PRODUCTS & PROJECTS
MAINTENANCE
ENERGY EFFICIENCY
FURNACE OF THE FUTURE
www.furnaces-international.com SEPTEMBER 2020
Contents
PRODUCTS & PROJECTS
MAINTENANCE
FURNACE OF THE FUTURE
ENERGY EFFICIENCY
www.furnaces-international.com SEPTEMBER 2020
FRONT COVER IMAGE: SMS GROUP Editor: Nadine Bloxsome nadinebloxsome@quartzltd.com Tel: +44 (0) 1737 855115 Production Editor: Annie Baker
Sales/Advertisement production: Esme Horn esmehorn@quartzltd.com Tel: +44 (0) 1737 855136
Sales Manager: Nathan Jupp nathanjupp@quartzltd.com +44 (0) 1737 8555027
Manuel Martin Quereda manuelm@quartzltd.com +44 (0) 1737 855023
Subscriptions: Elizabeth Barford subscriptions@quartzltd.com
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 September 2020
www.aluminiumtoday.com/furnaces/
Comment
Welcome to the September issue of Furnaces International.
There is always a feeling of going ‘back to school’ in September and after what feels like the longest summer ever, we are gradually returning back to the QBM office and to some sort of ‘normality’. 2
Projects and products
Electric heating 11 Heating without gas - Shifting to electric heating systems for more eco-friendly production
This feeling of entering a recovery period is also being felt across manufacturing and heavy industries. Whether plants
Maintenance 16 Six maintenance tips to maximize bricking machine longevity
have had to shut down fully or adapt to working conditions with lower numbers of workers, there is no doubt that the
CAB furnace 20 Do you know what truly happens in your CAB furnace? Energy efficiency 24 Hydrogen group aims to reduce emissions Emission reduction 26 Can the glass industry meet emission reduction targets?
ripple effects of the last few months will be continue to be felt.
Thankfully, it seems like there is still good news out there and the ‘Products & Projects’ pages in this issue are full of new investments, contracts and technological developments.
Furnace of the future 30 The Future of Glass Furnaces
This issue also has a strong focus on greener technology, Melting solutions 34 Fives: melting solutions for industrial projects
which continues to be a developing theme, despite any
Life after lockdown 36 SmartMelter Inspections during and after Covid-19 Lockdowns
industry set backs. There are dedicated articles on energy
Company profile 40 Condinuus-Properzi’s new look
electric heating.
efficient furnaces, emission reduction and also a look at
I hope you enjoy the issue!
Nadine Bloxsome, Editor, Furnaces International, nadinebloxsome@quartzltd.com 1 Furnaces International September 2020
Projects/Products
CAN-ENG CONTRACT CAN-ENG Furnaces International Ltd., was recently awarded a contract by Metex Heat Treating Ltd. to design and commission a Mesh Belt Heat Treat System with a production capacity of 6,600 lb/hr. CAN-ENG Furnaces International Limited has recently been contracted to design and commission a 6,600 lb/ hr Continuous Mesh Belt Atmosphere Furnace System for Metex Heat Treating Limited of Brampton, Ontario, Canada. This new system will be commissioned
2 Furnaces International September 2020
www.furnaces-international.com
Projects/Products
T for the hardening and tempering of high-volume automotive critical fasteners, stampings, and assembly components. The system includes a computerized loading system, mesh belt controlled atmosphere hardening furnace, oil quench system, mesh belt tempering furnace, pre and post wash systems and CAN-ENG’s PET™ System. By integrating CAN-ENG’s PET™ System, Metex has access to vital tracking of their products’ status, detailed process data
for continuous process improvements, comprehensive equipment diagnostics, cost analysis, inventory management, supervisory control and data acquisition (SCADA) enhanced features to support compliance with CQI-9 guidelines. This recent furnace design integrates enhancements to the Radiant Heating System that provides Metex with added capacity within a fixed system footprint. This contract will represent Metex Heat Treating’s 6th CAN-ENG Furnace System, providing Metex with over
400,000 lbs./day of continuous atmosphere processing capacity in addition to batch and Induction services, which are provided to customers across Canada and USA. Metex selected CAN-ENG to provide this additional equipment capacity as a result of the continuous improvements integrated into their systems, allowing them to meet the ever-increasing demands of the automotive industry. The furnace line is scheduled to commission Q4 – 2020.
