas

Figure 2. Temperature distributions in the horizontal burner plane of the furnace for the reference case with natural gas (left hand side) and a case

Figure 3.Theoretical impact of biogas admixture on CO2 emissions for a

where 30% of the energy input was provided by biogas (right hand side).

typical furnace.

upgraded to natural gas quality to be injected into the natural gas grid, i.e. the CO2 content has been removed and possibly LPG added to adjust the calorific value or Wobbe Index of the biomethane to local gas qualities in the grid.

This means that, from the point of view of combustion, biomethane behaves almost exactly as natural gas.

However, the upgrading of ‘raw’ biogas to biomethane requires electricity and thus, may incur a CO2 penalty [6], depending on how this electricity was produced.

This penalty could be avoided if biogas is used directly for process heating, further improving the overall CO2 footprint of biogas use.

We will therefore focus on the direct use of ‘raw’, roughly de-sulphurised biogas in this article.

In principle, the impact of switching from natural gas to biogas can be divided into two major categories: on the one hand, there are the effects related to main fuel gas quality criteria such as densities, calorific values or Wobbe Indices.

They will affect flow fields, mixing, combustion, heat transfer and pollutant formation within the furnace, and also have an effect on overall efficiency.

The second category encompasses effects due to trace components in the biogas which will not directly interfere with the combustion processes but may have an impact on refractory material, pollutant formation or glass quality.

Within the framework of a previous,

publicly funded research project called BiogasGlas I a mobile burner test rig was transported to a German biogas plant and used to investigate the impact of biogas combustion on glass quality and refractory materials.

The test furnace was connected to the biogas plant (Figure 1, left hand side) and samples of glass batch and various refractories were introduced into the furnace space (cf. Figure 1, right hand side). In this manner, the effects of the use of ‘raw’ biogas on the samples could be analysed.

It was found that no negative impact on glass quality or the material properties of the refractories could be detected, though some process parameters such as melting times had to be adapted due to the different combustion behaviour and temperature levels of biogas compared to natural gas.

Additional investigations at GWI’s semi-industrial burner test rig as well as CFD simulations showed that a co-firing approach of biogas and natural gas is the most promising way to quickly introduce biogas into the glass industry [7].

Burners should be modified to take the different fuel properties and mass flows into account, in order to minimise the impact of the fuel change on combustion, heat transfer and pollutant emissions.

Biogas-Glas II Based on the promising results of BiogasGlas I, a follow-up project was initiated to put biogas co-firing into practice in an

industrial-scale glass melting furnace.

The French glassmaker Verallia joined forces with GWI and HVG for this project, and offered to use its production site at Bad Wurzach, Germany, for the experiments where a medium-sized regenerative endport furnace is in operation.

This site was ideal for the purposes of the project, as a medium sized biogas plant was located in the immediate vicinity. A small pipeline was constructed to directly connect the biogas plant to the furnace.

Over the course of six months, various amounts of biogas were blended with natural gas and then burned in the melting furnace. At maximum, about 30% of the energy input into the furnace was provided by biogas.

During the time of the experiments, furnace operators reported no negative impact on the process in terms of glass quality or pollutant emissions.

Based on results of the previous project, the burner lances had been adapted prior to the experiments, to maintain a constant ratio of fuel and oxidizer mass flows to keep mixing processes near the burner nozzles as similar as possible.

The industrial-scale investigations were accompanied by CFD simulations (Figure 2), to analyse the differences between the different biogas admixture rates in more detail than it is possible with in-situ measurements.

One result was that the CFD simulations predicted a reduced heat transfer efficiency when co-firing biogas.

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Energy Efficiency

This was not confirmed by furnace operators, but it has to be kept in mind that overall process parameters and boundary conditions are far less easily controlled in a real-life furnace than in an idealised simulation.

Additionally, the contributions of various factors to the overall combustionrelated CO2 emissions were calculated for various biogas co-firing rates (cf. Figure 3), ranging from natural gas only to ‘pure’ biogas combustion.

For these theoretical calculations, all boundary conditions were kept constant except for the composition of the various natural gas/biogas blends and the firing rate to maintain a given heat flux into the glass melt.

The biogas composition was assumed to be 60 vol.-% CH4 and 40 vol.-% CO2.

Process-related CO2 emissions due to the decomposition of carbonate raw materials during the melting process were not considered.

The diagram shows that while total CO2 emissions of the furnace increase with increased biogas admixture, the actual relevant amount of CO2 emissions from the combustion of natural gas is reduced.

Only the emissions from the combustion of a fossil fuel contribute to the overall CO2 footprint. Theory also predicts a loss of process efficiency, however, due to the reduced calorific value of the fuel gas (Figure 4).

The key finding of the Biogas-Glas projects is that there are no technological reasons not to use biogas for glass melting.

There are still obstacles to overcome.

One bottleneck is an adequate supply of biogas.

In the industrial test runs, the limiting factor of biogas admixture was the capacity of the biogas plant which was unable to supply fuel for more than 30% of the required energy input of the furnace.

This could be overcome by establishing micro-grids where several mediumsized biogas plants supply an industrial site.

From an economic perspective, biogas co-firing is not viable under current market conditions. Natural gas (and CO2 emissions) is too cheap.

Finally, there are also regulatory hurdles.

German authorities stated that given

100 90 80 70 60

Figure 4. Theoretical

50

reduction of fossil

40

CO2 emissions and

30 20

process efficiency

10

for different biogas

Natural gas

10% biogas

20% biogas

Reduction of “fossil” CO2 [%]

admixture rates

30% biogas 30% biogas 100% biogas Efficiency [%]

the current legislation, a combined biogas/natural gas firing system for process heating in a furnace has to be treated as a municipal incineration plant which requires much more in terms of emissions control and plant monitoring.

This additional effort is unacceptable for operators of industrial furnaces.

Nevertheless, the projects show the potential that the use of biogas has for process heating to reduce fossil CO2 emissions without disrupting the overall process as a complete systems change from gas-fired heating to all electric heating would.

Conclusions CO2 emissions from the consumption of fossil fuels are a major challenge for energy-intensive industries, for which the direct use of biogas in furnaces might provide a solution.

