ENERGY EFFICIENCY
FURNACE MODERNISATION
REFRACTORIES
SAFETY
www.furnaces-international.com
JUNE 2020
Contents
ENERGY EFFICIENCY
FURNACE MODERNISATION
REFRACTORIES
SAFETY
www.furnaces-international.com
JUNE 2020
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
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Managing Director: Tony Crinnion CEO: Steve Diprose
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, 2020
Furnaces International June 2020
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Comment
Welcome to the June issue of Furnaces International Magazine. The world seems like a very different place since our last issue in March! The ripples of the COVID-19 pandemic have been felt across the furnace and heat treatment sector - mainly due to interruptions in manufacturing, as companies had to reduce worker numbers and offer adequate safe working spaces. Plant shutdowns were also inevitable as the world got to grips with a new way of working. 2
Projects and products
Foundries 18 European Foundry Industry Sentiment
Hopefully, as I write this, we appear to be coming out of the other side. Manufacturing sites are getting back up and running, or are at least now functioning at an increased
Energy efficiency 20 Optimising quality through consistent accurate temperature measurement in glass production Energy efficiency 24 Less dross and higher energy efficiency
production rate. This issue is full of product and project updates from across a number of sectors - all showing investments or innovations in furnace and heat treatment technology.
FEVE 30
Container glass to reduce CO2 by 50%
Also, as this technology continues to develop rapidly,
Furnace modernisation 32 Grasping the benefits of modern heat treatment furnaces
modern solutions are leaving older equipment and facilities
Refractories 36 Robust Anchor Design: Three important things you need to know
meeting industry requirements and quality standards. In a
Refractories 38 Energy saving designs
explains that while a new, custom-tailored modern furnace
behind in terms of energy-efficiency, temperature control,
dedicated article from ‘Heatmasters’ on page 32, the company
solution often provides a way to catch up, it is not the only Refractories 40 A software to compare crowns Safety 44
way to grasp the benefits of modern furnaces. There is also a look at energy efficient technology, a focus
Protecting What Matters: Cultivating a culture of safety with the right products and partnerships
on refractories and a safety feature from ‘Bricking Solutions’ about how to create a safety culture... something that in these times in even more important. Nadine Bloxsome, Editor, Furnaces International, nadinebloxsome@quartzltd.com 1 Furnaces International June 2020
Projects/Products
ABBOTT FURNACE COMPANY RECEIVES ORDER FOR STEAM Abbott Furnace Company, an industrial furnace manufacturer located in St. Mary’s, Pennsylvania, USA, has received an order for a steam treat furnace from a leading metal powder company, to be installed in Mexico. Abbott Furnace explains that this order is the latest in a long line of orders from the metal powder company, which has received more than 100
furnaces providing a variety of heat treat solutions. This latest steam treat furnace was selected due to its process flexibility, ease of installation, and the local regional support provided by the Abbott Mexico sales and service team. The steam treatment furnace includes the following features: • Humpback design Steam treaters isolate the steam
chamber, allowing greater throughput and improved efficiency. • Electric or gas-fired boiler The company offers both types of boiler heating, depending on the customer’s needs. • Continuous steam treating Enables sealing of the porosity, corrosion resistance and improved overall appearance of the parts
ARCELORMITTAL GETS €75M EIB LOAN TO SCALE UP ‘BREAKTH ArcelorMittal has been granted a €75m loan from the European Investment Bank (EIB) for the construction of two projects at its Ghent plant in Belgium.
The projects aim to reduce carbon emissions by converting waste and waste by-products into valuable new products, and helping to develop low-
carbon steelmaking technologies in line with the EU’s climate objectives. One of the projects is known as Steelanol, a €165m industrial scale
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M TREAT FURNACE • Monitoring & control
The company offers computerised monitoring and control systems that may supervise several different functions including: furnace temperature, atmosphere flow, dew point, oxygen content, carbon control, belt speed, etc
HROUGH TECHNOLOGY’ TO REDUCE CARBON EMISSIONS demonstration plant that will capture waste gases from the blast furnace and biologically convert them into recycledcarbonethanol, the first commercial
product of ArcelorMittal’s Carbalyst family of recycled carbon chemicals. The ethanol produced can be blended for use as a liquid fuel. The plant is expected to be completed in 2022, and will produce up to 80 million litres of recycled carbon ethanol a year. The second project is named Torero, and is a 50-million-euro large scale demonstration plant to convert waste wood into bio-coal, partially replacing the coal currently injected into the blast furnace. In the early stage, the Torero plant will be able to convert up to 60,000 tonnes of waste wood into around 40,000 tonnes of bio-coal every year. This volume will be doubled in a second stage of the project, after the start of the first Torero reactor. The initial phase is expected to be operational by the end of 2022. The Steelanol and Torero projects have also received funding from the EU’s Horizon 2020 research and innovation programme under grant agreements totalling €22 million. The EU has ambitious plans to make industry more sustainable, under its so called European Green Deal. “Even in the current difficult times, Europe keeps its ambitious climate targets and the EIB, the EU climate bank, is committed to continuing to be a key partner,” said EIB vice-president Ambroise Fayolle. “In particular in the steel industry, it means finding new ways to power machines and processes that are essential
for reducing carbon emissions.” Mariya Gabriel, European Commissioner for Innovation, Research, Culture, Education and Youth, said: “This EU backed loan will enable us to demonstrate that European steelmaking plants can be competitive while reducing carbon emissions and help us attain our climate goals. More than this, if we invest in European research, education and innovation we can demonstrate the global leadership that can secure and strengthen these industries and the people and communities they support for future generations.” Geert Van Poelvoorde, CEO ArcelorMittal Europe of Flat Products, said: “To date we have committed more than €250 million to developing and testing technology that will help make steelmaking carbon neutral, leveraging our R&D facilities around the world. “These two projects are our first large-scale implementations of new breakthrough solutions, as part of our commitment to reduce carbon emissions and transform steel production. With the EIB and European Commission’s support, we can scale up technologies and transition steel to carbon neutrality, and thereby play a significant role in helping Europe achieve its green ambitions.”
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CAN-ENG COMMISSIONED Can-Eng Furnaces International Ltd. was recently contracted to engineer and commission two large capacity heat treatment furnaces for a global producer of highly engineered metal earth moving, construction and mining wear equipment. As part of this turnkey contract, Can-Eng designed and commissioned individual tempering and stress relieving furnaces. Both Heat Treatment systems were assembled and tested at Can-Eng’s Niagara Falls facility prior to shipment and commissioning at
the customers facility. The furnace systems were part of a major expansion by the customer to satisfy increased demand for large steel castings and weldments used as part of their equipment designs. Both furnaces are equipped with high efficiency, natural gas fired heating and recirculation systems that have demonstrated to exceed the requirements of AMS2750 temperature uniformity. Can-Eng Furnaces International Ltd. was selected as the vendor of choice largely due to the
higher level of inhouse heat treatment equipment engineering capabilities and design experience. The customer was specifically impressed with Can-Eng’s controls capability to seamlessly integrate the systems Level 1 controls with the company’s existing Plant Supervisory and Production Control Systems (Levels 2 & 3). Both Systems integrated the company’s preferred PLC hardware which was upgraded to include a more flexible safety rated PLC over conventional hardwired safety circuits.
Can-Eng Furnaces International Ltd. is a global provider and leader in the design of state-of-the-art thermal processing systems. Headquartered in Niagara Falls, ON, Canada, Can-Eng is an ISO 9001:2015 Certified company.
For additional information contact Scott Cumming at scumming@can-eng.com or furnaces@can-eng.com. 4 Furnaces International June 2020
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FORGLASS INTRODUCES 4.0 TECHNOLOGY IN SCRAPING CONVEYORS
Imagine a factory where machines are able to make decisions by themselves or at least make the decision-making process easier for humans by seamlessly communicating with us. This isn’t science-fiction anymore. The factory of tomorrow is here today. Forglass, the Polish batch plant and furnace technology supplier is at the forefront of these changes. The company’s R&D department, in collaboration with The Main Mining Institute in Katowice, AGH University of Science and Technology in Krakow, Poland and other technical universities, have developed an array of technological solutions for both batch plants and furnaces. In the pursuit of maximising production and minimising costs for its clients, and even more importantly to
improve safety, Forglass developed an ‘intelligent’ scraping conveyor, named SmartScraper. Equipped with Overload Protection System (OPS), the design uses electronic sensors to continually monitor the working conditions of the conveyor, diagnose problems and react instantly to changes in operation. The machine’s built-in intelligence allows it to slow down or stop before its elements are damaged, including the protection system itself. Additionally, when connected to an array of sensors (e.g. temperature, working speed or efficiency), SmartScraper allows detailed analysis of its performance
to avoid future malfunctions. Forglass has already delivered a number of SmartScrapers to its clients’ factories, including packaging, float and glass fibre production facilities. The feedback has been overwhelmingly positive, so Forglass has decided to offer SmartScapers equipped with OPS as the only option in the company’s family of scraping conveyors.
CHONGGANG RESTARTS NO.1 BLAST FURNACE Chongqing Iron & Steel (Chonggang) restarted its No.1 2,500-cubic-metre blast furnace on 18 May following refurbishment, Kallanish notes. Work began on the furnace on 1 April, and lasted 48 days. The company's iron production decreased by 200,000 tonnes over the period. Following the refurbishment, the blast furnace is capable of producing 2.34
million tonnes/year of iron. Its material consumption rate is expected to lower by -2.7% compared with that in 2019 following the maintenance. One of its bar rolling lines has also just completed a period of maintenance, which also started on 1 April. This resulted in a 50,000t reduction in bar production. The steelmaker’s first-quarter net
profit slumped by -97.2% year-onyear to CNY 4.17 million ($587,035). Chonggang has also had to deal with a major environmental issue. The Central Environment Inspection Group discovered that the company had stacked almost 300,000 tonnes of solid waste just 800 metres away from the Yangtze River. They have instructed Chonggang to resolve the issue urgently.
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FURNACE MANUFACTURER ‘F South Africa-based foundry and engineering company Thos Begbie restarted its entire facility, in line with the regulations to facilitate the shift to Level 4 of the national Covid-19 lockdown, earlier this month. The company has implemented various shifts to maximise the physical distancing measures stipulated by the regulations, thereby reducing contact and possible transmission among employees.