For additional information contact www.can-eng.com
3 www.furnaces-international.com
Furnaces International September 2020
Projects/Products
CAN-ENG DELIVERS FURNACE Can-Eng Furnaces International, Ltd. (CAN-ENG) has recently delivered a high capacity Mesh Belt Heat Treatment Furnace line to Gallos Metal Solutions Inc., Milwaukee, WI (GALLOS). Specializing in continuous mesh belt atmosphere heat treatment, GALLOS selected CAN-ENG to provide a custom engineered continuous atmosphere heat treating system to be used primarily for demanding processing including Carbonitriding and Carburizing, while allowing for neutral heat treatment with a production capacity up to 4000 lb/hr. This furnace line is part of GALLOS’ massive plant expansion and modernization project which has more than doubled the existing plant square footage, increased capacity and added automation. Can-Eng’s highly engineered and custom system allows for an increase in usable hearth area to provide highvolume processing when running
products requiring carbon diffusion and lighter belt loading. This new capacity addition features: a computerized controlled automated bin dumping and vibratory part feeder system, dunk and spray pre-washer, protective atmosphere controlled mesh belt hardening system, oil quench, dunk and spray post wash system, forced recirculation temper furnace, in-line post cooling system, and CAN-ENG’s PETTM Level 2 SCADA system. By integrating CAN-ENG’s Level 2 Automation, GALLOS provides access to vital tracking of products’ status, detailed process data for continuous process improvements, comprehensive equipment diagnostics, cost analysis, and inventory management. This project marks the fourth Can-Eng Mesh Belt furnace line to be in operation at this facility. Through proven results, CAN-ENG Furnaces’ Continuous Mesh Belt Heat Treatment Systems remain to be the choice of demanding Commercial
and Captive customers for consistent and reliable performance. Can-Eng Furnaces International is a global provider and leader of stateof-the-art thermal processing systems. Headquartered in Niagara Falls, ON, Canada, Can-Eng is an ISO 9001:2015 certified company. For further information please contact Can-Eng at scumming@can-eng.com or furnaces@ can-eng.com. Gallos Metal Solutions Inc, of Milwaukee, Wisconsin specialize in the high-volume continuous mesh belt atmosphere heat treating services and are capable of processing large volumes of small parts requiring uniform case depths and hardness from part to part through precision atmosphere and temperature control. For further information please contact Gallos through their website https://gallosmetal.com/
For additional information contact www.can-eng.com
4
Projects/Products
WORLD’S FIRST CONTINUOUS GAS COMBUSTION-TYPE FURNACE “C-SERT-RHK” FOR MAKING LITHIUM-ION BATTERY ELECTRODES PUT ON SALE BY NORITAKE, TOKYO GAS AND TGES NORITAKE CO., LIMITED (Noritake), Tokyo Gas Co., Ltd. (Tokyo Gas) and Tokyo Gas Engineering Solutions Corporation (TGES) have announced the world's first continuous gas combustion-type furnace for making lithium-ion battery electrodes, achieving a 40% reduction in energy costs. The world's first "Gas-burning Roller Hearth Kiln 'C-SERT-RHK'(*1)" for making lithium-ion battery (hereinafter "LiB") electrode materials(*2) has a highly efficient heating device that achieves energy cost reductions up to 40%(*3). C-SERT-RHK is created by the fusion of Noritake's firing furnace technology(*4) and Tokyo Gas/TGES gas combustion technology(*5) exclusively for continuous gas combustion-type furnaces by deploying TGES' special ceramic radiant tube burner. This product performs stable heat treatment at high temperatures (1,000C or higher) required in the manufacturing process of a LiB electrode material which is in high demand in recent years. Although the energy cost of firing at high temperature can be reduced on a gas combustion-type furnace, an electric-type furnace has been chosen due to problems of the gas combustion type with fluctuations in furnace temperature and oxygen concentration, and durability, to name a few. However, by combining the three companies' technologies, they have overcome the problems and succeeded in commercializing this product. Noritake, Tokyo Gas and TGES intend to use the highly efficient heating technology of this product not only for LiB electrode materials, but also for applications such as the automobile-manufacturing field (i.e. hot stamping) and 5G electronic parts that require stable heat treatment at high temperatures. They will also apply this technology in other fields of applications to contribute to cost
The world’s first gas burning-type Roller Hearth Kiln for lithium-ion battery electrodes (C-SERT-RHK)
Pilot furnace
reduction of heating processes and ultimately to environmental improvement. They have solved the problems of gas combustion-type burners by adopting TGES' special ceramic radiant tube burner of high heat and corrosion resistances (active oxidation resistance(*6), and lithium attack resistance(*7)) as a heating element (radiant tube) in C-SERTRHK. Stable heating such as leveling of temperature distribution, smooth temperature follow-up, and maintenance of oxygen concentration becomes possible and thus temperature accuracy of delta t=10C or less is achieved at 1,300C.