Co-firing in particular offers a relatively quick way to reduce CO2 emissions without unduly disrupting the manufacturing process.

Investigations show that combustion processes have to be adapted somewhat to take into account the different fuel characteristics, but if this is done properly, biogas can be used without loss in product quality or refractory lifetime.

Theoretical considerations predict a loss of efficiency; however, these could not be measured during the project’s sixmonth testing period.

While obstacles remain in terms of economic viability, potential supply bottlenecks and regulatory issues, the project demonstrates that from a purely technological point-of-view, biogas cofiring is a quick and effective way to significantly reduce CO2 emissions from glass melting.

Acknowledgments The authors gratefully acknowledge AiF for the funding of this project (IGF Grant No. 18685 N). The final report (in German) is available for download on the GWI website (www.gwi-essen.de).

References [1] Kempers, J., Morris, G., “Heineken urges glassmakers to follow its example and be greener”, Glass International, no.

July/August, pp. 14–16, 2017.

[2] Beerkens, R.G.C., van Limpt, H.A.C., Jacobs, G., “Energy efficiency benchmarking of glass furnaces”, Glass Science and Technology, vol. 77, no. 2, pp.

47–57, 2004.

[3] Pont, R.S., “History and Evolution of Clean Efficient Firing Techniques for Glass Melting Furnaces”, 10th International Conference on Industrial Furnaces and Boilers (INFUB10), Porto, Portugal, 2015.

[4] Reynolds, A., “Large capacity allelectric furnaces”, Glass International, no. July/August, pp. 81–83, 2017.

[5] Meuleman, R., “The efficient future for the glass industry is ‘all-electric’”, 14th International Seminar on Furnace Design, Velke Karlovice, Czech Republic, 2017.

[6] Adler, P., Billig, E., Brosowki, A., Daniel-Gromke, J., Falke, I., Fischer, E., Grope, J., Holzhammer, U., Postel, J., Schnutenhaus, J., Stecher, K., Szomszed, G., Trommler, M., Urban, W., Leitfaden Biogasaufbereitung und -einspeisung, 5th ed. Fachagentur Nachwachsende Rohstoffe e. V. (FNR), Leipzig, Germany, 2014.

[7] Märtin, M., Fleischmann, B., Leicher, J., Giese, A., Böhm, P., Wuthnow, H, “Applicability of fermentation gas for melting glass (IGF-AiF Project No. 397ZN)”, ESG, Parma, Italy, 2014.

*Gas- und Wärme-Institut Essen e.V. (GWI). Essen, Germany www.gwi-essen.de **Hüttentechnische Vereinigung der Deutschen Glasindustrie e.V. (HVG), Offenbach, Germany. www.hvg-dgg.de/home.html

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Energy Efficiency

Efficient preheaters improve safety and energy consumption

By Jean-Francois Desmeules*

Aluminium producers use a lot of material under the form of sows and ingots. Alloying elements also often come in ingot bundles. It is well known that sows and ingots often have hidden shrinkage cavities that communicate with the surface via cracks. Internal scrap such as cracked sheet ingot or billet can also trap moisture. According to the “Guidelines for Handling Molten Aluminum” from the Aluminum Association, section 14, “The capability to dry scrap or other charge materials such as primary sow, T-ingot and alloying agents (especially magnesium) possibly

containing moisture is a critical feature of a safe operation”. Therefore, a preheating furnace is a critical component of the production line. The good news is that not only it improves the safety, but it also improve energy efficiency and cycle times.

Dynamic Concept developed a modular design furnace that is cost effective and easy to implement.

Safety requirements An explosion can occur when moist material is charged in molten aluminium.

When water is trapped between a solid surface and molten aluminium, it quickly

turns to steam and expands its volume approximately 1700 times, projecting molten metal at a large distance, injuring employees and damaging equipment. This is the “physical” explosion. Furthermore, the dispersed metal has a great affinity with oxygen so depending on the conditions, a second explosion can occur, the “chemical” explosion. According to thermodynamic calculations, it has been estimated that the energy release of one part of aluminium reacting with oxygen is equivalent to detonating three parts of TNT. Thus, explosions are to be taken very seriously. Even material that appears to be

* Vice-President Technologies and R&D

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Energy Efficiency

dry must be considered moist. The history of a given sow between production and melting can hardly be known and one must act as if it was exposed to rain and snow. Even without exposure to elements, some parts of the world have cold night and warm, humid days, causing condensation on stored metal.

The greatest danger comes from sows with internal voids where water is trapped, but the exterior appears dry. If such a sow is submerged in molten aluminium, it may not cause an immediate explosion. It will rather be sealed with a layer of frozen aluminium while its internal temperature rise. The explosion will occur a few minutes later when no one is suspecting the danger.

To avoid these risks, the charge material must be preheated. For example, the Aluminum Association recommendation for typical LME sows is that “furnace drying for 4 hours after the internal metal temperature has reached 400°F (204°C) should adequately dry 1500 pounds (680 kg) sows”. Important terms here is “internal temperature” and “should”.

Internal temperature means that for a preheating program to be valid, testing must be made with thermocouples drilled inside the material to establish the heating curves. The use of the word “should” means that the user is responsible for establishing the preheating procedure, as the nest paragraph of the Guidelines explains that individual companies should develop their practices according to their operations. Some companies have more stringent requirements.

with the same excess air is only 40%. The lower setpoint uses 1.5 times more heat from the gas to heat the load.

Moreover the heat losses through walls and air infiltration are greater when the internal temperature is higher.

Therefore it is more efficient to heat metal from the room temperature to a given setpoint when the temperature inside the furnace is lower.

Charging hot metal in a melting furnace is not only safer, it is also economical since less heat have to be transferred to the charged and less time is required to melt it.

The Dynamic Concept preheating furnace In order to provide a solution to the safety requirements as well as providing a way to improve the efficiency of the melting process, Dynamic Concept developed a modular preheating furnace that can be used with aluminium and alloying elements.

Description The Dynamic Concept preheating furnace is a modular enclosure fitted with natural gas burners and convection fans. The convection fans are sized to provide better

heat transfer and temperature uniformity inside the furnace. A stainless steel liner inside the furnace protects the insulation.