“This means that the company will restart its manufacture and supply of furnace equipment for one of the largest global copper operations, diversified major BHP’s Olympic Dam mine,” says Thos Begbie sales engineer Esli Bantjes. Bantjes suggests that, as with many suppliers, production has been delayed by at least four weeks, but the company is confident that it will be able to make up lost time with the additional shifts. He explains that the Olympic Dam mine
contract entails the manufacture and supply of critical smelter components, some of which remain in service for up to eight years, adding that others are of a consumable nature, requiring more frequent replacement. Thos Begbie has been working with various engineering design houses since 2003 on improving the design and manufacturing process of the critical components for the Olympic Dam copper smelter in Roxby Downs, South
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FIRED UP AND READY TO GO’ Australia. The components that the company is manufacturing under contract will be used for the next routine maintenance shutdown. This entails a major de- and reconstruction endeavour scheduled around statutory requirements stipulated by the Australian environmental authorities. As technology changes and more commodities are used in everyday electronic appliances, non-ferrous
smelters have no choice but to keep up with the high demand of supplying highgrade metals. This means that the output of furnaces needs to increase and, therefore, “the furnace performance is analysed every few years and redesigned using the latest technology”, Bantjes points out. The company is an approved vendor with a “notable record” of meeting the quality and commercial requirements of this particular copper smelter over the
past two decades. “Thos Begbie has a long-term contract, which simplifies the complex processes of tendering for each item,” he adds. Bantjes says furnace linings are constantly repaired or replaced as necessary, and these changes will improve efficiency instead of increasing tonnage, he states. All the components Thos Begbie supplies to the metallurgical smelting industry both locally and globally are manufactured at its works in Middelburg, in Mpumalanga. Bantjes points out that the company has developed and refined its processes so that all aspects of the manufacturing process, nondestructive testing and accreditation are done on site. The barriers to entry in the foundry casting business are so high that it remains commercially sound to manufacture locally and export as needed, he asserts. However, with the increased demand for faster delivery, a bottleneck developed in terms of supplying approved coils that were completed inhouse, causing unnecessary pressure on the casting team in the copper foundry. Consequently, Thos Begbie sourced the required computer numerical control automated machines to do the rolling and bending of these critical items. The company also added an automated elbow press to its manufacturing process to comply with stringent customer standards. Since commissioning the above machines, the company has reduced unnecessary costs on reworking and additional welding, as well as importing the elbows that were adversely affected by the fluctuations in exchange rates. Bantjes points out that relying on external resources meant that the company had little control over the lead-times and quality standards. He concludes that the company is a self-sufficient furnace component manufacturer verified as a preferred vendor by most non-ferrous smelters, not only in South Africa, but globally.
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HEGLA LAUNCHES CTF GLASS TEMPERING FURNACE HEGLA TaiFin has now expanded its expertise in the glass processing sector by launching the CTF Series of flat glass tempering furnaces. A full convection tempering furnace that incorporates new patented technology has been specifically designed for low-e products as well as all glass types needing to be tempered. The new flat tempering furnace provides outstanding quality with an innovative convection system incorporated, that achieves excellent results in sophisticated architectural glazing products. For glass processors it is essential that a furnace can meet the tough demands of today’s glass market as well as tomorrow’s. It is vital that the overall bow is excellent with the edge curvature needing to be as near to zero as possible. In addition the local bow or roller wave
must be an absolute minimum. In all these respects the glass anisotrophy measuring systems that are fitted to HEGLA TaiFin CTF Series furnaces achieve the highest quality. The technical advantages that have been incorporated into the design include a number of patented attributes. A patented convection system, a convection position control as well as, under hot conditions, a patented heater exchange. The furnaces have been meticulously designed to provide excellent quality of all glass types and coatings. Thanks to a flexible modular design the machine design caters for up to 3600mm glass width with no limit in length and can handle glass thicknesses from 2.85mm – 25mm. The range of HEGLA TaiFin furnaces can be customised to individual
requirements and are all equipped with a simple, user-friendly interface with special software functions. These ensure that the glass tempered products are absolutely flat and the chance of any anisotropic variances in the glass are eliminated. Used in conjunction with Hegla-Hanic GmbH software, each glass run can be perfectly optimised . In addition to this the HEGLA automated systems can be equipped with the company’s proven laser marking technology, to further simplify and streamline manufacturing methods. Steve Goble, HEGLA UK, Managing Director comments, “Despite the uncertainty of current times, it never hurts to look ahead and make plans. The CTF series is a gamechanger that will set benchmarks for the industry.”
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LADLE FURNACE MARKET REPORT GIVES LATEST TRENDS the Ladle furnace Market research report includes an in-sight study of the key Global Ladle furnace Market prominent players along with the company profiles and planning adopted by them. This helps the buyer of the Ladle furnace report to gain a clear view of the competitive landscape and accordingly plan Ladle furnace market strategies. An isolated section with top key players is provided in the report, which provides a complete analysis of price, gross, revenue(Mn), Ladle furnace specifications, and company profiles. The Ladle furnace study is segmented by Module Type, Test Type, And Region. The market size section gives the Ladle furnace market revenue, covering both the historic growth of the market and the forecasting of the future. Moreover, the report covers a host of company profiles, who are making a mark in the industry or have the potential to do so. The profiling of the players includes
their market size, key product launches, information regarding the strategies they employ, and others. The report identifies the total market sales generated by a particular firm over a period of time. Industry experts calculate share by taking into account the product sales over a period and then dividing it by the overall sales of the Ladle furnace industry over a defined period. Download Full PDF Sample Copy of Report: jcmarketresearch.com/reportdetails/21466/sample The research covers the current market size of the Global Ladle furnace Market and its growth rates based on 5 year history data. It also covers various types of segmentation such as by geography North America, Europe, Asia-Pacific etc., by product type Global Ladle furnace Market, by applications Metallurgy Others in overall market. The in-depth information by segments of Ladle furnace market helps monitor performance &
make critical decisions for growth and profitability. It provides information on trends and developments, focuses on markets and materials, capacities, technologies, CAPEX cycle and the changing structure of the Global Ladle furnace Market. This study also contains company profiling, product picture and specifications, sales, market share and contact information of various international, regional, and local vendors of Global Ladle furnace Market. The market competition is constantly growing higher with the rise in technological innovation and M&A activities in the industry. Moreover, many local and regional vendors are offering specific application products for varied end-users. The new vendor entrants in the market are finding it hard to compete with the international vendors based on quality, reliability, and innovations in technology.
SIBERIA’S SIBSTEKLO SET TO CONSTRUCT FURNACE IN OCTOBER Siberia’s SibSteklo set to construct furnace in October Siberian container glass manufacturer SibSteklo is set to start construction of a furnace in October. Design has been entrusted to the Italian company Glass Service, while experts from the UK, Germany, the Czech Republic and Turkey have been invited to oversee construction work. CEO of the Novosibirsk-based company, Pavel Bobosik, said the company had increased its output from 470 to 597 million containers a year in 2019, after several years on investment and quality. Revenues increased from 2.8 billion to 3.68 billion while it also achieved savings in fuel and energy resources, improved the organization of the glassmaking process. The EBITDA of the glass container business in 2019 was 750 million
rubles ($10.6 million) - 42% higher than in 2018. The company had planned to start construction work earlier but it had to be postponed due to coronavirus. Five forming machines will be installed and the factory’s capacity
should increase to 720-740 million items, with an estimated EBITA of 1.250 billion rubles ($17.6 million).Image caption: Pavel Bobosik, SibSteklo’s CEO, said construction of the furnace will start in October
Image Source: Metalloinvest Ural Steel
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MMK’S BLAST FURNACE NO.2 ENTERS FINAL RECONSTRUCTION PHASE At Magnitogorsk Iron and Steel Works, the reconstruction of the blast furnace No 2 is entering its final phase. The updated unit is due to be commissioned in July. MMK started reconstruction of the blast furnace No 2 in February 2020, in line with its major repairs programme. As a result of the renovation, the productivity of blast furnace No 2 will be increased. In addition, it is expected to specifically reduce consumption of coke, which should result in a significant economic effect. Dust emissions will be reduced due to new aspiration systems. The total investment in the modernisation of the furnace will amount to more than RUB 5 billion.
During the scheduled renovation, all elements of the old furnace are due to be dismantled and completely replaced and the cooling system modernised. The cooling of the blast furnace will be transferred from tile vertical cast-iron refrigerators to copper horizontal box coolers in the thrust washers and tuyere zones. This design feature in the cooling of the blast furnace has already been used at MMK during the reconstruction of blast furnace No.1 in 2018. The equipment for the cooling system of blast furnace No. 2 is supplied by the Luxembourg company Paul Wurth. Following its reconstruction, the new furnace will have non-lintel design. An important element of the reconstruction of MMK's blast furnace No.2 is the reconstruction of the casting beds with a system of closed gutters and the aspiration of the casting beds and charge feed. The main technological equipment required for the production of pig iron and slag will be replaced by modern hydraulic equipment manufactured by Dneprohydromach (machines for opening and closing the flaps and manipulator). 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. In addition, the flumes will also be equipped with an aspiration system air-duct. 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 MMK’s employees. Prokatmontazh has acted as the general contractor. Currently, the lining of the furnace has been completed and the installation of copper box coolers produced by Paul Wurth has begun. A new water treatment system for the cooling system has been built. Currently, the Western casting beds are about 90% complete, construction and installation works have been completed and equipment is being installed. Construction works are underway at the Eastern casting beds. As part of the work on the engine room, a new skip winch produced by Paul Wurth is being installed. The installation of the aspiration system at the casting beds is currently approximately 75% complete. The air ducts remain to be mounted and the power supply set up. The charge transfer aspiration system is approximately 95% complete, the pipeline wiring to the dusting points has been installed and electrical work is underway to connect the air intake control valves. Commissioning works are underway on air heaters for preheating. MMK's blast furnace No. 2 was commissioned in June 1932. 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 and the capacity is about 3800 tonnes of pig iron per day. In 2010, a bell-less top charging mechanism provided by Paul Wurth was installed on blast furnace No 2
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ALTEK DÖKÜM RELIES ON PROVEN OTTO JUNKER QUALITY
OTTO JUNKER reference line
Based in Istanbul in Turkey, the company Altek Döküm Hadde Mamulleri San.S. A. placed an order with OTTO JUNKER GmbH for a strip flotation furnace in December 2019. The furnace will be integrated into a continuous strip degreasing, annealing and pickling line for copper and copper alloys. Altek Döküm has an extensive product portfolio that includes copper and copper alloy strips, sheets, washers, specialty alloyed products, coin blanks and cartridge case cups. The company specializes in rolled products made of copper and copper alloys, and supplies its products to the electrical, electronics and automotive industries, as well as to the textile, sanitary systems, automation, construction, roofing & cladding and minting sectors. For the expansion of its production
facility, the company was looking for an innovative system that meets particularly high quality standards for strips. Altek Düküm therefore opted for tech-nology from OTTO JUNKER. The line is designed for strip widths between 300 and 460 mm and thicknesses ranging from 0.1 to 1.2 mm. In the gas-heated 2VX-T strip flotation furnace, the metal strip is supported only by a cushion of protective atmosphere of nitrogen and hydrogen, without any mechanical contact, as it passes through the annealing and cooling sections. The patented 2VX-T strip flotation furnace was developed in close cooperation with RWTH Aa-chen University. Its specified target characteristics were optimized using computational fluid dynamics (CFD) and had been confirmed by previously supplied systems of this type:
• High buoyancy and stable strip position • Uniform heat transfer across the strip width for consistently high product quality • Aerodynamic strip centering by means of patented centering nozzles • Long-life centrifugal fans for optimum efficiency • No feed-throughs from outside into plenum chambers The plant also meets the highest standards in terms of CO2 savings. In addition to the typical features for minimizing energy losses, such as recuperative burners or optimum insulation, the furnace will be equipped with the OTTO JUNKER heat recovery system. With this system, up to 30% of the useful energy input is re-used to heat the rinsing baths.