YOUTUBE: HTTPS://YOUTU.BE/I27RXB8AWA8
Special ceramic radiant tube burner to achieve stable heating and high durability
5 www.furnaces-international.com
Projects/Products
OMK TO BUILD COMPLEX TO MAKE STEEL IN DRI PELLET-FED ELECTRIC ARC FURNACE Russian steel pipe and railway wheel manufacturer OMK will build a pellet to steel production complex, the first in Russia with iron ore feed and steelmaking facilities to be installed on a single site, with a 70% smaller CO2 footprint than that of a traditional basic oxygen furnace. The complex -- expected to be commissioned in the second half of 2024 -- will comprise a 2.5 million mt/year plant producing metallized pellets using Direct Reduced Iron (DRI) technology and an electric arc furnace (EAF) with up to 1.8 million mt/year of steel capacity. The complex's technological capabilities will allow it to produce a range of semi-finished feedstock for pipe and railway wheel production. The EAF-based meltshop will cast steel in three forms: heavy slab, round wheel blooms and round pipe billet. All these semis will go into pipe and railway wheel manufacturing at OMK's flagship Vyksa Metallurgical Plant (VMZ), in the Nizhniy Novgorod region,
with any excess sold on the market. Notably, the complex will be able to produce heavy slabs up to the highest requirements for steel purity and quality, which will be transformed at the Vyksa mill into plates for the manufacture of large diameter pipes for subsea pipelines. The project represents a total investment of Rb150 billion ($2 billion), including VAT. The chosen technology is the most environmentally harmless and energy efficient ever applied in Russia, according to OMK, and is promoted under the green label. It represents the latest solution to make steel and yet achieve a 70% reduction in CO2 emissions compared with blast furnace-based production and has a 99.5% gas cleaning efficiency, with the output to meet current and future EU requirements for responsibly made steel goods. The technology also implies the shortest production chain. For the first time in Russia, iron ore feed-to-
steelmaking facilities with continuous supply of hot reduced pellets to an electric arc furnace will be installed in one site. Italian engineering company Danieli will supply Eur400 million ($474 million) worth of solutions and equipment for the complex. This includes a DRI unit based on ENERGIRON technology, a system for feeding hot pellets into an EAF, a 180 mt EAF, a ladle furnace, a vacuum degasser, a gas cleaning system and a continuous casting machine. "The project is of strategic importance for Russia's economy: it will contribute to the growth of domestic consumption of natural gas and iron ore ... and to the growth of domestic production of high value added goods, necessary for Russian oil and gas and shipping companies," said OMK Chairman Anatoly Sedykh. "This is an example of the best green technology available today, which can give an impetus to the domestic steel industry and improve air quality in industrial regions."
SAIL’S ROURKELA STEEL PLANT SETS NATIONAL RECORD WITH NEW BASIC OXYGEN FURNACE SUPPLIED BY SMS GROUP Rourkela Steel Plant, a unit of Steel Authority of India (SAIL), has set a national record with the new Steel Melting Shop 2 supplied by SMS group. On July 2, SAIL produced 48 heats in 24 hours with the 150-ton basic oxygen furnace No. 3 of the Steel Melting Shop 2 in Rourkela. All functional and support departments worked perfectly in tandem to make this result happen. SMS group congratulates all departments of the Rourkela Steel Plant on this great success. This quantum leap in raising the bar will not only motivate the steel plant staff to continue making efforts towards excellence. The achievement will also help optimize the use of resources and promote confidence
building within the Rourkela team. And it has set an international benchmark for the technological advancement in steel making.
This record has reiterated the customer’s trust put in SMS group technology and demonstrates the high
quality of the supplied equipment, along with state-of-the-art automation systems and the excellent operating skills of the staff at the Rourkela Steel Plant. The employees of SMS group are proud of having contributed to the achievement of this milestone at the Rourkela Steel Plant. We look forward to building further plants in India in the future, enabling our customers to set even more new benchmarks. SMS group is a group of companies internationally active in plant construction and mechanical engineering for the steel and nonferrous metals industry. It has some 14,000 employees who generate worldwide sales of more than EUR 2.9 billion. The sole owner of the holding company SMS GmbH is the Familie Weiss Foundation.
6 Furnaces International September 2020
www.furnaces-international.com
Projects/Products
PLIBRICO’S NEW INSULATING REFRACTORIES EXHIBIT EXCEPTIONALLY HIGH STRENGTH WITH LOW DENSITY Plibrico Debuts Plicast LWI 24 HS and Plicast Al-Tuff LWI 24 HS Refractory Material for Boilers, Furnaces, and Incinerators NORTHBROOK, IL, MAY 28, 2020 -- The Plibrico Company introduces its newest insulating castable refractories with Plicast® LWI® 24 HS and its aluminum resistant version Plicast® AlTuff® LWI® 24 HS. Both, are the safe choice for lightweight refractory linings inside high-temperature incinerators, boilers and furnaces. Used in thermal environments of up to 2400°F, these materials have low shrinkage and a low thermal conductivity rating. Perfect for refractory back-up linings and producing lightweight precast shapes in applications where weight is a factor. Plibrico's Plicast LWI 24 HS and its Al-Tuff aluminum resistant version, possess exceptionally high strength in conjunction with low density. When compared to traditional lightweight refractories, these materials offer an impressive 200% more in cold crushing strength (CCS). The castables increased strength does not affect its density, which is maintained at a noteworthy 80 pounds per cubic foot (pcf). The high strength exhibited in these materials help maximize the life of heating equipment and maintain the integrity of any precast shape. Another value-adding advantage is the materials low shrinkage, contracting very little during high temperature use. By doing so, it prevents the formation of cracks and loss of strength typical with cartable refractories of lessor quality.