The access door in the front allows total access to the interior of the furnace to deposit the charge using a forklift. A safety lock keeps the door in safe open position for the operation and maintenance.

The design is modular, allowing a tailor made design suitable the exact capacity required by the customer. The modular design also facilitates the shipping overseas in ISO containers with facilitated assembly and installation.

Automated treatment sequence manages fans speed, temperature ramps, closed loop temperature control and automated door opening.

Optional bumpers for the lining and fans, as well as stairs and maintenance access floors are available as an option.

Furnaces have been designed for capacities ranging from 12 T to 48 T but our modular system makes it easy to adapt to different capacities or load configurations. It is also possible to use electrical resistance heating.

Process qualification Are furnaces are fully assembled and tested in our shop prior to shipping,

Melting energy efficiency While it is important to ensure the safety of the process, it is always desirable to combine this with cost reduction or added value. The aluminium melting process, although consuming much less energy than the reduction of alumina, is still requiring large amounts of energy.

Typical energy efficiency using cold air burners is around 30%, with the bulk of the combustion heat exhausted in the atmosphere under the form of hot products of combustions. Indeed, the temperature of the products of combustion in the exhaust flue is roughly the same as the setpoint temperature. The hotter the exhaust gasses, the less energy transferred to the charge. For example, the available heat with 600°C furnace gas exit temperature with natural gas at 10% excess air is approximately 66% while the available heat for 1150°C exit temperature

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Energy Efficiency

to minimise site assembly and commissioning requirements.

Of course, site specific parameters require adjustment during commissioning, such as load configuration, altitude and exhaust chimney configuration.

During commissioning a complete qualification procedure is performed.

Charge material is drilled to insert thermocouples at the core. Multiple thermocouples are used at various places inside the furnace to ensure that for a given load configuration, the preheating sequence will guarantee compliance to the safety requirements.

The typical load will heat to the minimum “safe” temperature in 1 to 2 hours, followed by the required holding time.

For example, a batch of sow aluminium will typically require 2 hours to reach 204°C internal temperature. With a holding time of 4 hours the total cycle time is 6 hours plus loading/unloading.

Since a holding time is required, we recommend continue heating instead of holding the temperature to reduce melting time further in the process.

One of our preheating furnaces is being used to dry and preheat 48 metric tonnes of sow aluminium at temperatures up to 450°C in a cycle of 6 hours.

About Dynamic Concept Our mission is to increase the competitiveness of light metals producers by supplying custom-fit equipment and systems adapted to the specific conditions of each process line.

We assist our clients at all stages of a project, from preliminary studies to start up, including design, engineering, fabrication, testing, erection of equipment, and the supervision of commissioning and start up.

Our success is measured by the longevity of our business relationships with our customers as well as their satisfaction.

Level measurement The patent pending FLASER provides an accurate level measurement even in the presence of dross.

Temperature measurement We developed an automated adjustable height temperature measurement system that allow measurement of the temperature at different depths in the molten metal bath. This systems works with the FLASER to determine the temperature distribution inside the metal.

Energy efficiency improvements We can provide many custom improvements to existing furnaces, including door replacements, to improve the energy efficiency.

Other furnace technologies available

References

Siphon transfer Dynamic Concept developed a thorough expertise in siphon metal transfer. This system allows a safe and efficient transfer while minimizing oxidation.

Aluminum Association’s Guidelines for Handling Molten Aluminium, 4th edition.

North American Combustion Handbook, Volume 1, 3rd edition

World class manufacturer of High Quartz Bricks

Our BRO HQB have an outstanding resistance to corrosion by cryolite and liquid aluminium

33 route de Castres 31250 Revel France  +335 62 71 32 32  info@fontes-refractories.com 30 Furnaces International June 2019

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Emission Reduction

Primary measures to reduce the NOx concentration in waste gas Dr Hartmut Hegeler* discusses a method that increases the residence time of the waste gases in the furnace and that therefore reduces NOx emissions to levels previously not possible through the use of primary measures.

Environmental measures require a steady reduction of emissions from glass melting furnaces. NOx emissions have been reduced over recent years through primary measures. At present, however, a level has been reached where primary

measures have reach their limits and, for further reduction, secondary measures such as emission control systems with catalysts are necessary.

Sorg has developed a process that allows further reduction of the current level of

emissions through primary measures.

Every thermal process involving the use of fossil fuels produces NOx due to various thermal reactions. In glass melting plants mainly thermal NOx is present, which is unstable. Formation and decay

1500 NO unstable

Vol% NO

500mg/m3 Fuel NOx

1000

500

NO metastabil

No concentration

Speed of decomposition increasing

Thermal NOx N2O

1000

NO formation

Prompt NOx

0 800

NO decomposition

1200

1400

1600

1800

°C

2000

Flame temperature

Figure 1. NO concentration depending on flame temperature (Source: HVG Fortbildung-

400

500

1600

1700

1800

1900

2000

T/°C

Source: Holleman Wiberg

Figure 2.Temperature range of the NO formation and decomposition.

skurs: Effiziente Verbrennungstechnik für die Glasindustrie, Dr.Ing. Anne Giese, GWI Essen.)

Base case without injection with fire left

Injection right with fire left

Figure 3. Mathematical modeling: residence time of the combustion gases without (left) and with air injection (right).

*Sales Director Area 2 and Marketing Manager, Sorg, Lohr am Main, Germany www.sorg.de

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Emission Reduction

are influenced by residence time and temperature in the combustion chamber of the melting furnace.

While the temperature is prescribed by the melting process and can only be varied in a narrow range at most, the change in the residence time – in this case the increase – has no influence on the melting process.

Based on this fact and after intensive mathematical modeling, Sorg has developed and successfully tested a method that increases the residence time of the waste gases in the furnace. Thus, NOx emissions are reduced to levels that were previously not possible through the use of primary measures.

The increase in the residence time of the waste gases in the combustion chamber is achieved by the injection of compressed air in the area of the burners, which prevents the direct outflow of the combustion gases. The longer residence time allows a high decay rate of NOx due to its instability. The increase in the residence time is illustrated in the mathematical modeling.