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Example of CFD analysis results
Example of FEM analysis results
[Source: OTTO JUNKER News, No. 23, April 2014]
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NEW PHOENIX TM OPTIC SYSTEM OPTICAL PROFILING OF YOUR CAB AND VACUUM BRAZING FURNACES PhoenixTM has complemented its existing range of ‘Thru-process’ temperature profiling systems with the exciting innovative new “Optic system” for use in continuous Brazing furnaces. The unique system allows for the first-time process engineers to view the inner workings of the furnace under normal production conditions. Travelling through the furnace, with the products being processed, the Optic system gives a product’s eye view of the entire heat treatment journey. The unique Optic thermal barrier has been designed to provide thermal protection for both 4K high definition video camera and high temperature
torches, providing an independent light source to ensure picture quality and definition. The resulting video “Optical Furnace Profile” show process engineers so much about how their process is operating without any need to stop, cool and dismantle the furnace. This allows safe routine furnace inspection without any of the problems of costly lost production and days of furnace down time. From the video evidence, the root cause of process problems, possibly already highlighted by running the PhoenixTM temperature profile system, can be identified accurately and efficiently. Furnace structural damage or faulty furniture such as recirculating
fans, control thermocouples or heater elements can be detected. Buildup of unwanted flux within the furnace can be monitored allowing accurate service and clean down schedules to be planned preventing future unplanned costly line stoppages. Damage or distortion of the conveyor belt compromising the safe smooth transfer of product through the furnace can be isolated with accuracy helping reduce corrective action turnaround times. Backed up with efficient local service and technical support the PhoenixTM Optic system is a valuable new addition to the process or maintenance engineers PhoenixTM tool kit.
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TENOVA IEAF® TECHNOLOGY CHOSEN BY NLMK URAL, IN REVDA
Castellanza, February 17, 2020 – Tenova, a Techint Group company specialized in innovative solutions for the metals and mining industries, was recently awarded a contract for Tenova’s Industry 4.0 technology system, iEAF® (Intelligent Electric Arc Furnace) by NLMK Ural, the core company within NLMK Long Products Division controlled by NLMK Long, for its plant in Revda, Russia. The iEAF®, which will be installed on the existing EAF at the NLMK plant, is an advanced modular technology for dynamic optimization of the melting process based on real time data, advanced process models and algorithms. This breakthrough technology enhances EAF
melting efficiency, reduces consumption and operative costs as well as carbon footprint. “Our discussion with NLMK was focused on offering economic and technological advantages and Tenova’s iEAF® was recognized as the best solution to reduce production cost and to enhance the performance of the existing EAF”, stated Davide Masoero, Area Manager Europe – Melt Shops. In addition, Tenova iEAF® technology has been successfully installed at 24 plant locations across seven countries, spanning over four continents. This contract represents a new milestone, opening up new market scenarios for
this leading Industry 4.0 technology in Russia, signifying once again the reliability of Tenova’s technologies and its commitment to bring value added solutions to the Russian steel market. About Tenova Tenova, a Techint Group company, is a worldwide partner for innovative, reliable and sustainable solutions in metals and mining. Leveraging a workforce of over 2,500 forwardthinking professionals located in 19 countries across 5 continents, Tenova designs technologies and develops services that help companies reduce costs, save energy, limit environmental impact and improve working conditions.
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URAL STEEL MANUFACTURES CHUTES FOR BLAST FURNACE PRODUCTION Metalloinvest’s Ural Steel has mastered the manufacturing of chutes for blast furnace production. Individual elements of the path used to transport slag and pig iron from the furnace are formed in the modular casting facility. Plant specialists develop sketches and designs of the moulds for casting billets and the
production technology, they also create wooden models. Based on that, they produce a sand mould, which is then filled with molten metal. The resulting chutes are delivered to the blast furnace shop, where they are assembled into a combined structure. At present, 47 types of chutes are required for Ural Steel’s
casting blast furnace. Their total weight is over 250 tonnes. Mass production is expected to deliver savings of up to 10 million roubles per year due to the low cost of products. Ural Steel is currently considering the possibility of launching full-scale chute production.
Image Source: Metalloinvest Ural Steel
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Foundries
European Foundry Industry Sentiment The Coronavirus crisis affects the European foundries more negatively than the mood may indicate While the coronavirus spread around Europe, the COVID-19 pandemic affected the health care and the socio-economic systems of the European countries to varying negative extents. Accordingly, the European Foundry Industry Sentiment continued to decline in April, after the mood already worsened in March. This was primarily due to the deterioration in expectations for the coming six months. Because COVID-19 has a strong impact on the automotive industry and machine manufacturers, European foundries are facing a sharp drop in incoming orders and consequently lower production. But the sentiment does not show the full scope of the challenging impacts,
because the response rate this month was lower than usual. However, the Business Climate Indicator visualises the negative mood of industrial companies in the Euro Area: The BCI decreased dramatically to -1,81 points. But it remained above the record low of April 2009 during the financial crisis. The FISI – European Foundry Industry Sentiment Indicator – is the earliest available composite indicator providing information on the European foundry industry performance. It is published by CAEF the European Foundry Association every month and is based on survey responses of the European foundry industry. The CAEF members are asked
to give their assessment of the current business situation in the foundry sector and their expectations for the next six months. The BCI – Business Climate Indicator – is an indicator published by the European Commission. The BCI evaluates development conditions of the manufacturing sector in the euro area every month and uses five balances of opinion from industry survey: production trends, order books, export order books, stocks and production expectations. Please find the chart enclosed or combined with additional information at www.caef.eu.
BACKGROUND INFORMATION ON CAEF:
CAEF CONTACT:
CAEF is the umbrella organisation of the national European foundry associations. The organisation, founded in 1953, has 22 European member states and works to promote the economical, technical, legal and social interests of the European foundry industry. At the same time, CAEF implements activities which aim at developing national foundry industries and co-ordinating their shared international interests. The General Secretariat is situated in Düsseldorf since 1997.
Sophie Steffen CAEF The European Foundry Association Secretary Commission for Economics & Statistics phone: +49 211 68 71 – 301 sophie.steffen@caef.eu
CAEF represents 4 700 European foundries. Nearly 300 000 employees are generating a turnover of 43 billion Euro. European foundries are recruiting 20 000 workers and engineers per year. The main customer industries are e.g. the automotive, the general engineering and the building industries as well as the electrical engineering industry. No industrial sector exists without using casted components. Further information at www.caef.eu.
18 Furnaces International June 2020
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Long Life, Keep Cool Rollers Even a good design can be improved upon and we have made some major changes lately. Our Hot-Jet Furnace offers improved efficiencies, long life rollers, easy access hoods, and quickly removable side panels. • • • •
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5/30/19 1:04 PM
Energy Efficiency
Optimising quality through consiste measurement in glass production
Philippe Kerbois*, Glass Sector Lead at AMETEK Land and Neil Simpson*, Consultant of S melt furnaces that are helping to optimise productivity.
Ensuring consistent temperatures in glass melt tanks is essential to maintaining high-quality glass production and extending the campaign life of a furnace. Within the glass-melt furnace there are a variety of locations in which the temperature must be closely monitored to achieve these objectives. To ensure the best results, it is important to be able to trend temperature measurements throughout the whole furnace, especially in areas such as the crown and port arch. Innovation in remote, infrared imaging technology now allows hundreds of thousands of temperature measurement points to be recorded every second. These measurements give the operator enhanced accuracy and greater control of temperatures in the melt tank to ensure optimum product quality, efficiency and asset longevity. Technologies, such as AMETEK Land’s NIR Borescope (NIR-B) Glass Thermal Imager, provide continuous monitoring, as well as displaying a highquality visual image that can be used to optimise flame propagation. This short wavelength infrared borescope imaging camera produces high-definition (656 x 494 pixel) thermal images and enables accurate temperature measurement from any point.
Benefits of a technology-based approach There are many advantages to thermal vs. visual imaging and point temperature measurements. Using a permanently installed thermal imaging camera that actively records all necessary and useful
AMETEK Land’s NIR-B with pneumatic auto retraction
data means that the video can be stopped at any frame and accurate measurements can be taken of every port at the exact same point in the process, allowing reversals to be tuned more accurately. Introduced in 2014, the NIR-B (Near Infrared Borescope) continuously measures 324,000 temperatures across a high-resolution pixel image - giving real-time monitoring that ensures high product quality, helps detect furnace structural damage, and improves melt
tank efficiency. It also generates a visual image based on these temperatures. There have been over 50 installations of NIR-B in the past four years in glass plants across the world. Using our proven, short-wavelength NIR-B thermal imaging technology, the camera connects to a Windows PC running dedicated LIPS NIR processing software. This provides accurate data analysis, along with automated alarms and control for 24/7 monitoring.
*Combustion & Energy Consultant to Ametek Land, Dronfield, UK www.ametek-land.com
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Energy Efficiency
ent accurate temperature
Simpson Combustion & Energy, look at advances in temperature measurement in glass
Optimised for measuring high temperatures between 1000 – 1800 °C (1832 – 3272 °F), NIR-B Glass is suitable for glass industry applications, including: float glass, container glass, borosilicate glass and fibre glass melt furnaces. As part of the decision-making process, trials of the NIR-B are carried out at a customer’s site. The quality of the visual image in isolation is sufficient for the majority of end-users to commit and justify the small incremental investment of a thermal NIR-B over a conventional visual CCTV camera. All of the original sales were based on the clarity of the
image and not the thermal benefits which have been subsequently realised, providing an added bonus. As part of a recent customer optimisation exercise, the historic data from an original demonstration was reanalysed using the knowledge gained in the intervening period. The historic data acted as a “baseline” and combined with current “live” data was able to show the variance or changes in furnace operation and provide an indication of the furnace deterioration through ageing. For decades, glass manufacturers and their suppliers have used in-furnace
endoscopy and external furnace thermal imaging to monitor and record visual changes in refractory. With the NIR-B there is the potential for an additional “visual endoscopy” with previously unmeasured thermal data. Wherever there is an existing peep site there is the potential to obtain a 45° or 90° field of view image. Whilst a visual image will look similar, the thermal data can identify a difference of only a few degrees. An NIR-B survey is often recommended as it offers all of the benefits of a permanent and continuous temperature measurement install, which provides
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Energy Efficiency
significant benefits over the traditional “snap-shot” method. In all cases, the key benefit of continuous measurement during a furnace reversal, is that it gives better visibility of maximum and minimum temperatures. That is important because if the temperature goes below 1388° there is a risk of NaOH condensation. In addition, the continuous survey will enable cold and/ or hot spots to be viewed from multiple angles. If these are detected it may indicate that there is too much cooling or even worse a hole? In these situations corrective action can be taken before it results in a more costly or disruptive outcome. It’s worth bearing in mind that often, cold spots are historic and indicate a prior repair, although the location of these will be logged in the software for easier identification. Hot spots are without exception due to flames, however this could be as a result of the burner angle, stoichiometry and/or regenerator condition(s).