Cracking can result in a loss of boiler efficiency, and the creation of hot spots on the casing or outer shell of a furnace, boiler or incinerator - all of which require costly repairs. The Plibrico Company recommends
stacks, over-the-road aluminum ladles, and backup linings in aluminum furnaces. With the introduction of Plicast LWI 24 HS and Plicast Al-Tuff LWI 24 HS; boiler, furnace, and incinerator users now have
these lightweight refractory materials for the aluminum, steel, petrochemical, incineration, and boiler industries for applications that include: precast shapes, linings in reheat furnace floors, annealing furnace cartops, fired oil heater stacks, carbon monoxide boiler duct linings, olefins cracking furnace
access to a superior insulating refractory material that is lightweight, and offers exceptionally high strength with a low density. This terrific combination provides users with a refractory material that maintains integrity and maximizes the life of heating equipment.
For more information, please visit www.plibrico.com.
7 www.furnaces-international.com
Furnaces International September 2020
Projects/Products
OTTO JUNKER SUPPLIES PUSHER FURNACE FOR ALUMINUM In 2019, OTTO JUNKER GmbH handed over a new furnace for heating and homogenizing aluminum ingots to Logan Aluminum Inc. in Russellville/ Kentucky/USA. Logan Aluminum Inc. is one of the world‘s leading manufacturers of flat rolled aluminum sheet, a product that is primarily destined for use in
the beverage market. In order to expand production, the company now operates the largest ingot furnace OTTO JUNKER GmbH has supplied in its entire history. The gas-fired furnace is dimensioned to simultaneously hold 32 ingots weighing up to 32 tonnes per piece, resulting in a charge
weight of over 1,000 tonnes. Apart from the furnace with active cooling system, the scope of delivery also included machinery for charging and discharging the ingots, as well as a gantry crane and a mobile roller table as a connection to the existing rolling mill feed table.
Complete system as seen from the entry end
www.otto-j 8 Furnaces International September 2020
www.furnaces-international.com
Projects/Products
M INGOTS WITH A CAPACITY OF 1,000 TONNES TO THE USA OTTO JUNKER technology is highly efficient when it comes to even temperature distribution, energy consumption and automation. High convection technology ensures fast heating and cooling with short cycle times and low energy consumption. Otto Junker’s skid system integrated into this furnace has been
tried and tested over many years and is virtually maintenance-free. Used to transport the ingots one by one through the furnace, it is made of a number of cast parts manufactured in OTTO JUNKER‘s own stainless steel foundry. During the earlier stages of the skid system development, the extensive expertise of OTTO
JUNKER’s stainless steel foundry could already be drawn upon when selecting alloys. With the successful completion of this order, OTTO JUNKER has demonstrated that its pusher furnace technology is highly efficient in the largest class of this type of furnace.
Furnace exit zone
junker.com 9 www.furnaces-international.com
Furnaces International September 2020
Projects/Products
MAJOR AVIATION INDUSTRY PROVIDER CONTRACTS WITH SECO/WARWICK FOR VIM SYSTEM MODIFICATIONS SCOPE OF WORK, MODIFICATIONS AND UPDATES
The customer is a large supplier of solutions for the aviation industry, including jet engine turbine blades. The company has over a dozen plants in North America and Europe, and its plants process materials such as aluminum, magnesium and superalloys.
The scope of modification covers two furnace design systems. The first one is a pumping system, in which the existing oil pumps will be replaced by dry pumps, which will significantly reduce maintenance and improve control of these mechanisms. Dry pumps are as efficient as oil pumps, but they require much less frequent inspection and service. Currently, pump manufacturers recommend dry pumps for furnaces operating in VIM technology. The second area of modification involves the addition of an automatic crucible cover in the melting chamber. The purpose of this upgrade is to eliminate the cases where spatter from the melting process finds its way into the vacuum baffle of the furnace, necessitating cleaning. Both modifications will improve the production process, reduce the risk of downtime and significantly extend the time between inspections and servicing of selected furnace elements.