To regulate and control the compressed air, Sorg has an air station in its product portfolio, which is also suitable for retrofitting to an operating melting furnace. The station shown includes an electro-pneumatic actuator as well as data acquisition and bypass with manual adjustment and on-site display.

The operating principle and the installation were verified several times in the practical test. The test clearly demonstrated the NOx-reducing influence of the injection, both with regard to NOx-optimised systems and to non-optimised systems.

Figures 4 + 5. Control station for the air injection.

In the case of non-optimised plants, the NOx values were at the level of approximately 900mg/Nm³.

After commissioning of the injection, NOx values were measured around the 500mg/ Nm³.

After the optimisation of the melting plant, measurements of emissions were carried out again. By means of air injection, the NOx value was reduced from 650mg/Nm³ to 450mg/Nm³.

Summary With the injection of compressed air, Sorg has developed a method by which the NOx emissions from glass

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L

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R

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9

10 R

L

R

L

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9 8

7

700,00

7

1200,00

6

600,00

6

1000,00

5

500,00

5

800,00

4

400,00

4

300,00

3

200,00

2 1

1400,00

NOx[mg/Nm3]@ 8% O2

8

800,00

1600,00

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NOx[mg/Nm3]@ 8% O2

1000,00

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600,00

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400,00

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melting furnaces can be further reduced successfully by primary measures. The use of cost-intensive secondary measures for NOx reduction is therefore no longer necessary.

By using an air station inside the melting plant, this additional primary measure can be easily implemented and can also be subsequently integrated into existing melting plants. Sorg supplies everything from a single source - from calculation and plant technology to process optimisation.

0 Measured values from 13.09.2016/08:00-15:30

Figure 6. Effect of air injection on NOx in a non-optimised furnace: on the left

Figure 7. Effect of air injection on NOx in an optimised furnace: significant reduc-

side of the green line no injection, on the right side NOx values after starting the

tion of NOx due to air injection.

injection.

33 www.furnaces-international.com

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04/06/2019 12:33:56

Integration

Refial expands capacity with new GHI equipment Refial, an european aluminium scrap recycling plant dedicated to the production of liquid aluminium and secondary ingots, has trusted again in GHI Smart Furnaces for the integration and supply of new key equipment of its expansion of the melting process area and the new salt-slag cooling system. Refial and GHI have been collaborating since 2010.

One of the main challenges of the companies focused on aluminium recycling is the characterization of the aluminium scrap that they intend to process, since depending on its composition the performance of the overall recycling process varies, and therefore the company incomes. In this regard, GHI Smart Furnaces, an European leader designing and providing integral solutions for the aluminium recycling market has designed different types of

equipment that allow to recover the highest metal yield from any kind of aluminium scrap with the highest energy efficiency and performance.

Refial’s aluminium recycling plant is equipped with cutting edge technology, allowing the company to process a large range of aluminium scrap. Its productive means are made of two twin production lines in order to guarantee a “Just in time� aluminium delivery to its customers and to satisfy the high demand of aluminium

of the market.

A long-term relationship The relationship between GHI and Refial began in 2010 with the turnkey supply of five furnaces and its auxiliary equipment.

At that time GHI supplied two melting towers, each one with a capacity of 5 tons per hour, to process aluminium alloy ingots or medium size scrap with a high metal yield and high energy efficiency due to the optimal use of heat from fumes.

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Integration

The scope also included two rectangular reverberatory holding furnaces of 25 tons, specifically designed for receiving, holding, alloying and preparing molten aluminium. The open front of the furnaces, allows access to the entire chamber for cleaning and dedrossing operations, thus optimising finished product quality. The furnaces are equipped with porous plugs that homogenize the temperature and the alloy resulting in high-quality metal.

Additionally, GHI delivered one 30 tons tilting rotary tilting furnace, for low-grade scrap recovery, with its auxiliary equipment. The careful and studied design carried out by GHI on this kind of furnace, provides exceptional performance and metal yields producing significantly lower rates of undesired contaminant salt slags than traditional models.

Production increase and Salt Slag cooling System Due to the great results obtained for the last 8 years and the current market demand, Refial has opted for expanding its production facilities and optimizing the plant layout. To that end, Refial has trusted again in GHI agreeing a turnkey project that comprehends a second 30 tons tilting rotary furnace and a salt slag cooling system and their auxiliary equipment. The new equipment was started up in May 2019 having widely achieved all the requested performance parameters.

The rotary tilting furnace is a twin of the previously supplied one in 2015 with a capacity of 30 tons for processing lowgrade scrap. The new supplied salt slag

cooling system contains the fumes and prevent the oxidation of the returned aluminium, increasing the metal recovery and drastically reducing the space required for cooling the traditional salt slag baskets.

The principle of operation of the salt slag cooling system is based on the cooling down of the salt slag coming from the rotary furnaces, which is classified depending on the size and metal content.

The cooling system is automatically fed by a fit for purpose conveyor that carries the salt slag from the rotary tilting furnaces, avoiding the use of traditional baskets.

The system triggers automatically when the emptying of salt slags of the rotary furnace stars. The salt slags are poured over the conveyor and are transported to the inlet of the cooler feeding a trommel where they start to cool down. The salt slag never comes in direct contact with the cooling water, which makes this system completely safe.

The trommel has two directions of rotation based on its operation mode: cooling-wise and emptying-wise. At the outlet of the trommel, the temperature of the salt slag is continuously measured to determine the proper operation mode, and hence the direction of rotation, upon reaching the target temperature. The internal side of the trommel is provided with several buckets positioned in such a way that depending on the direction of rotation allow to keep the salt slag inside the trommel, continuing their cooling down, or to discharge the salt slag emptying of the trommel once the target temperature is achieved.

Once the cooling cycle is completed, at the output of the trommel, the salt slags

pass through a screen which based on their size are discharged on two different conveyors, one for dust and fines that transports them to the storage silos and other for coarse items which convey them for its final storage on baskets.

Finally, the storage silos are provided with a vibratory discharging system including a telescopic discharge protection sleeve with level sensors to minimize the formation of dust during the loading of the trucks for its further processing in the external salt slag processing plant.