Back to Basics The furnace thermal profile will define the hot spot and the location of the thermal up-well. If the furnace is flat bottomed with no “mechanical” influencers then the hot spot can move. However, if there is a mechanical device such as weir wall, bubblers, electrodes then the hot spot of the thermal profile needs to be at the same location. If it is not, then there is a conflict and the mechanical and thermal systems will fight one another with quality/yield being the only loser. With the fixed system NIR-B there is an opportunity to continuously view the thermal profile, by looking from a survey there is a chance to also see the profile along the entire length of the furnace. A single CCTV camera is traditionally located in the Bridge Wall or throat end of the furnace. 60-80% of the furnace is typically visible, however you never see the wall where the camera is located. As part of a thermal endoscopic survey there is the opportunity to briefly install an NIR-B as a part of a survey. Some questions to determine are: how hot is the bridge wall at the end of the firing cycle? How much of the wall has physically worn? Has there been a period of dry batch where the bridge wall appears to have been sand-blasted on the dog-house side? When an NIR-B thermal survey is performed on a float furnace it is typical to view from all four corners. This
establishes the hot spot and specifically if it has moved or is different from one side to the other! In the majority of float furnaces the view from the dog-house towards the waist highlights areas where the temperature is below 1388°. Sadly, in some cases it highlights the damage which has already occurred to the silica refractories due to the NaOH attack. If one exhaust port is hotter than previously with another colder it may suggest that the colder port is becoming blocked and the exhaust flow is being restricted. With reference to Image 3 below it is clear that port 4 is significantly hotter than port 3 on both the firing and exhaust sides. If time permits and support is available, there is the option to view each port either through the target wall peepsite or through an under-port burner block. This will help determine if there is an in-balance from the right to the left side target wall temperatures. The view can show which flame is hotter (has a higher intensity) and suggest which burner needs to be adjusted. When multiple burners are installed it is surprising how one poor flame can influence the others. The challenge is being able to identify which burner is causing the effect. By utilising the “integration” function the flames are averaged. Typically only one burner is creating the problem and only one needs to be adjusted. Whilst “obvious” it is necessary to make another set of measurements to confirm the issues have been resolved or at least partially addressed. Any structural damage caused by abnormally high operating temperatures can be identified early on and remedied quickly. For example, when a crack develops, it may show up as a cold area where air is being pulled in. Using thermal imaging to identify a problem as soon as it starts allows for corrective action to be taken before it develops into something far more serious, avoiding potentially dangerous situations, expensive repair costs and lost production time. Thermal imaging technology makes it possible to accurately image the temperature of a large area of a furnace through only a small opening in the wall. It gives the operator access to data that would have previously been either time consuming or impossible to collect. By monitoring the live video recording, operators can begin to improve melt-tank efficiency and enhance product quality, resulting in reduced process costs. In
addition, the NIR-B borescope with its auto-retraction system provides a level of protection from overheating damage, should water or air services fail, therefore reducing any associated maintenance or replacement costs.
Real-time data The latest infrared temperature measurement systems allow real-time data to be streamed in time-lapse modes. This allows process engineers to visualise the flow of the glass melt batch during processing. As a result, alarms can be set in the control equipment to alert operators and ensure optimum glass quality production. Precise thermal imaging can extend the lifespan of the melt tank and provide greater asset protection through more accurate temperature measurement. Thermal imaging devices can measure, monitor and log refractory temperatures, allowing information to be transmitted instantly and can trigger alarms if temperature differences occur. Thermal imaging cameras can also be positioned underneath the melt tank to detect hot spots early on, potentially preventing a break-out below the tank. Infrared borescope equipment has been found to extend the lifespan of the melt tank and provide greater asset protection through more accurate temperature measurement. These recent advances in measurement technology are helping plants to make significant improvements in the melt tank process, both in the improved quality of output and in reducing operating costs. Thermal imaging technology that enables operators to maintain an accurate visual of the entire glass-melt tank, as well as take temperature measurements at any point in the process and in any location within the tank, can provide invaluable data for the operation of any modern glass plant. Following a complete survey of the melt tank, the recommendation may be for a permanently installed NIR-B or a transportable device for continued inhouse use. With an NIR-B installed, plants can reduce the risk of problems arising in the future as well as extending the furnace life.”
For more information on NIR-B Glass and its ability to measure temperature profiles inside furnaces, visit ametek-land.com.
22 Furnaces International June 2020
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ALUMINIUM 2020 13th World Trade Fair & Conference
Your personal de voucher co FI2020
GET YOUR FREE TICKET NOW 06 – 08 October 2020 Exhibition Centre Düsseldorf, Germany www.aluminium-exhibition.com/ticket
Officially supported by
Energy efficiency
Less dross and higher energy efficiency By Benjamin Köster*
Figure1. Two QUADRAFLO SWEEP© burner flame pattern
Over 65 installations of the QUADRAFLO SWEEP© Aluminium Melting System have shown various benefits compared to conventional air fuel and oxy fuel systems: � Proven Energy Saving 15-60%
The QUADRAFLO SWEEP© Aluminium Melting System is an oxygen based combustion system. Of course oxygen burners are generally more energy efficient than cold air or pre-heated air burner, but how is it possible to reduce the dross so drastically, when applying oxygen combustion technology? Aluminium, is the 3rd most abundant material in Earth’s crust. Aluminium metal has a strong affinity for oxygen and because of this affinity aluminium does not occur as a metal naturally in nature. Therefore you may ask how and why is it possible to use pure oxygen with natural
� Typical heat dross reduction
about 20% and more � Reduced cycle time and increased melting capacity � Low NOx and reduced CO2 emissions
gas to melt aluminium without increased oxidation. It is achieved through proper application of oxygen burner technology within an aluminium melting or holding furnace. XOTHERMIC Inc. has developed the QUADRAFLO Sweep© Aluminium Melting System. Instead of applying a burner used in other high temperature applications like glass, steel, copper or other related fields, XOTHERMIC researched aluminium melt applications and developed through field trials an optimal design. The QUADRAFLO SWEEP© Aluminium Melting Technology
� High bath coverage with less
burner installed � Extended furnace refractory
life time � Improved control
Figure 1
offers the highest energy efficiency, lowest dross formation for the best economics. Hotwork International has the license for the QUADRAFLO SWEEP© Technology, being a direct partner for the industry to apply this technology in cooperation with XOTHERMIC Inc.
Design philosophy Our initial penetration into the aluminium market was secondary aluminium Reverbratory furnaces. This is the traditional furnace utilised worldwide for both primary and secondary aluminium melting. It is primarily a
CEO, HOTWORK International AG www.hotwork.ag
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Energy efficiency
Figure 3. Reverb furnace with QADRAFLO SWEEP© burner
Figure 2. Burner block and typical set-up
refractory lined steel box with energy input from a combustion system, an exhaust port, cold metal charge port, in some cases a separate dross port and a molten metal discharge port. There are many configurations of this design, however the basic principle of operation is the same for all designs. A heat source from the combustion system transfers heat into the cold metal with sufficient force to cause the metal to retain the heat until the melting point is reached, on average 657 degrees C. During this process it is most desirable to do this heat transfer with minimum amounts of oxidation. Further heating is required to provide sufficient energy to maintain the aluminium in a molten state during the final end process of the production cycle, on average 750 degrees C. What causes excess oxidation? All aluminium forms an oxide layer from interaction with the oxygen in the atmosphere. This degree of oxidation depends on the age of the metal and its condition, such as paint, enamel or other types of passivation. This in most cases, is minor. The oxidation that is referred to is oxidation created during melting as a byproduct of the combustion process. Excess oxidation is generally generated from exposure of the cold charge to excessive heat and oxygen concentrations. How to prevent excessive oxidation? This is the main premise behind the design philosophy of the QUADRAFLO SWEEP©
49 mton tilting reverb Burner position
Air fire
Oxygen burner competitors
Quadraflo sweep
End wall
End wall
Roof
Cycle time (h)
13
11
8
Cycles per day
1.8
2.2
3
Melting capacity mt/d
42.5
50.2
70.5
Melting rate mt/h
1.8
2.1
2.9
Capacity increase`-
18.2
66
NG demand NM/mt
120
70
55
DROSS AVERAGE
8%
8%
7%
-
-
225.6
Metal savings per year mt
Figure 4. Table comparison
Figure 5. Reverb furnace with QUADRAFLO SWEEP© burner
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Energy efficiency
mounted QUADRAFLO SWEEP© burners utilize a greater area of the furnace for melting with a very even heat and no localized overheating, as the flame is not fixed in one spot. The charge pile melts down evenly with less oxidation. Post combustion, to compensate for hydrocarbon gases from burned off coating etc., can be achieved with the automatic control system. In addition to the production increase, a corresponding increases in energy efficiency and metal recovery can be seen. � Energy saving 15-25% � Dross reduction: 20-40% � Melt rate increase: 20-40% Figure 4 and 5
Tower melters
Figure 6. Tower Melter with QUADRAFLO SWEEP© burner
Aluminium System. We designed a burner system that minimized generation of a hot spot on the charge material. This was achieved with the use of a flat fishtail shaped flame that moved or swept across the charge. Another requirement is that burner velocities are low momentum to minimize disturbing the molten metal bath. The flame movement is up to a 45-degree angle. Moving the flame over a period of several seconds allows the heat to be transferred over a significantly greater area than a fixed flame. Fixed flame burners heat an area of the charge to excessive temperatures in an effort to transfer heat to other parts of the pile. This creates significant hot spots and greater dross formation. Also provided are flow control systems that maintain a very close tolerance on the oxygen to fuel ratio. This is vital as you are paying for the oxygen and therefore do not want to waste it, excess oxygen, even with air creates more dross. It must be understood that regardless of the oxygen source, air or pure oxygen, the excess oxygen is still the same, on the order of several percent. Because pure oxygen is used, does not mean the dross will go up. It is the excess temperature that has a greater effect. In fact putting a blanket of pure oxygen over a bath of molten aluminium at 657 degrees C and no flame will show little or no increase in dross over a blanket of air at 21 percent oxygen. Figure 2.