The modifications apply to the furnace purchased from Retech, part of the SECO/WARWICK Group. “Since we create furnaces from scratch, we perfectly understand their nature, because we are their architects, constructors, and not just a producer. The R&D Center of SECO/WARWICK Group has been working continuously for decades, looking for solutions not only related to new products and technological requirements of the market, but also verifying existing structures in terms of their improvements. With knowledge supported by experience and research results, we are constantly improving upon the technologies used years ago, both by our Group and external companies. Optimization of devices already operating at customers’ sites requires knowledge and experience, and we have a wealth of those assets. The proposed changes are always tailored to the individual needs of the client,
where we find innovative opportunities to better use their existing equipment to help reduce new investment outlays,” says Robert Szadkowski, VP of the Aftermarket Segment at SECO/ WARWICK Group. Processes, applications, key parameters The process of vacuum melting and casting is extremely technologically advanced. It requires enormous precision in the fabrication of individual elements and in designing the process architecture in order to run with optimal use of resources. Power turbines and jet engine turbines require high industry standards for materials and machining accuracy. The most important parameters of this process are: warm-up speed, cooling, safety, automation, chamber size, process cleanliness and ecology. Relationship – expert skills, speed of reaction The Retech brand of SECO/WARWICK Group has served most of the world’s suppliers of critical components for the aviation and energy industry for many years. In this particular project, as part of the cooperation, in addition to the service and control work, a number of other technological modifications were made at the request of the client. “For many years, we have been delivering ready-made technologies, modifying existing ones and improving processes based on the team’s experience. Retech and SECO/WARWICK engineers always work closely with engineers on the client’s side, creating appropriate procedures, improving processes, using operating devices in an increasingly effective way. This is how we understand partnership, one of our core values,” says Earl Good, President of Retech, a subsidiary of the SECO/ WARWICK Group.
10 Furnaces International September 2020
www.furnaces-international.com
Projects/Products
STEKLARNA HRASTNIK BEGINS INVESTMENT IN NEW OXYGEN-BASED FURNACE Steklarna Hrastnik has began its investment in the new oxygen furnace for the production of glass packaging. The investment is of key importance for the long-term existence of the glassworks, and for its competitiveness in the global market. The EUR 18.5 million worth of investment will include the investment in the G furnace, the purchase of new production lines (IS machines), and the optimisation of parallel production processes. The work is planned to be completed in November 2020. The investment will allow Steklarna Hrastnik to incorporate the latest and the cleanest technologies and innovative approaches into its production. Peter Čas, General Manager of Steklarna Hrastnik, said: “This investment is of key importance for the existence of Steklarna Hrastnik. “The B furnace in the Special unit is slowly reaching the end of its lifespan, and if anything unforeseen were to happen with this furnace, this would mean that Steklarna Hrastnik would be left without a furnace and thus without the possibility of delivering its orders.” Mr Čas said that the technology of the new furnace will be based on clean technologies with the joint usage of oxygen, and enable the production of even more complex glass for packaging. This allows Steklarna Hrastnik to accept the most prestigious projects in packaging glass for sprits and perfumes, and means Steklarna Hrastnik achieves higher sales values per kilo of glass, reinforcing its position in the market. The investment also brings an additional, separate production facility, which will be used exclusively for the production of packaging glass, bringing additional security to its customers. Compared to the existing furnace, the new G furnace will also
be more effective, as the use of state-ofthe-art technology and future upgrades will enable higher capacities. The furnace will be prepared for the implementation of innovative technologies allowing the joint usage of hydrogen as a fuel for the furnace. “As this is a pilot and pioneer project, the implementation will take time and resources; however, projections are promising – a 20% lower CO2 footprint for Steklarna Hrastnik,” emphasised Mr Čas. The current investment will also mean the optimisation of parallel processes in the new production facility – its own production of oxygen will be set up, the batch plant upgraded (division preparing the batches of glass for the furnace), the transport of batches and shards automated, etc. In order to implement additional automation, digitalisation, and
robotisation in Steklarna Hrastnik, this year’s investment will be followed by a new investment cycle in the next two years, a cycle that has been postponed due to the coronavirus epidemic. Almost 300 providers are planned to be involved in the implementation of this year’s investment, including some 100 employees of Steklarna Hrastnik.
. rofiling..your furnace! P l a ic t p O ye thru ….the e
PhoenixTM Optic System ´Thru-process` Optical Profiling Capture a video
of what your product sees through the entire furnace during a live production run
Ideal for your CAB and Vacuum Brazing line!
Discover so much more
Combine our Optical and Temperature Profiling Systems.
New Innovative Technology from PhoenixTM www.phoenixtm.com PhoenixTM Ltd UK PhoenixTM GmbH PhoenixTM LLC USA sales@phoenixtm.com info@phoenixtm.de info@phoenixtm.com
11 www.furnaces-international.com
Furnaces International September 2020
Electric Heating
Heating without gas - Shifting to electric heating system
12 Furnaces International September 2020
www.furnaces-international.com
Electric Heating
ms for more eco-friendly production The green revolution is accelerating in many industries, as next-generation electric heating systems gradually replace gas burners. But how can a furnace help achieve a business’s sustainability goals? Here, Daniel Burton, business manager at Kanthal, a provider of industrial heating products and services and part of Sandvik Group, explains how helping customers switch from gas to electric furnaces has achieved results that are worth celebrating.
In aluminium production, for instance, each process presents a specific set of challenges, and heat is the ingredient that solves many of these potential issues. For example, anodes are large carbon blocks that conduct electricity during the aluminium reduction process. Due to the porous nature of their material, anodes accumulate humidity, which can result in explosion or a connection failure upon becoming energised. As a result, the anodes must undergo preheating to dry them out. At an anode preheating station, a critical part of the process is to raise the temperature of the anode slot to above 100 degrees Celsius in less than one minute, before pouring molten iron into the slot. Extreme heat requires extreme power and, because of this, furnaces play a vital role in fuelling aluminium production.