In addition, in order to control the emission of dust, a complete air treatment system has been installed with several suction nozzles in critical points, such as cooling output and screening, conveyors and storage silo discharge.

Beyond 4.0 services Thanks to BEYOND 4.0 technology, GHI can carry out an integral control of all the parameters of the process in real time, which allows the anticipation and diagnosis of any possible incidences. GHI’s equipment is conceived from the design stage for its integration in the industry 4.0, ensuring its features throughout its useful life. The SmartFurnace solution offers GHI’s customers recommendations for improvement, intelligent predictive maintenance and assistance in the use of the installation, through the 4.0 After sales service.

GHI offers a new concept of complete and intelligent plant with the highest performance in the market and a 4.0 solution that allows customers to move from data-driven insights to data-driven actions.

More information: www.ghihornos.com Visit us at Thermprocess Hall 10 / F39

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Integration

Metalfino gets ready for an aluminium future Moto Honda’s partner, Metalfino selects two StrikoMelter melting furnaces to set-up its own melting capacity.

A new era: Brazilian light alloy supplier Metalfino takes productivity one step further, and modernizes its fusion sector. To do this, it relies on modern melting technology from StrikoWestofen.

Image: StrikoWestofen.

On hand for the ceremonial inauguration of the StrikoMelter melting furnaces in Manaus: Honda Senior Vice President Yukimitsu Shiga.

Image: StrikoWestofen.

To make significant improvements in productivity and to future-proof operations making them ready for a rapidly growing aluminium market, Brazilian industrial supplier Metalfino da Amazonia Ltda. in Manaus, Brazil, decided to develop melt capacities inhouse. To do this they opted for two StrikoMelter furnaces from Norican technology, StrikoWestofen.

Close consultation with Metalfino’s biggest client Moto Honda (Japan), which already operated three StrikoMelter technologies, convinced them that these high-tech melting furnaces would be the right choice. The company was impressed not just by the StrikoMelter’s excellent energy consumption efficiency, metal yield and system availability, but also by the excellent teamwork between Metalfino and StrikoWestofen during installation and commissioning. So much so that Honda Senior Vice President Yukimitsu Shiga attended the inauguration ceremony for the StrikoMelters in December 2018 in person.

Brazilian industrial supplier Metalfino

da Amazonia Ltda. casts two different types of standard alloy using 30 die casting cells for Moto Honda. To secure its position in the growing aluminium sector and to increase productivity, the company decided to take the next step and revamp its fusion process.

To do this, Metalfino turned to stateof-the-art melting technology from Norican technology StrikoWestofen (Gummersbach, Germany).

The perfect solution for Metalfino Metalfino previously purchased liquid metal from local suppliers, and re-melted returns and ingots using old hearthtype melting furnaces supplied by local manufacturers. To improve its own melt capacities, the company installed two StrikoMelter melting furnaces more than doubling its melting capacity, which were commissioned in December 2018 in a ceremony attended in person by Honda Senior Vice President Yukimitsu Shiga. StrikoWestofen customised the furnaces exactly to the customer’s

needs. Metalfino’s melting furnaces are equipped with a furnace weighing system and a shaft filling level laser, which continuously monitors the filling level in the furnace shaft. When there is no more charging material in the upper shaft area, the feed process starts automatically.

This means that the Metalfino site at Manaus can now melt 4,000 kilograms of aluminium per hour.

Winning teamwork An additional steel structure was needed to accommodate the waste gas system of the new furnaces – the roof of the production hall was not designed for the loads involved. This was a challenge that demanded teamwork: StrikoWestofen carried out engineering planning for the supporting frame, which Metalfino then manufactured. Alongside the features of the StrikoMelters themselves like low energy consumption and high metal yield, it was also this special level of service that impressed Metalfino. “For such a crucial investment in our future, it was important for us to have an expert

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Integration

partner by our side,” explains Oldair Silva de Arruda, Production Manager at Metalfino. “We knew the Norican Group offered integrated solutions and special support. And we see our cooperation with StrikoWestofen as a shining example of that support”.

In fact, cross-team cooperation also played an important role in the decision on the preferred melting technology: extensive consultation between Metalfino and colleagues from its main client Moto Honda, which already operated three StrikoMelter systems, influenced the decision in favour of these modern melting furnaces. “We are pleased that our trustworthy and

High energy efficiency, metal yield and system availability set the StrikoMelter apart from competition.

These features, along with outstanding service, including on-site support, were the deciding factors for automotive supplier Metalfino.

Image: StrikoWestofen.

www.strikowestofen.com

consistent support helped us win Metalfino’s order,” says Burkhard Schäck, Area Sales Manager Equipment Sales Support at StrikoWestofen. “Through our global network of strong partners, in this case ‘HeatingParts’ in Manaus, we also ensure that our customers always receive expert support – during local working hours and in their local language.”

Aluminium recycling furnace for Fonderie Pandolfo Tenova LOI Thermprocess, supplier for custom-made heat treatment lines and furnaces and specialist for recycling plants for contaminated aluminium scrap, has received an important order from Fonderie Pandolfo, Italy, for the delivery and installation of a Twin-Chamber Melting Furnace TCF®.

Fonderie Pandolfo is the recycling and melting enterprise within the Panalco Holding, specialised in processing of aluminium, mainly for extrusions. The casted billets are mainly extruded in the extrusion shops of the main European extruders.

Currently, over 60,000 tons of refined and recycled aluminium are molten and cast into semi-products. Fonderie Pandolfo already operates a set of TCF® and casting furnaces supplied by Tenova LOI Thermprocess in 2008. The new installation will double the production rate, aiming to satisfy the continuous market requests.

The TCF®, with a capacity of 65,000 tons/year, is designed for aluminium scrap recycling. In order to cover a broad range of scrap and contamination degree, the TCF® combines pre-treatment and melting in one furnace.

The beneficial TCF®-process relies on the efficient melting by limiting dross formation due to pre-treatment, while the evolving Volatile Organic Contents

(VOCs) are combusted completely in the furnace to decrease the overall energy consumption and fulfil the most restrictive environmental regulations.

By combining regenerative air heating (CCR) and optimised thermal treatment of the organic scrap components, this proven furnace technology reaches an unmatched grade of energy and metal efficiency.