Application and experience As mentioned before, there are numerous reverb and other furnace designs therefore there is a demand for Individual design modifications unique to the particular furnace design and application.
Tilting reverb Regenerative to Oxygen Conversion Oxygen burners produce about 60-80% less exhaust gasses than an air burner as the nitrogen has been removed. This results in better energy efficiency, less NOX production and less gas to clean prior to exhausting to the atmosphere. The energy efficiency compared to regenerative burner can be as high as 50% better. On top, the furnace pressure can be reduced significantly, avoiding flames during high fire to damage refractory and furnace doors, etc. The Furnace generally operates cooler as with air fuel burner. Various conversation have proven: � Energy saving 35-40% � Dross reduction: 20-40% � Melt rate increase: 20-40% Figure 3
Oxygen to Oxygen Conversion Existing oxygen combustion system produce localized overheating and as a result increased dross. Low momentum QUADRAFLO SWEEP© Burners with full automatic controls are installed. The roof
The QUADRAFLO System also includes burners for Tower Melter. This Melter operates primarily with clean scrap and ingot. It is used primarily by continuous casters. This is not a batch operation nor is alloying done, most ingot is at specification. Because of this, it is possible to have a continuous pour operation. This suits the Tower Melter design very well. A major supplier of cast aluminium auto parts required an increase in capacity as there was insufficient room to add additional furnaces. In addition, emissions were a concern, therefore there was a need to minimize the pollutants from the process while increasing production. A tower Melter has a tall refractory lined shaft with a melt box at the bottom that serves as the main melt zone as well as preheat for the incoming charge and an exhaust conduit. The molten aluminium flows from the melt box into the holding chamber over a raised ledge. The holding furnace attached to the tower served only for holding with no melting. The initial design used an oxygen burner in one of the air fired burner positions. The production was increased from 1.4mton/hr to 2.1mton/hr or 50% with a reduction in dross by 1%. It was observed that greater yields could be achieved through the use of hot gas recirculation using an oxygen burner to heat the hot recycled gas as it entered the melt box at the bottom of the tower. The hot gas fan was provided by an outside supplier in conjunction to our burner technology. The increased volume from the recycle gas, which provided energy savings by coming in at 900 to 1100 degrees C, increased melt rate and reduced both
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Energy efficiency
Figure 7. QUADRAFLO SWEEP© burner hot face
energy consumption as well as dross. The melt rate was increased to 3.5 mton/ hr or 150% increase over the air burners. Dross was reduced significantly over 60%. The emissions were also within the legal limits set by the State. Figure 6
Holding/melting Many processors utilize two furnace that complement one another. One such application was for a Rotary/Holding furnace. The customer wished to increase holding capacity and add some melting capability to the holding furnace. The problem was that the holding furnace had absolutely no room for air burners and the bulk of the material to be melted was silicon for alloying and sows. The rotary was providing in excess of 80mtons per cycle to a holding furnace that was in excess of 120mtons. 10% of the holding furnaces capacity was charged as silicon as one charge. The solution was two 1800 kW nominal (900 to 3600) QUADRAFLO Automa tic Sweep burne r s mounted in the roof. After conversion from cold air fired burners and furnace enlargement there was a significant reduction in energy consumption and reduction in dross by 20%. The customer was impressed to the point of ordering a second system within a month and two new furnaces with the QUADRAFLO Automatic Sweep burners within the year. Additional customers have similar
system as well. Figure 7 and 8
Rotary furnaces One traditional furnace that has met with numerous improvements is the rotary furnace. With the advent of new and better refractory and the inclusion of oxygen burner technology, the Rotary Furnace has come of age. Depending on the application, rotaries come in either fixed bed or tilting designs. It can be used to demag aluminium, used for irony
scrap, dross processing and general scrap aluminium melting. We have found that providing a low momentum high luminosity burner that has an adjustable flame pattern as well as an adjustable bracket, it is possible to tailor the burner operation to the specific use for maximum energy efficiency, maximum metal yield with minimum down time. The bracket can be moved thus moving the burner placing the heat where it is needed and does the most good. Burner life is dependent on plant maintenance. Periodic cleaning of the area around the burner insures maximum life for the burner. A monitoring system can be installed for dirty scrap that allows an increase in oxygen to help burner up volatiles as they evolve off the charge. Additional features in our automatic control monitor when the charge is melted thus minimising metal loss by firing longer than needed and burning metal. Typically, one can expect the following benefits from converting to oxygen from air firing. These numbers are ranges as the type of material dictates the ultimate benefits from oxygen conversions. �
Energy saving 40-60% Dross reduction: 20-40% � Melt rate increase: 15-30% Our control system for any of these installations is fully automatic and can be expanded to cover such items as furnace pressure, temperature and associated items such as bag houses for emissions control. �
Fig 8. QUADRAFLO SWEEP© typical flame
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Energy efficiency
furnace pressure, door opening and closing, bag house monitoring to name some common additions. The customer’s furnace design and control is often incorporated into the touch screen displays for convenience. Figure 9
Conclusion
Figure 9. QUADRAFLO SWEEP© burner typical skid on roof installation
Process controls and instrumentation Hotwork and XOTHERMIC utilises state of the art combustion control equipment with various types of PLC controllers and HMI touch screens. Electrical and mechanical systems are CE rated for European compliance. Flow sensing is from 0 to maximum flow with a high
degree of accuracy. Ratios and temperature control is by PID control. NEMA 12 rated electrical enclosures are used to protect the electrical components. Upon request by the customer we incorporate into the control system other mechanical and electrical components of the furnace. Chlorine injection monitoring and control, molten metal pump control,
Today, focusing on environmental friendly production and products, such as lighter products in vehicles and air crafts, we at Hotwork International facing these challenges with our oxy-fuel aluminium Melting Technology. With lower emissions and higher efficiency, the QUADRAFLO SWEEP© burner assists customers in reducing their CO2 footprint, getting credits and improving production all at the same time. We continuously work on further improvements, based on client’s requests and feedback. Recent improvements to the system make installation and operation much more simple and cost effective. During the past few years, these improvements and upgrades have resulted in improved performance, longer part life and increased safety.
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FIC ads 2019_Layout 1 15/11/2019 10:01 Page 2
, Tomorrow s Technology Today
Are you interested in CO2 reduction? Come to FIC for superboosting and large all-electric furnaces – we have the answers to reduce carbon footprint
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GLASS SERVICE
A Division of Glass Service
FEVE
Container glass to reduce CO2 by 5 For the first time ever, European container glass manufacturers come together to build the first large scale hybrid electric furnace to run on 80% green electricity.
Brussels, embargoed until 16 March 2020 at 9h00 a.m. BXL Time The ‘Furnace of the Future’ is a fundamental milestone in the industry’s decarbonisation journey towards climateneutral glass packaging. It will be the first large-scale hybrid oxy-fuel furnace to run on 80% renewable electricity in the world. It will replace current fossil-fuel energy sources and cut CO2 emissions by 50%. For the very first time, the industry has adopted a collaborative approach where 20 glass container producers have mobilised resources to work on and fund a pilot project to prove the concept. “We are extremely proud to announce this joint-industry project”, comments Michel Giannuzzi, President of FEVE. “The hybrid technology is a step-change in the way we produce and will enable us to significantly reduce the carbon footprint of glass packaging production.
The move marks an important milestone for the glass sector in implementing our decarbonisation strategy”. The industry already works with electric furnaces in several of its 150 glass manufacturing plants across Europe, but they are small scale and exclusively used to produce flint (colourless) glass with virgin raw materials, therefore using very little or no recycled glass content. With this new technology, the industry will be able to produce more than 300 tonnes per day of any glass colour, using high levels of recycled glass. Ardagh Group – the second largest glass packaging manufacturer in the world – has volunteered to build the furnace in Germany. It will be built in 2022, with an assessment of first results planned for 2023. “With this new technology we are embarking on the journey to climateneutral glass packaging, and ensuring
the long-term sustainability of manufacturing”, states Martin Petersson, CEO of Ardagh Group, Glass Europe. “We aim to demonstrate the viability of electric melting on a commercial scale, which would revolutionise the consumer glass packaging market”. Bringing the ‘Furnace of the Future’ to life is an extremely ambitious project requiring significant financial and human resources and a wide range of expertise. For this reason, the industry has committed to work together. By adopting a sectoral approach, it also intends to gain the support of the European Commission through the ETS Finance for Innovation Fund Programme. Despite its key importance, this project is not the only one the industry is working on. Other pathways towards clean production technologies and climate-neutral glass packaging are already implemented and others are also being explored.
1. ABOUT THE PROJECT. WHY IT MATTERS: Today, the use of electricity as the main energy source in the container glass industry is limited to small-scale furnaces for flint (white) glass without the use of recycled glass. The new technologies will address these limitations. By replacing 80% of the natural gas with green electricity, the technology reduces the furnace emissions by 60% or 50% of the total CO2 emissions of a container glass factory. For the first time ever, this project will
bring together the best engineers from 20 glass container manufacturers to demonstrate that this can be done. The technology will allow the industry to use high rates of recycled glass which is currently not possible with electric furnaces. For each additional 10% of recycled glass in the furnace, there is an additional reduction of CO2 emissions by 5% and energy consumption by 3%. The hybrid technology flexibility can switch to other sources of energy in case
of supply issues. This will guarantee no disruption to production. The additional cost (Capital Expenditure and Operational Expenditure) of a hybrid furnace compared to a conventional furnace are estimated to be up to 40 MEur over the 10 Year lifetime of the furnace. This is mainly due the cost of electricity compared to natural gas (about three times higher per MWh).
steps will be to select a furnace supplier, to apply for a grant to the EC Innovation
Fund and set up a new legal entity to manage the project.
TIMELINE: The Demonstration Project will be built in 2022 with first results in 2023. The next
30 Furnaces International June 2020
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FEVE
50% 2. LIST OF THE 20 “THE FURNACE OF THE FUTURE” FOUNDING MEMBER COMPANIES (AS OF 16 MARCH 2020) Allied Glass
www.alliedglass.com
SGD
www.sgd-pharma.com
Ardagh Group
www.ardaghgroup.com
Steklarna Hrastnik
www.hrastnik1860.com
BA Glass
www.baglass.com
Stoelzle
www.stoelzle.com
Beatson Clark
www.beatsonclark.co.uk
Verallia
www.verallia.com
Bormioli Luigi
www.bormioliluigi.com
Verescence
www.verescence.com
Gerresheimer www.gerresheimer.com
Vetreria Etrusca
www.vetreriaetrusca.it
GCA Gürallar Cam Ambalaj
www.gca.com
Vetropack
www.vetropack.com
O-I Europe
www.o-i.com
Vidrala
www.vidrala.com
Pochet
www.groupe-pochet.fr
Wiegand- Glashüttenwerke GmbH www.wiegand-glas.de
Saverglass
www.saverglass.com
Zignago Vetro
www.zignagovetro.com
About FEVE FEVE is the Federation of European manufacturers of glass containers for food and beverage and flacons for perfumery, cosmetics and pharmacy markets. Its members produce over 80 billion glass containers per year. The association has some 60 corporate members belonging to approximately 20 independent corporate groups. Their 160 manufacturing plants are located across 23 European States and maintain 125.000 direct and indirect jobs along the total supply chain. See more at www.feve.org.