Cut the cost However, all of this heat comes at a price. Most commonly, the furnaces that deliver the temperatures needed for aluminium production are powered by fossil fuels. While fossil fuels are effective, their negative impact on the environment is no secret. Yet demand for aluminium is rising. While we continue to rely on aluminium, much of this increase in demand is actually part of efforts to reduce
emissions. For example, aluminium cars are lighter than ones made from steel, which helps to reduce fuel consumption. Aluminium is also easy to recycle, which reinforces its potential as a green resource. To support this potential, and also to further it, aluminium production must undergo some environmental improvements. One is to switch from fossil fuels to electric-powered furnaces. Electric heating systems by Kanthal are designed for a range of industrial heating applications, including aluminium and steel processing. They are shown to deliver significant reductions in energy consumption compared with gas-heated systems. In fact, the net efficiency of Kanthal electric heating systems is 70 per cent, compared with only 20 per cent for gas. Electric furnaces can also help achieve a cleaner, safer and quieter working environment, making it a much healthier place for employees.
Go green Aluminium production has changed little since the 1800s, when the smelting process was initially pioneered. Because of this, while electric furnaces demonstrate “a new dawn” of sorts for aluminium, the material’s long and unchanged history makes it difficult to realise new
innovations. To help its customers begin the process of switching from fossil fuels to electricpowered furnaces, and to help them reach their own sustainability targets, Kanthal has developed a service portfolio that includes a customised, onsite evaluation service. The service provides calculation models, reports and recommendations to help identify the best electric furnace for each customer’s specific needs. The services are helping to deliver a measurable and lasting environmental impact for Sandvik, its customers and the planet. This is backed-up by data from measuring 34 installations of Kanthal electric furnaces across the globe. Kanthal tracks a running total of the CO2 savings that these furnaces have achieved. The total, which updates every second, has counted hundreds of millions of kilograms, so far.
Winning results To recognise the success of Kanthal’s sustainable innovation, Kanthal Services was nominated for the first Sandvik Sustainability Award in Memory of Sigrid Göransson, named in honour of the famous Swedish philanthropist (1872-1963) who was born, and died, in Sandviken, Sweden, the town where the Sandvik company was founded. Award entries came from all three
13 www.furnaces-international.com
Furnaces International September 2020
Electric Heating
of Sandvik Group’s business units — Sandvik Materials Technology, Sandvik Rock and Mining Technology, and Sandvik Machining Solutions — all of which have made considerable progress towards the group’s sustainability goals. These objectives include halving Sandvik Group’s CO2 impact by 2030, towards which Kanthal Services significant contribution saw it crowned as the winner of this year’s award. In addition to aiding Sandvik’s goals,
Kanthal’s evaluation has helped its customers meet their own sustainability and workplace targets, comply with regional emissions rules, and has even facilitated support from the Government of Sweden for expansion projects. Creative collaboration and identifying the need for change are key to breaking age-old traditions, which include those relating to sustainability and aluminium production. While it’s clear that we need to change our approaches to industrial
heating, executing these changes isn’t always easy. That’s why, by implementing a progressive evaluation process, Kanthal and Sandvik have demonstrated that a simple switch can deliver significant progress. Using electric heating for processes such as anode preheating, the right equipment can contribute towards reducing CO2 emissions, even in unlikely applications.
ABOUT SANDVIK GROUP
PRESS ENQUIRIES Courtney Cowperthwaite or Jasmin Shearan
Sandvik is a high-tech and global engineering Group with around 40,000 employees with a strong commitment to enhancing customer productivity, profitability and sustainability. The business achieves world leading positions in tools and tooling systems for industrial metal cutting equipment and tools, service and technical solutions for the mining and construction industries and advanced stainless steels and special alloys as well as products for industrial heating.
Stone Junction, St Mary’s Place, St Mary’s Grove, Stafford, Staffordshire, ST16 2AR Telephone: +44 (0) 1785 225416 e-mail: courtney@stonejunction.co.uk or jasmin@stonejunction.co.uk www: www.stonejunction.co.uk Ref: SAN025/07/20
CONNECTING THE INTERNATIONAL ALUMINIUM INDUSTRY Published six times a year, Aluminium International Today is dedicated to the production and processing of aluminium. Keep up-to-date with the industry by subscribing to AIT
CHOOSE YOUR SUBSCRIPTIONS PACKAGE... PRINT + DIGITAL SUBSCRIPTION 6 print copies a year posted to your chosen address Our annual AIT Directory Digital issue of every magazine and two special digital only supplements sent directly to inbox Access to our digital archive of past issues Regular premium content including podcasts, video interviews and specialist reports
DIGITAL ONLY SUBSCRIPTION
An annual yearplanner The weekly email newsletter Exclusive subscriber only content Priority places on industry webinars Discount to attend the Future Aluminium Forum PLUS...access to all digital issues of our sister publication Furnaces International
WWW.ALUMINIUMTODAY.COM/SUBSCRIPTIONS
Join the Aluminium International Today Group
With a digital subscription you receive all the benefits of the Print + Digital option, excluding print copies!