A sophisticated automation technology, applied by Tenova LOI Thermprocess with the aim to streamline a fully automatic charging machine, increases efficiency further.

The scope of supply contains the turnkey-installation, including a state-ofthe-art flue gas treatment plant.

The TCF® is expected to go into operation at the end of 2019.

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Optimisation

Furnace optimisation through in-house improvements

Figure 1. Platform for inspection and maintenance access to the combustion air

Figure 2. Removable grating panels for easy access to inspect the roof refractory

fan and valve train on a furnace roof.

and anchor system.

Irrespective of the process, whether continuous casting, Direct Chill casting, foundry casting or back yard sand casting, the one common thread that connects them all is the furnace. Furnaces are the workhorse in every casthouse. Because of the nature of the process, the furnace is also typically treated the most aggressively and receives the least attention compared to the rest of the systems in the operation.

The result is the performance, efficiency and overall condition of the furnaces often deteriorates over years in service.

When casthouse optimisation is considered, most companies will look at the bottleneck in the process and focus their attention on improving the performance of this critical path system.

When the bottleneck is the furnace, it is not uncommon for producers to focus on upgrades or modernization of the furnace rather than considering the drop in performance since the furnace was first installed. Many furnaces in operation today are decades old, but with the correct utilization and practices, they can still operate efficiently before investing in enhancing devices like stirrers and higher performance burner systems.

Mechanical abuse is one of the major factors causing a premature drop in furnace performance, especially in melting furnaces. Dropping of heavy

charges on the hearth, impact with furnace tending tools, and doors closing on metal covered sills all lead to deterioration of the furnace refractory especially around door sills, lintels and jambs. It is not uncommon to walk into any casthouse and witness doors sitting against damaged refractory and the sight of emissions or even flames pushing out around the door. Typically this situation does not receive attention until a planned shutdown so the furnace may operate for many months in this or typically, a gradually worsening state of repair. Not only does this condition lead to a less efficient furnace, lengthened cycle times and increased melt losses, the hot spots around the door can cause localised deformation of the door and furnace structure itself, leading to poor sealing even after a repair of the refractories.

Many plants will attribute the blame for mechanical abuse on the operators, saying they are heavy handed and clumsy when charging the furnace. Although true in some cases, it is not typically the mentality of the operator to cause undue damage to equipment but rather they are simply trying to do the best with the tools and the conditions they have available. Operating a boom on the end of a fork truck that may be as long as 6m with the associated flex and bounce in

order to try and skim or clean a furnace already takes a skilled operator to master.

Add a potentially uneven plant floor, scrap and debris to negotiate over and a tool that maybe only a few centimetres shorter than the door opening is tall and it becomes clear how damage can occur.

Charge cars, custom charging machines and automated skimming machines can greatly minimise or even eliminate this form of mechanical damage. However, the capital budget to install these machines and the layout of the furnace bay may inhibit automated machines from being introduced. In these cases, the evaluation of the existing furnace tending practices and developing in house solutions can provide an effective alternative. A furnace bay floor that is regularly maintained and kept clean of scrap and debris minimises tool bumping. Tools that are correctly designed can also minimise bounce and flex. Typically, the channels on the tools that mate with the truck forks are oversized to ease engagement.

However, this also makes control of the tool more difficult when in operation, so it is important to consider which of the two operations is most important. The correct geometry of the tool head can also improve the simplicity of the furnace tending process and minimise the risk of unintentional impact on refractories.

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Figure 3. Working area for media bed inspection and access to the bath thermocouple located between the burners.

A common argument heard recently is that natural gas prices are at a historical low, so producers are not concerned about specific fuel consumption or inefficient burner operation as this is considered to have a minimal impact on the operation’s bottom line. This may be a valid argument when considering utility cost alone but fails to account for the indirect cost and lost opportunity created by poor burner operation, control and maintenance, not to mention out-of-spec emissions.

Increase in furnace cycle times caused by reduced burner power can often account for reduced production cycles on the downstream equipment. Hearing experienced operators saying that they used to be able to get more cycles from their furnace in the past than they do today is surprisingly common, and the blame is typically placed on the furnace crews now operating the equipment. Gaining an extra cast a day or even a portion of a cast simply through burner maintenance and proper practice in a 24/7 operation equates to a considerable production increase over the entire year for minimal expense. Less easy to calculate, but still a critical factor in any casting operation’s profitability is the effect of burner tuning on melt loss.

A wide range of products and services are available today to recover a good percentage of aluminium from dross, but

typically less attention and time is spent focusing on reducing the amount of dross generated in the first place than how much recovery is possible from the dross sent to recyclers. Irrespective of the type of furnace charge, the amount of dross generated in a furnace can be directly associated with the overall combustion system efficiency and operating practice; this efficiency itself being a combination of burner air-fuel ratio control, damper system for furnace pressure control, furnace sealing, burner condition, control strategy and refractory condition. All of these parameters are readily controllable by operating crews, maintenance crews and burner service technicians.

Metal quality is another factor impacted by poor burner efficiency. In addition to increased melt losses, the quality of the molten aluminium is directly influenced by burner performance. In one GNA installation producing high quality products where regenerative burners are used, the quality control department noticed that the hydrogen content in the metal as it left the furnace could be used as a reliable indicator of the condition of the media beds and when the beds needed cleaning/changing. As with all in line degassing systems, the hydrogen removal efficiency is a function of the amount of hydrogen entrapped in the incoming

metal. Therefore if the incoming levels can be minimized by optimized furnace operation, the final product will have a lower hydrogen content, which can be significant in critical end use products.

One upgrade to existing, dated furnaces that can provide significant benefit is an upgrade to a modern PLC system. A PLC based control system has the capability of improving all aspects of the furnace operation including efficiency, maintenance, safety and systems monitoring. The modern PLC is able to supervise and control the air-fuel ratio and burner operating parameters to automatically regulate burner operation, change control modes as required, prevent furnace or bath over temperature and enhance safety through flame detection and associated monitoring capabilities.

Linked to an inline pressure and temperature compensated gas meter and SCADA system, the historian capability of the PLC system can notify changes in furnace performance whether operator influenced or as a result of maintenance or burner related situations.