For further information, please contact: Fabrice Rivet, Technical Director, FEVE f.rivet@feve.org, Direct Line: +32 (0)2 536 00 83 Michael Delle Selve, Senior Communication Manager, FEVE m.delleselve@feve.org, Direct Line: +32 (0)2 536 00 82, Mobile +32 475 52 24 58
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Furnace modernisation
Grasping the benefits of modern he Furnace and heat treatment technology continues to develop rapidly, and modern solutions are leaving older equipment and facilities in the dust in terms of energy-efficiency, temperature control and meeting industry requirements and quality standards. Whilst a new, custom-tailored modern furnace solution often provides a way to catch up, it is not the only way to grasp
the benefits of modern furnaces. Furnace modernization is often a suitable and cost-effective method to achieve capabilities for heat treatment operations fulfilling the strict heat treatment requirements & standards expected by industry leaders today, especially those that are processing mission-critical parts. Heatmasters recently provided a client
with a furnace modernization solution which allowed them to move from an old gas-burner furnace to a modern electric furnace. Like all of our solutions, it was custom-tailored to meet their needs whilst providing all the benefits of a modern furnace and temperature control system. Our client had decades of know-how and experience with surface treatment and coating processes, specializing in
1. The old furnace was in poor condition prior to the modernization.
1
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Furnace modernisation
eat treatment furnaces professional surface treatment with Teflon- and fluoroplastic coatings. Their coating solutions are utilized across all industries, which means their processes and equipment need to meet the expectations of their clients and rigorous quality standards. The client’s surface treatment facility utilized an outdated furnace with gas-burners to heat metal parts. Heating was done to ensure that
there were no contaminants such as dirt and grease prior to the application of surface coating. Size of the furnace is 5x2,5x2,5m (16,4x8,2x8,2ft) with a maximum operating temperature of 500°C (932°F).
What was the issue? The client shared their concerns related to this furnace with our team of heat
treatment specialists. The furnace was unreliable and had issues with temperature uniformity. The fact that the furnace was fueled by gas was also an issue as it required additional permits. And this furnace was quite old, which meant it lacked the energy efficiency of modern furnaces and cladding was in poor condition. The temperature control system was also outdated.
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Furnace modernisation
2
2. The modernization process was completed by our heat treatment specialists at the customer’s facilities.
The old furnace was in poor condition prior to the modernization.
What did we do? After discussing and mapping the needs of our client and careful analysis of the old gas-burner furnaces condition, Heatmasters decided that the best route of action was to modernize the furnace into a modern electric furnace with convection heating. This modernization was done locally, at the client’s surface treatment facility. The modernization process was completed by our heat treatment specialists at the customer’s facilities. During the furnace modernization process, all gas-burners and related equipment were removed as the new furnace would no longer be fueled by gas. The rest of the furnace was dismantled down to its frame and new insulation and cladding were installed to ensure optimal energy efficiency. Electric heating elements were installed along with convection blowers to ensure even heat distribution during the heating process. Naturally, all electrical systems and electric cabins were also installed to meet today’s standards. The modernized furnace is supported by
Heatmasters’ modern temperature control system, ensuring accurate monitoring, wireless control of the heating process and digital documentation of the heat treatment process among other perks such as receiving heating status updates & alarms to your mobile device worldwide. The gas-burner furnace was converted into an electric furnace utilizing convection heating. The “new” furnace will provide our client with: � Higher energy efficiency and associated cost savings � Accurate heating through the integration of modern temperature control system � Reliable electric heating, as the gas fuel option was no longer suitable for the customer They are pleased with the new furnace and we enjoyed working with them during the process. We look forward to future cooperation and ensuring the furnace continues to operate flawlessly by providing regular furnace maintenance services and upgrades according to their future needs. “We are pleased with the results and
flexibility during the project. Our needs for the features and usage of the furnace were well understood by Heatmasters.” - Managing Director of our client. New furnace cladding and insulation material installed to ensure optimal energy efficiency. In addition to our refurbishment, upgrade and maintenance services, we design custom-tailored heat treatment furnaces to meet your needs. Heatmasters also provides temporary, modular furnace solutions for heat treatment at your facility, anywhere in the world. “Heatmasters is headquartered in Hollola, Finland and globally provides a wide range of flexible heat treatment and industrial services in addition to innovative heat treatment equipment such as furnaces, transformers & control systems. Heatmasters delivers only the highest-quality solutions to greenfield and maintenance projects in oil refineries, power plants, nuclear power plants, pulp mills and chemical plants whilst meeting all industry requirements & job regulations by following their integrated quality management system (ISO9001/ ISO45001/ISO17663).”
Visit the website: www.heatmasters.net/en/ 34 Furnaces International June 2020
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Furnace modernisation
3
“We are pleased with the results and flexibility during the project.
�
Our needs for the features and usage of the furnace were well understood by Heatmasters. - Managing Director of our client.
4 3. The gas-burner furnace was converted into an electric furnace utilizing convection heating. 4. New furnace cladding and insulation material installed to ensure optimal energy efficiency.
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35 Furnaces International June 2020
Refractories
Robust Anchor Design: Three impor Refractory Engineers’ and Managers’ Best Tips on Metallic Anchors
It is estimated that up to 40% of refractory lining failures can be attributed to a problem with the design of the anchor system or improper installation. This is a significant number. When designing a refractory lining for an industrial application, anchor design becomes one of the most important factors in creating a robust lining that is supported properly. In particular, the tips of the anchors experience the highest temperatures because they are closest to the hot face and thus become an important consideration. Anchors have several functions. They hold the refractory to the wall to keep it from falling in. They also prevent wall buckling due to the internal thermal stresses created by high temperatures. And, to a lesser degree, anchors can also help support the load of the refractory weight. To create a monolithic refractory lining that is properly supported and maximizes service life, here are three important metallic anchor tips you need to know.
Anchor Types and Service Temperatures For refractory linings in which metallic anchor systems are used, refractory engineers and designers almost always use Class III austenitic stainless-steel anchors of various qualities. The typical grades of stainless steel used are AISI 304, 309, and 310. These contain chromium and nickel to provide the best corrosion resistance and ductility at high temperatures. For some applications in which temperatures are more extreme, and the use of ceramic tile anchors is not practical for various reasons, AISI 330 and even Inconel 601 is sometimes used. These anchors have higher nickel content for superior oxidation resistance and tensile strength at temperatures of 2000°F or higher. Inconel 601 gives the added advantage of good resistance to both carburization and sulfidation in extreme applications.
Anchor type
Service limit (°F)
Mild Steel
800
304 SS
1700
309 SS
1850
310 SS
2000
330 SS
2100
Inconel 601
2200
Figure 1.0. Recommended anchor tip temperature limits for various common alloys
depends on the refractory thickness and number of components. Some designers use the practice of sizing the anchor height to be 75%-85% through the main dense castable or gunned lining. Other rules of thumb used in the industry dictate that the anchor tip should be no more than two inches from the hot face of the refractory for thicker lining designs greater than 6”-7”. For refractory applications, it is useful to know the temperature gradient through the refractory lining, from the hot face to the cold face, to choose the proper anchor size so that one doesn’t exceed the temperature limit of the alloy being used. To help calculate the correct temperatures at different points in the refractory lining, many industry professionals will use a heat loss calculator/estimator. Using a heat loss calculator/estimator, one can choose the
proper anchor height by determining the anchor tip temperature it will experience. There are numerous heat loss applications that can estimate the cold face of a furnace lining given the input conditions of a thermal unit. As part of its valueadded service as a refractory solutions provider, Plibrico Company, LLC, has a web-based heat loss application that gives a good estimation of the thermal gradient of the refractory lining from hot face to cold face to maximize the anchor thermal performance. For example, look at figure 2.0. You can see a 9” side wall of refractory lining using 6” of a typical 60% alumina low-cement castable and 3” of 2300°F lightweight insulating castable for an application operating at 2000°F with an ambient temperature of 80°F. For this application, we would select 309 SS or 310 SS metallic anchors because the intermediate temperature at about 80% of the main lining thickness is at about 1900°F. Although 304 SS anchors would be more cost effective and are most commonly used in the industry, the anchor tips would oxidize at this temperature and would essentially burn out.
A Word on Anchor Tips Standard practice for a years now has been to allow for expansion of the anchor tines by covering the anchor tips with plastic
Figure 2.0: Typical refractory anchor lining configuration
Industry Best Anchor Practices Anchor sizing for a refractory lining
36 Furnaces International June 2020
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Refractories
rtant things you need to know caps, dipping them in a wax, or putting tape on them. Metallic anchors expand at about three times the rate of aluminosilicate refractories. The expansion material affixed to the anchor tips burns out at low temperature and allows the anchor a space to expand without causing cracks in the refractory. Best practices in metallic anchor design also must include anchor spacing. Greatly a function of the specific equipment and geometry size, refractory engineers must consider the specific installation area. For example, anchor spacing patterns will be different in a flat wall or roof, as compared
to a section that has a transition of geometry or a less critical area of a vessel. Anchor spacing should be based on the features of each specific project, such as mechanical properties of the anchor, and the refractory lining as a function of the temperature. Refractory engineers will use these properties in mathematical models to help create the optimal anchor spacing pattern and plan. Often, failures commonly attributed to the refractory component can, in fact, be caused by deficiencies in the anchoring system. A robust anchoring system is key
to maintaining monolithic refractory lining integrity, even when it is cracked, to prevent a total structural collapse. To prevent vessel lining failures, increase service life, and maximize refractory performance, incorporate these metallic anchor tips. With these tips, it is possible to design and optimize an anchoring system that will work well with the demanding needs of refractory linings today. Author: Dan Szynal, Vice President of Engineering and Technical Service for the Plibrico Company
For more information about metallic anchors and refractory anchoring systems contact the Plibrico Company at contact@plibrico.com or 312-337-9000.
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Refractories
Energy saving designs Kenji Matano* discusses how refractories can save energy based on their designs. Energy efficiency has a big impact on glass manufacturing costs and has been of major interest for a long time. There is also a strong desire to reduce environmental load such as carbon dioxide emissions. For glass melting furnaces, insulating materials can be a key solution. Improvements to the insulating structure may cause serious damage such as accelerated corrosion or melt down of refractories located on the inside of the furnace, therefore insulating design should be done carefully using tools such as heat calculation by computer simulation.