CONTACT US TODAY Email subscriptions@quartzltd.com to take advantage of our special subscription packages
@AluminiumToday BUSINESS MEDIA
14 Furnaces International September 2020
www.furnaces-international.com
HY2 the hydrogen hybrid burner: the future of combustion
SMS group S.p.A. Via Udine, 103 33017 Tarcento (UD), Italy info.spa@sms-group.com www.sms-group.com
Leading Partner in the World of Metals
Maintenance
Six maintenance tips to maximize b By Heather Harding, Bricking Solutions Managing Director
Cutline: In addition to a visual inspection of the pneumatic cylinders before use, operators should make sure the oil reservoir is full and the lubricator ďŹ lter is working properly. Two to three drops of oil should fall each time the master valve is cycled.
16 Furnaces International September 2020
www.furnaces-international.com
Maintenance
bricking machine longevity Cutline: To help with equipment inspection and recertification, certain industry-leading companies offer on-site equipment safety evaluations. These one- or multi-day visits include a visual inspection, safety and machine systems testing.
Refractory installation is a demanding application, and harsh kiln environments take a heavy toll on bricking machines and other equipment. Making routine maintenance a priority is vital for facilities and contractors looking to ensure bricking machine longevity. With proper care, a bricking machine won’t just be ready for the next job, but for decades to come. Robust engineering and heavy-duty components from toptier manufacturers play a major role in this reliability, but operators are also responsible for protecting their investment to optimise ROI. To make it easier for crews and foremen, here are six tips to streamline routine maintenance.
1. Designate a Responsible Employee For facilities that provide a bricking machine for use by a third party, it’s important to designate an employee who is responsible for the machine. This employee can work with the bricking crew to ensure the facility’s bricking machine is handled properly during setup, operation and teardown. He or she can also track parts or systems that might need to be repaired after operation by performing after-use inspections and routine maintenance. Refractory installation contractors who provide their own bricking machine don’t necessarily need to be reminded how important the equipment is to their operation. But designating a specific employee to oversee maintenance can still ensure things don’t fall through the cracks, such as ordering parts and performing service during downtimes. By having an employee with intimate knowledge of the equipment, facilities and contractors can rest assured that the bricking machine is well cared for and ready for operation when it’s needed, helping ensure a successful shutdown and relining project. It also increases rig longevity and overall ROI.
2. Follow Manufacturer Instructions From setup and operation to tear down and storage, following manufacturer recommendations is the best way to ensure your bricking machine is ready
when you need it. To help contractors and facilities ensure proper operation, some industry-leading manufacturers offer onsite training with equipment commission, as well as follow-up training by request. However, since the crew on the jobsite tomorrow might not be the same as the one on hand for the initial training, these manufacturers also recommend operators frequently review key procedures inhouse. It’s important to follow operational and maintenance instructions for all bricking machine components. There are also a few systems that might require extra care and attention, as well. The arch’s pneumatic system is chief among these. This system powers pneumatic cylinders that push the bricks into place. It was designed to reduce the risk of crew injuries from unsupported overhead bricks, which is common with earlier bricking methods, and is available on many top-tier bricking machines. In addition to a visual inspection of the pneumatic cylinders before use, operators should make sure the oil reservoir is full and the lubricator filter is working properly. Two to three drops of oil should fall each time the master valve is cycled. Air pressure should also be doublechecked. Optimal pressure will vary by manufacturer, but most require 90 to 120 psi for proper function. During operation, masons should keep an eye on oil levels and air pressure. The pneumatic system is also vulnerable during transportation, since the lubricator filter can be damaged by accidently striking it against a wall or other surface. Use a spotter during transportation and take care when hanging or leaning the machine against a wall to ensure all systems are undamaged and ready for operation next time the rig is needed.
3. Cleanliness is Key Kilns are dirty. Left unchecked, the dust and debris that accumulates on a bricking machine during refractory installation can shorten useful life and increase maintenance costs — especially for pneumatic cylinders. For optimum performance, keep bricking machines clean.
17 www.furnaces-international.com
Furnaces International September 2020
Maintenance
Cutline: A specialized container can also help to keep bricking machine components protected and contained during storage. These are available from select manufacturers.
18 Furnaces International September 2020
www.furnaces-international.com
Maintenance
Wipe down cylinder rods and other surfaces after each shift. Once the job is complete, a more thorough cleaning is necessary before storage. Clean the arches, handles and cylinder bodies. To prevent rusting, open the bleed valves and drain any moisture. Leave valves open during storage since changing temperatures could create condensation.