Standard operating practices tend to change over time; some of these for good but often can have more of a negative impact on furnace performance than positive. Changes in casthouse management, charging methods to

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Optimisation

Figure 4. Furnace hearth thermocouples, one on the exterior steel surface and

Figure 5. Boom-mounted furnace tending tool used to clean the refractory

the other embedded in the refractory lining. The temperature data is displayed

hearth. This should be part of the daily routine in furnace operation and preven-

on the HMI screen in the Operator Panel and used for evaluation of the refracto-

tive maintenance.

ry condition and maintenance planning

best adapt to scrap types, production requirements and numerous other reasons can formalise furnace operation practices into the “well this is the way we have done this for years” category.

Similar to safety training, refresher courses and training / retraining of the latest techniques and best practices should be adopted for furnace operators.

The benefits are not only seen in furnace efficiency, the safety aspects and potential hazards of furnace operation alone should be a prerequisite for conducting regular, scheduled training of operators and crews.

As identified in the opening paragraph of this article, any casthouse operation depends entirely on the availability of the furnace. If the furnace is out of operation for any reason, production is directly impacted. Being that the melting furnace is exposed to the most arduous duty and toughest environment, it should not be overlooked that failures, whether mechanical, electrical or otherwise may occur. Preventative maintenance is a critical part of prolonged furnace operation. Failures with the furnace are often the result of hot spots on the furnace where refractory construction has been compromised through wear, damage or movement. These hotspots can burn control or power cables, hydraulic lines or even result in catastrophic failure of the overall furnace integrity resulting in metal leaks and potential fire risk.

Regular inspection of the furnace casing for hot spots is a practice that takes only a

few minutes, the same way a commercial pilot inspects the exterior of the aircraft prior to flight and in many ways is equally as critical.

Despite regular inspections and a robust preventative maintenance program, the chance of downtime from mechanical damage, refractory failure or hydraulic, fan or electrical failure is still present. An inventory program with critical spare parts is mandatory to prevent lengthy downtime. The furnace supplier, the refractory installer and the plant’s own maintenance and operating crews can readily develop a list of recommended parts and it is then the role of management, purchasing and warehousing to ensure the stocking and correct storage of these parts, especially temperature critical refractory parts.

In conclusion, furnace enhancing devices available on the market today are well proven and valuable tools to improve casthouse efficiency. In many cases, it is advisable that existing furnace practices are reviewed in advance of investing in the capital cost of new systems. Considerable improvements can be made in many cases without major investment and these improvements should be benchmarked and used as a basis to implementing further improvements. Without this step, the advantages of new systems may not be fully realised and the potential return on investment may not be as beneficial as expected.

Equipment upgrades are not intended to be a substitute for a poor operation.

Nothing is a substitute for equipment availability and this is achieved by having a sound practice, disciplined operating personnel and the necessary spare parts to support a sustainable operation. This strategy will go a long way in getting metal shipments to your Clients.

Here is a list of ideas and activities that have proven to give positive results and should be considered in the operation of melting and holding furnaces: � Regular casthouse review for operator and maintenance personnel safety and comfort � Self-evaluation process to determine the Best Practice for your operation � Execution of the Best Practice instilling self-discipline and motivation in the operators � Thermocouple choice and location for bath, roof, flue system and hearth refractory temperature control and monitoring � Review of tools, strategies and frequency for furnace charging, skimming and cleaning � In-house support and planned maintenance activities with critical spare parts on hand � Challenges for management – how to face them and convince the operating and maintenance staff of the benefits specific changes can bring to the casthouse � Monthly BBQ for the casthouse staff

Ted Phenix is CEO of GNA alutech inc., www.gna.ca Ted can be contacted at +1 514 956-1776 or by E-mail at tphenix@gna.ca 40 Furnaces International June 2019

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Measurement

Accurate temperature measurement for the forging industry AMETEK Land, Global Infrared (IR) Product Manager, Manfred Hayk and Physics Section Manager, Dr. Fiona Turner discuss how accurate temperature measurement and process control in forging processes are essential for achieving high product quality and optimising tool life.

Forging of metal semi-finished products has been an important manufacturing method for hundreds of years. During forging processes, steel slabs or billets are converted into semi-finished rolls; steel or non-ferrous metal bolts dropforged to make parts for the automotive industry, functional parts or fittings. The required throughput and price pressure on manufacturers is steadily increasing, but so are quality requirements for the processed materials and manufactured components.

Compliance with narrow workpiece temperature ranges and active process control are essential parts of hot forming processes to ensure material and part quality, minimise failure rates, optimise tool lifetime - and secure the market position of companies in global competition.

Heating of semi-finished products Components are typically heated to the respective forging temperatures in reheat furnaces between each forming step. Larger metal billets are normally heated in gas-fired walking beam furnaces and smaller components in gas-fired or induction push-through furnaces.

During induction heating, surface eddy currents are induced in conductive materials. For magnetic materials, additional magnetisation effects further heat the components with penetration depth and zones depending on the frequency and material. The heat is then distributed into the bulk of the material at a rate dependent on its thermal conductivity. Temperature measurement should be performed immediately before delivering the heated components to the

forging process to ensure all components have reached the required temperature and uniformity and that their edges have not overheated or burned.

Temperature measurement requiremements In many gas heating furnaces thermocouples are used for furnace control.

Thermocouples measure indirectly. They are typically positioned to measure the temperature of the furnace atmosphere or the combustion gas in the vicinity of the refractory rather than the moving parts. Thermocouples cannot be used in induction heating furnaces due to

the strong induction fields. For induction furnaces, temperature is often estimated from the frequency and dwell time of the process using a predetermined model.

This does not allow for precise process control.

In applications such as drop-forging, the heated semi-finished products are moved quite fast – sometimes falling down a slide – so the temperature of the part is maintained right into the forming process. Temperature must be determined quickly and accurately in the short space of time between a part leaving the furnace and entering the forming process. Pointmeasuring infrared pyrometers and thermal imaging cameras are ideal for such applications.