Conventional insulating materials Insulating materials such as blankets and boards are widely used for glass melting furnaces because of their low thermal conductivity and high usability. They contain Refractory Ceramics Fibre (RCF). It is reported that RCF shrinks even under the service temperature because of crystallisation. Bio Soluble Fiber (BSF) that doesn’t contain RCF is also used; however it has the same behaviour as RCF at a high temperature. As a result, heat loss from furnaces increases during operation because crystallisation gives the insulating material a dense structure therefore leading to increased thermal conductivity. RCF is categorised as Probable Human Carcinogen in several countries. This means it has restricted use.
AGCC’s approach AGC Ceramics (AGCC) developed an insulating material named Thermotect. It is a monolithic refractory which achieved high thermal resistance and glass vapour resistance without using RCF, meanwhile since they are flexible monolithic materials, it can be applied easily to complex parts. In addition, it consists of AGCC’s originally developed fused ceramics
Service Temperature [°C]
1600°C Grade
Installation Quantity [ton/m3]
1300°C Grade
1.00
1000°C Grade
0.95
0.45
SiO2
<1 13
39
Chemical Composition [%]
83 69
39
6 4
-
Al2O3
ZrO2
110°C×24h 2.5 4.5
Cold Crushing Strength [MPa] 1000°C×3h
1.0
2.1
1.1 0.9
1600°C×3h 2.5 -
-
Thermal Conductivity [W/m-K]
at 500°C
0.48
0.46
0.16
at 1000°C
0.54
0.50
0.31
Table 1. Property of Thermotect series
particle, using recycled materials generated from its plant, meaning it contributes to reduced emission. The Thermotect series has three types of products according to service temperatures (Table 1). To obtain the optimal insulating wall, it is necessary to choose the most suitable materials depending on operating temperature and subsequent design multilayer insulating wall.
was measured. As a result, the RCF 1260˚C grade shrank 6% at 1200˚C, the BSF 1200˚C grade shrank more than 10% at 1200˚C . The Thermotect 1600 and 1300 grade had little or no shrinkage up to its maximum service temperatures. Meanwhile, mineralogical compositions of these samples were analysed to determine the chemical reaction that caused the shrinkage. Before heating, RCF and BSF consisted mostly of non-crystal. After the test, mullite was formed in the RCF samples, and Cristobalite, Tridymite, Wollastonite and Enstatite was formed in the BSF samples respectively. On the other hand, the Thermotect 1600 and 1300 grade had no change in its mineralogical composition.
Stability Heating up tests were performed to evaluate the stability of insulating materials at a high temperature (Figure 1). The insulating materials were kept for 100 hours at each temperature, and after cooling, the linear shrinkage rate
Conventional design Material
New design
Thickness(mm)
Material Thickness(mm)
Seal material
40
TMT-1600
210
Bonding bricks
65
TMT-1000S
150
Insulating bricks
130
Blanket (RCF)
Insulating structure
100
Total
335
Total 360
Temperature on outer face (°C)
109
101
Diffused heat loss (W/m2) 1442
1264
Decreasing rate
12%
-
Total weight of insulating materials Kg/m2) 438
280
Decreasing rate
36%
-
Table 2. Crown insulating design of oxy-combustion furnace. Crown material: fused cast AZS, Temperature inside: 1600°C ambient: 30°C
* Manager, Material Development Group, Development Center, AGC Ceramics, Japan https://www.agcc.jp/
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Refractories
Installation in actual furnaces Optimal insulating design depends on the operating condition of each furnace. AGCC proposes the design with the Thermotect series for each furnace by using heat calculation in advance. It is possible to reduce energy consumption by 2% to 3% in comparison with conventional ones. Furthermore, in the case that took account of deterioration on conventional insulating materials, the margin will expand more because the Thermotect series is expected to keep good insulating performance over the long operation. The Thermotect series was installed in various parts of actual glass melting furnaces such as melter crowns, breast wall, ports and regenerator wall (Figure 3).
30% BSF 1200°C grade 25% BSF 1250°C grade Linear shrinkage rate (%)
In addition, a glass vapour corrosion test was performed (Figure 2) because corrosion resistance against glass vapour is one of the main development targets of the new materials. As a result, there was no change in appearance, bulk density and mineralogical composition therefore they were expected to keep good insulating performance during furnace life.
20%
THERMOTECT 1300°C grade
15%
THERMOTECT 1600°C grade
10%
Figure 1. Heating up test of
5%
insulating materials 0% 1000
1100
1200
1300
1400
Temperature (C°) Dwell time 100 hrs
THERMOTEC 1600°C GRADE METHOD Temperature Time: 2 days 1500 [C°] Temperature: depending on samples
1300°C GRADE 1250
Test sample Platinum crucible Soda lime silicate glass
Before => After Reaction face
Melter crown As the result of the heat calculation for oxy-combustion melter crown with a fused cast refractory blocks, the new insulating design was decided (Table 2). Although thickness is almost the same, the weight of new design was lighter, and diffused heat loss from the outer surface of the crown was less than a conventional one. The new design was installed in several live furnaces. It was carried out by means of the precast block method for quick installation, on the other hand it is also possible to install through casting and troweling methods. The pre-cast blocks, casted and dried in advance, were installed on the fused cast blocks. Subsequently, clearances between the pre-cast blocks were casted by monolithic materials of Thermotect. This meant that heat loss from joint gaps could be reduced compared with the conventional design which had much joint gaps of insulating bricks. After four years from the start of operation of the furnace, the new insulating wall didn’t have any deterioration and kept good insulating performance. AGCC also developed the new
Figure 2. Glass vapour corrosion test
Figure 3. Installation records of the Thermotect series
Crown Port
Reg. wall insulating design for air-combustion melter crown with silica bricks and installed it in the actual crown. As a result, it was confirmed that the insulating performance kept as it was designed in
Hybrid structure of breast wall the long term. Therefore, the new insulating designs are expected to keep the insulating performance during the whole life of these furnaces.
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Refractories
A software to compare crowns Santiago Suarez Arango* & Manuel Alejandro Parra Rangel** provide the results of CFD software looking at four different case studies putting monolithic against traditional brick furnace crowns.
Figure 1
The need of a higher thermal efficiency in melting glass processes guides companies to look for improvements in any area. For Magneco/Metrel this topic is of a big concern too and itâ&#x20AC;&#x2122;s for that reason that it has continuously improved its methods and materials to offer the best option to build more efficient glass furnaces in the market. This paper describes the results obtained in a 3D modeling and simulation by the use of a CFD software in which the heat transfer and energy losses in the crown of a glass furnace are analysed in four different configurations:
1. Case of study: Monolithic crown with insulation 2. Case of study: Monolithic crown without insulation 3.
Case of study: Traditional brick crown with insulation
4.
Case of study: Traditional brick crown without insulation
The main objective of this study is to perform the heat transfer analysis specifically in the crown of an end port glass melting furnace by using CFD software to identify the main differences between thermal behaviours of a monolithic crown versus a traditional one, Figure 1 shows the furnace crown general arrangement.
Figure 2
*Vice President Sales, Latin America, Magneco/Metrel Inc ** Operations Manager, IPM de Tlaxcala S.A.S.
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Refractories
Development of the study Based on the technical specifications granted to carry out the modeling, materials from different trademarks were selected; choosing those whose physical properties were public knowledge, used insulation is listed on Fig. 1 detail D, monolithic refractory used for the modeling was Metsilcast from Magneco/ Metrel and GEN-SIL blocks were used for simulating traditional construction crowns.
Case study one shows that temperature distribution on the cold face of the crown is homogeneous for most of the surface and that the only area where a considerable difference in coloration is seen in the corners where temperature is lower than that of the rest of the crown. Case study three shows temperature profile on the cold face of the traditional crown where is observed that temperature distribution is relatively homogeneous, however, lines can be appreciated in a
different hue that indicate an increase in temperature in these areas, due to the leakage of heat through spaces/joints between blocks. On the other hand, a higher temperature in the cold face of a surface means energy losses. Fig. 3 shows it is possible to appreciate the heat flow outside the furnace crown in both scenarios (Monolithic vs traditional configuration) with insulation, an interesting difference is noticed.
The parameter established as border conditions for carrying out the study of heat transfer in the four study cases were: � Ambient temperature: 40°C � Crown convection coefficient: 9 W/m2K � Gas flow at the entrance: 10 m3/s � Pre-heated air flow: 6.6 m3/s � Gas temperature at entrance: 1726.85°C � Pre-heated air temperature: 1250°C
These values were determined from the scientific literature consultation due to the difficulty of getting complete technical information first hand. A temperature of 1726.85°C (2000°K) corresponds to the maximum flame temperature which decreases longitudinally and transfers heat to the glass surface and furnace structure (O.H. Díaz, 2011). Temperatures of 1250°C correspond to the pre-heated air of the regenerative chamber, by combining these, an average temperature of 1500°C is obtained inside the furnace. For analysis purposes, in the simulation are only considered near-reality values and results for the crown case, walls may not correspond to values close to reality due to they are not considered in the border conditions in this specific case of study.
Figure 3
Results comparison Once the results of both case studies were obtained, a comparative analysis of one with respect to the other was carried out with the purpose of identifying the main differences between the thermal and energy behaviour of a traditional crown constructed with blocks and a monolithic one, Figure 2 shows the different temperature scenarios in the cold face of the crown with insulation.
Figure 4
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Refractories
From the analysis of both thermal profiles it can be defined the next observations and differences: � Monolithic crown has a relatively homogeneous temperature distribution on the cold side, unlike the traditional crown that has higher temperature points which coincide with the joint areas.
Figure 5
� Average temperature in the monolithic crown is 140°C while the traditional crown is 195°C, it means a difference of 45°C which indicates there is a greater heat loss in the traditional crown as a result of the existence of joints. � Traditional crown has more hot spots which in real conditions generates accelerated wear of the working refractory
and, in turn, a deterioration of the installed insulation.
Comparison of results between case studies two and four In the same way as the comparison of cases one and three, a comparative analysis was carried out between the thermal and energy profile results of case of studies two and four, Figure 4 shows the thermal profile of furnace crown in configuration monolithic versus traditional but this time without insulation (note that higher temperature observed on the surface to the crown corresponds to the expansion joint). In the case of study two, the heat distribution on the external surface of the crown is not homogeneous since it has higher temperature zones located at the lateral and front ends of the crown corresponding to the flue gas flow inside the combustion chamber. For the case of study four the images show that the temperature distribution is not homogeneous as spots of a different colouration are seen in different areas of the crown, sections with a red coloration indicates hot spot which are result of heat leakage through the spaces between blocks. Note that the union of the crown with the back wall shows a colder area attributing this effect to the location/ proximity of the ports where the start/end of the flame is held (lower temperature).
After analysis of thermal behavior, the following observations and differences were defined: � Although no homogeneous distribution was observed in either case, it is important to emphasize that a smaller number of hot spots were identified in the monolithic crown � Average temperature observed in the monolithic crown is 390°C and 420°C in the traditional one, this confirms that the traditional crown has more heat losses and in turn negatively affects the thermal efficiency of the furnace � Traditional crown has hot spots up to 512°C in the central zone (expansion joint), this means, 80°C above the average temperature which indicates that in real conditions this zone would have an accelerated refractory wear Figure 6
�
The un-insulated monolithic
42 Furnaces International June 2020
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Refractories
crown holds better the heat inside the furnace due to the inexistence of joints in comparison with the traditional crown (case study four)
Figure 5 show the comparison between energy profiles results of cases two and four (monolithic versus traditional crown without insulation). An additional analysis was carried out when making the modeling regarding temperature and flow behavior of the gases inside the furnace. Figure 6 observes a higher thermal efficiency and a more laminated flow of gases can be granted in the case 1 corresponding to the Magneco/ Metrel’s Metsilcast monolithic crown with insulation and the crown with bigger energy losses thus like more turbulent flow corresponds to the traditional blocks crown, this last arrangement also means a risk of condensation, accelerated wear of the refractory and a higher energetics consumption.
Conclusion From the mentioned comparisons it can be concluded that: � A monolithic crown has a higher thermal efficiency than a traditional crown. � A traditional crown without insulation has a large number of hot spots which in turn can become critical hotspots due to the high temperatures reached in these areas. � A monolithic crown with insulation contains better the heat inside the furnace obtaining a temperature in cold face from 40 to 50°C lower than the temperature on a traditional crown. � In a practical case, a monolithic crown requires lower insulation thickness in order to get the same temperature in the cold face that a traditional crown (higher thermal efficiency). �
It was found that a traditional
crown has an average heat flow (energy losses) to the exterior of 4651.35 W/m^2, this means a 535% above the monolithic crown with insulation (869.84 W/m^2); this is attributed mainly to the losses observed on the expansion joints thus like in joints between blocks. � If removing the sampling points corresponding to the expansion joint, would be observed an average heat flow in the traditional crown with insulation of 3839.84 W/m^2, this means a 429%above the average heat flow of the monolithic crown with insulation (893.48 W/m^2). More information regarding the complete analysis (temperature, energy losses, gas flow, gas temperature, temperature gradients along cross sections, energy savings percentages, dynamic simulations, and others) can be gained by contacting Magneco/Metrel Inc. where a professional specialist can assist to get a specific technical/ commercial proposal which suits your process.
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Safety
Protecting What Matters Cultivating a culture of safety with the right products and partnerships By Chris Jones, Bricking Solutions Lead Engineer*
Employee safety is an important factor in every industry. According to the International Labor Organization, more than 2.78 million people die as a result of occupational accidents or work-related diseases each year. The organisation tracks a further 374 million non-fatal work-related injuries a year, as well. High-risk applications — where people are operating heavy machinery, manoeuvring large loads, or working in confined spaces, overhead or at heights — account for a significant percentage of these injuries. The U.S. Bureau of Labor and Statistics reported nearly 200,000 non-fatal occupational injuries and illnesses in the construction industry alone in 2018. Though refractory installation techniques and equipment have evolved over the years to offer increased safety, there are still a number of risks involved with the process. Cultivating a culture of safety on the jobsite is key to making sure every shift ends without incident. To help further on-site efforts, original equipment manufacturers have often been at the forefront of safety initiatives in the refractory industry, providing innovative equipment that addresses the specific risks of refractory installation. Working with these industry-leading manufacturers can result in a number of safety- and productivity-enhancing options specialised for refractory applications. Additionally, they provide a safety-conscious partner for continued support.
A Culture of Safety An abundance of equipment options means contractors and facility managers can easily incorporate safety enhancement
into their current process. However, to build a culture of safety, it’s important to create partnerships with manufacturers that share the same commitment. Rather than simply meet prescribed standards, industry-leading manufacturers strive to exceed these guidelines. They carefully engineer and test products as well as offer continued support long after the initial purchase, ensuring long-term safety.
Design A quick comparison of design features can help evaluate a manufacturer’s commitment to safety. Start with materials. Equipment manufactured with 6061-T6 aircraft aluminium offers the best strength-toweight ratio, providing the durability of steel at a third the weight. However, welding aluminium products requires certified aluminium welders and specialised equipment, limiting its use by in-house engineers and certain manufacturers. Incorporating this lightweight material into designs, though, has a number of safety benefits. Modular pieces created with heavy-duty aluminium are lighter and easier to assemble, reducing risk of physical strain. Additionally, the material’s strength can produce a high safety factor when combined with highquality engineering. For example, some parts of the world allow workers to enter before refractory and coating is removed. These operations can employ safety cages and personnel tunnels available from a number of manufacturers, but not all models offer the same degree of protection. A safety cage manufactured with 6061-T6 aluminium, is strong enough to protect workers from
debris up to 140 kilograms (250 pounds) falling from a height of up to 2.4 meters (8 feet), while still being light enough for two people to manoeuvre. Additionally, industry-leading manufacturers also use aircraft grade aluminium for custom-designed kiln access ramps. This equipment takes into account challenges presented by an operation’s burn floor, cooler and kiln and can support as much as 6,804 kilograms (15,000 pounds) live load, increasing protection for workers and equipment moving across the ramp. A review of other standard features can also help differentiate more safetyconscious manufacturers. With the majority to refractory installation contractors opting to use a bricking machine, there are a number of models in operation around the world that offer varying degrees of safety. Originally designed to reduce physical strain and safety risks compared to traditional installation methods, such as pogo sticks, mechanical jack screws, gluing, and jack and timber, many decades-old, first-generation bricking machines can still provide basic protection for workers, as long as they are well maintained. However, newer models provide the most innovative and cutting-edge technology, such as adjustable dual-arch systems with pneumatic cylinders to push bricks into place, greatly reducing the risk of injuries from unsupported material overhead. Machines featuring ergonomic design elements further increase worker comfort and safety. For example, some models offer a cut-away section for unobstructed access to the keying area to increase ease and visibility for closing out a ring. Additional safety features are also
*Chris Jones is lead engineer for Bricking Solutions, a world leader in kiln refractory installation solutions.
44 Furnaces International June 2020
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Safety
Industry-leading original equipment manufacturers strive to exceed prescribed safety standards, rather than simply meet them, by carefully engineering and testing products and Chris Jones is lead engineer for Bricking
offering continued support to ensure
Solutions, a world leader in kiln refractory
long-term safety
installation solutions.
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Safety
Equipment manufactured with 6061-T6 aircraft aluminium offers the best strength-to-weight ratio, providing the durability of steel at a third the weight. For example, a safety cage manufactured with this material, is strong enough to protect workers from debris up to 140 kilograms (250 pounds) falling from a height of up to 2.4 meters (8 feet), while still being light enough for two people to manoeuvre
46 Furnaces International June 2020
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Safety Newer model bricking machines provide the most innovative and cutting-edge technology, such as adjustable dual-arch systems with pneumatic cylinders to push bricks into place, greatly reducing the risk of injuries from unsupported material overhead
Comprehensive and continuous testing is another way top-tier manufacturers ensure equipment meets or exceeds safety standards. With a bricking machine, for example, stress modelling and static load testing is used to identify any design flaws that could lead to equipment failure
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Safety
Safety features contractors should look for include fall guards, railings, kick plates, non-slip surfaces and stainless-steel netting. Standard inclusion of these features indicates engineers have carefully considered real-world applications during the design phase and developed products with the human element in mind
available from specialised manufacturers, including non-slip decks, dual braking systems and fall guards. Other design elements contractors should look for include fall guards, railings, kick plates, non-slip surfaces and stainless-steel netting. Standard inclusion of these features indicates engineers have carefully considered realworld applications during the design phase and developed products with the human element in mind. Dropped tools, pinch points, distracted workers and other common jobsite mishaps are given as much attention in design as overall function. This intuitive engineering requires a thorough understanding of not only refractory installation techniques, but the men and women on the jobsite, and is often a hallmark of equipment from manufacturers with a long history in the industry. Custom design is also worth mentioning when it comes to evaluating equipment safety features. Working directly with a manufacturer for tailor-
made equipment means site-specific concerns can be addressed in design. For example, a factory in South Carolina needed to safely transport materials using a narrow ramp. To make sure there was no risk of accidently driving equipment over the edge and falling into the cooler, the manufacturer included a 406-millimetre (16-inch) curb guard on its customengineered access ramp.
Testing In addition to thorough design, comprehensive and continuous testing is another way top-tier manufacturers ensure equipment meets or exceeds safety standards. A number of live and simulated tests are performed throughout the design and manufacturing process. With a bricking machine, for example, stress modelling and static load testing is used to identify any design flaws that could lead to equipment failure. Movable parts, such as brick arches using a trolley system, are also tested in real-world scenarios to
ensure safety. A drop test will determine if safety cage crumple zones will perform within specification. Each product is put through a battery of tests based on its function. While some manufacturers are satisfied if equipment passes initial tests, others continue to analyse and adapt. Incident reports from around the world are reviewed and recreated to see if a similar problem could arise. Additionally, safetyconscious manufacturers work with customers to make sure their concerns are considered from every angle and the products are rigorously tested to everyoneâ&#x20AC;&#x2122;s satisfaction.
On-going Commitment to Safety Some manufacturers take their commitment to safety a step farther. In addition to continued product testing, they offer on-site equipment inspections, parts and service to ensure long-term safety. For bricking machines, manufacturers recommend inspections every three
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Safety
years or five uses. After eight years, ongoing annual inspection is encouraged. A technician conducts a visual evaluation as well as dye penetration tests on all welds. Depending on the model, they will also check additional features, such as valves on machines with pneumatic cylinders. Based on results, the technician will recommend repairs and replacements that should be performed as well as advise on any safety upgrades available for a particular machine. These inspections can also be turned into a learning opportunity. Some manufacturers can combine on-site evaluations with training for plant
personnel and contractors covering general maintenance, safety and storage procedures. Over time, crews change. Those on hand for the initial commissioning — where assembly, maintenance and storage requirements were originally outlined — may not be the same faces three years later. Taking advantage of continuing education opportunities is key to upholding a culture of safety. Additionally, top-tier manufacturers offer premium parts and service support. From yearly maintenance to parts tracking, partnering with a reputable manufacturer ensures equipment is ready
for operation during unscheduled kiln downtime. A lasting partnership with these manufacturers means facilities and contractors have access to original parts and expert advice to optimise safety and efficiency.
Lasting Safety Partnerships A safe workplace requires commitment, awareness, training and high-quality, well-maintained equipment. Partnering with a manufacturer that factors safety into every aspect of its products – from design, to testing, to aftermarket support – means everyone can feel confident each shift will end without incident.
Partnering with a manufacturer that factors safety into every aspect of its products, from design, to testing, to aftermarket support, means everyone can feel confident each shift will end without incident — like it did for the employees at a cement plant in Turkey who were saved by this safety cage
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