Within a few seconds the process control system must evaluate whether the temperature of the part is within the required range. Parts with incorrect temperatures must be safely removed. For safety-related parts – e.g. for automotive or aerospace industry - all part temperatures must be documented and rejected parts stored securely. The number of rejected parts (nOK parts) is checked to ensure that no faulty component is delivered.

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Measurement

Challenges of infrared temperature measurement In induction heating, semi-finished products are exposed to the atmosphere during heating and delivery to the forging process. About 21% of the surrounding air is oxygen, which quickly reacts with surface metallic components to form an oxide layer or scale. The level of oxidation has a major effect on the ‘emissivity’ of the surface, i.e. how it appears to an infrared thermometer.

Emissivity is the ratio of the emitted radiation of a real object to the emitted radiation of a theoretical black body at the same temperature. The emissivity of a part depends on its material, viewing angle, temperature, measurement wavelength and surface condition.

Emissivity is 1-reflectivity, so a white shiny object produces less radiation than a matte black object of the same temperature. The emissivity must be known or measured precisely for accurate infrared temperature measurement, so pyrometers and thermal imagers must be carefully selected for each process and material.

The emissivity of metals typically increases with increasing oxidation of the surface. Metals have a fairly high emissivity of 60-70% in the shorter wavelength “near infrared” region. The initial thin oxide layers that grow on a freshly formed metal surface increase its emissivity to around 75-85% (in the spectral range around 1μm). These initial oxide layers are well connected to the bulk material of the component and have the same temperature. As the thickness of the oxide layer increases during extended periods at a high temperature, scale forms which is thicker and less well connected to the surface. Scale can be significantly cooler than the bulk component. Its emissivity is higher, but not enough to compensate. Instead measurement is performed on the apparent hot patches, where the loosely attached scale has flaked off during the forging or handling process.

a 1μm instrument, but 8°C with an 8 14μm instrument.

Emissivity can change by 5-10% in forging and forming processes. Incorrect understanding of that emissivity could lead to 5-10°C measurement errors from a 1μm instrument but significantly greater deviations if a longer wavelength device was used. Therefore, a pyrometer or thermal imager with the shortest possible wavelength should always be selected to achieve the highest accuracy and reproducibility of the measurements.

Ratio or two-colour pyrometers can compensate for emissivity changes under certain conditions – as long as the change affects both of the measurement wavebands or ‘colours’ proportionately.

Ratio pyrometers are predominantly used when physical objects, dirt, fumes, smoke or water vapor partially obstruct the optical field of view between the measuring device and the object, or when the object is smaller than the measuring spot of the pyrometer.

Ratio pyrometers are not always reliable on the growing oxide layers on metallic components. A disproportionate emissivity change at the two

measurement wavebands can lead to larger measurement errors than for singlechannel devices. In such applications, a short-wavelength measuring pyrometer or thermal imaging camera may be preferred.

For certain processes and materials where the oxide layer formation is well understood, an algorithm pyrometer may be available that accurately tracks the relative emissivity changes at different wavelengths.

Precise and reliable temperature measurement solutions Portable Pyrometers The industry-proven portable AMETEK Land Cyclops pyrometer is successfully used in a wide range of applications. With high-precision through-the-lens sighting, the pyrometer guarantees the highest measuring accuracy and easy handling under the harshest environmental conditions. Bluetooth connectivity, data storage of up to 10,000 readings and the free Cyclops Logger software provide a complete solution.

Within the product family different

Optimising infrared temperature measurement Due to the nature of black body radiation, longer wavelength instruments can read down to lower temperatures, but the potential measurement error from incorrect emissivity estimation increases with wavelength. The error in a measurement temperature of 1000°C from a 1% emissivity error is only 1°C in

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Measurement

temperature and spectral ranges are available. In hot forming processes, the 1μm C100L is typically used.

Stationary SPOT Pyrometers AMETEK Land SPOT pyrometers are ideal for fast-moving parts prior to dropforging, as they have a detection time of only 1ms. Single wavelength M100 and ratio R100 SPOT pyrometers both have wavelengths around 1μm. Their small measurement spot diameters allow as many points as possible along the component during the movement. The measuring field is indicated with a green LED pattern, which is clearly visible even with glowing components.

Within the fully digital SPOT pyrometers, peak values can be automatically identified for display as an object passes by. These peak values will originate from areas where the scale has flaked off the product, so they will represent the correct object temperature.

The SPOT can also be configured to “hold” the last captured value and output it via digital or analogue interfaces until the next component is detected and measured.

The analogue output (0/4 ... 20 mA), digital interface (TCP / IP Modbus), an

integrated webserver and dedicated SPOTViewer / SPOTPro software make it possible to fully visualise and document the measured values in accordance with INDUSTRY 4.0 requirements. The integrated digital switch contact in the SPOT pyrometer can also be used to control a switch for OK and nOK parts.

The SPOT pyrometers are designed to withstand the harsh industrial environments encountered in most forging processes.

Sapphire windows of the pyrometer optics are extremely resistant to scratches and breakages. The SPOT pyrometers provide accurate measurements up to operating temperatures of 60 °C and a comprehensive range of accessories are available for operation in higher ambient temperatures.

The SPOT pyrometer portfolio is completed by the SPOTViewer and SPOTPro advanced pyrometer software, which features intuitive visualization, data trending and extensive logging functions.

Thermal Imagers and Systems While pyrometers detect temperatures from a single measurement area, fully radiometric calibrated cameras from

AMETEK Land - such as the NIR Thermal Imager - measure the exact temperature at > 300,000 pixels over an extended measurement area. The NIR camera works in the near-infrared range at 1μm and is thus ideally suited for forming and forging processes to enable highly accurate temperature measurements with minimal influence of emissivity changes.

Areas where scale has flaked off during the forging process can be detected as hot regions within the image. This analysis and other temperature calculation functions are performed in real time for huge numbers of pixels and multiple frames per second in the advanced software. As well as continuous process visualisation, process control can be provided via a variety of output options for advanced temperature and derived parameters, profiles and trends.

The exact location of the hot, thinoxide areas where scale has flaked off is unknown within the captured image.

Their automatic detection enables a greatly expanded wealth of thermal process parameters and extremely precise control of the forming processes.

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