4. Carefully Inspect Machine After Use It’s natural for tired crews to want to hurry through inspections and maintenance after an installation. But, as the saying goes, “An ounce of prevention is worth a pound of cure” — especially in the refractory industry where even slight delays cost facilities dearly in lost production. Here are some key areas to focus on for after-use evaluation:
Machine Frame ABOUT BRICKING SOLUTIONS Bricking Solutions manufactured the industry’s first bricking machine in 1966 to give refractory installers a safer, more efficient alternative to manual installation methods. From that time the company has believed that machines should do the heavy work rather than the people and customer feedback should drive product development. Bricking Solutions manufactures a wide variety of equipment for the cement, foundry and steel industries, including bricking machines, conveyors, pallet transfer systems, suspended platforms, ramps and safety cages. For more information: Bricking Solutions, Inc., 1 144 Village Way, Monroe, WA 98272; 1-360-794-1277; info@brickingsolutions.com; w w w. b r i c k i n g s o l u t i o n s . c o m ; Facebook; Twitter or YouTube.
ABOUT THE AUTHOR Heather Harding is the managing director for Bricking Solutions, a world leader in kiln refractory installation solutions.
� Visually inspect all welds — including frame and all structural members such as leg and outriggers — for cracks, stress or distortions. � For machines eight years or older, manufacturers recommend a dye test to ensure the viability of welds with follow up testing every two years thereafter.
Arch Trolley Cart � Visually inspect trolley cart for stress and weld cracks. � Ensure wheels are lubricated and in good working condition. Lubricate with standard grease if necessary. � Check condition of pins, locks and brakes. � Inspect arch adjustment plates for sagging or bending.
Arches � Visually inspect all panels for cracks, stress or distortions. � Ensure all ledges are straight and free of major gouges. � Make sure hinges are in good working order.
Cylinders & Rubber Bumpers � Make sure cylinders extend and retract freely and aren’t leaking. � Handles should be free of damage. � Bumpers should not be able to rotate more than 10 degrees and be free of major gouges. � Check quick connections for cracks and leaks.
� Inspect hoses for cracks and leaks.
Keying Jack � Make sure hoses and fittings are free of leaks, damage and debris. � Ensure gauges work properly. � Ensure fingertip control and foot treadle are in good working order. � Visually inspect the swivel feet for cracks and damage. Carefully inspecting and evaluating your bricking machine at the end of operation ensures maximum lead-time for any necessary parts orders or repairs.
5. Storage Once a bricking machine has been cleaned, inspected and disassembled, it should be carefully stored until the next installation. For contractors working with their own machines, this might only be a short time. However, for facilities that will be storing a unit for longer period of time, manufacturers recommend finding a storage location that keeps the machine out of the way of normal operations. This location should be away from the burner to avoid unnecessary heat damage. A specialized container can also help to keep machine components protected and contained during storage. These are available from select manufacturers.
6. A Partner for Success After five years, manufacturers recommend on-site equipment inspections annually or every two years. Equipment inspections and recertification helps facilities and contractors remain compliant with regulations and provides assurance that equipment is safe and ready for operation. To help with this, certain industry-leading companies offer onsite equipment safety evaluations. These one- or multi-day visits include a visual inspection, safety and machine systems testing. At the end of the evaluation, the facility or contractor is provided with a complete report of findings, as well as recommended repairs and replacements. A bricking machine is a significant investment. And, with proper care and routine maintenance, it can last several decades, making that investment a longterm one. For that reason, it’s important to choose a manufacturing partner with proven longevity in the industry and a commitment to continued service.
19 www.furnaces-international.com
Furnaces International September 2020
CAB Furnace
Do you know what truly happens in your CAB furnace? Applying ‘thru-process’ optical profiling to fully understand, what is happening inside your Al brazing furnace…a products eye view! By Dr Steve Offley*
In the global Industrial heat-treating market tens of thousands of aluminium brazed products are sent through conveyorized CAB furnaces each and every day. The thermal processing of these products is often critical to the quality or performance of the finished product. Learning what is truly happening to the product inside the black box, that is your furnace, is important and shapes the success of your operation and customer satisfaction. As discussed in a previous editorial1 to fully understand the operational characteristics of the aluminium CAB heat-treat process an essential technique is that of thru-process temperature profiling where the environment and brazed product temperature is continuously measured as the product travels through the process. Such technique provides what is referred to as a ‘temperature profile’ which is basically a thermal finger print for that product in that particular process. This thermal finger print will be unique and allow understanding, control, optimization and validation of the heat
treat process.
Root Cause Analysis – Process Profiling Help The temperature profile of any thermal process is invaluable to get a better understanding how the furnace is working and is a critical tool in fault finding when things go wrong, because they do and they will! Root cause analysis is a standard tool used in industry to identify the root cause of product or process problems without jumping to conclusions or making knee jerk reactions. In root cause analysis it is important to distinguish between symptoms and problems and drive to find, in the mist of many potential causes, the true root cause. Taking an example of the Aluminum CAB brazing process, the temperature profile trace may show that the cause of a quality issue is due to the product braze temperature in a particular zone of the furnace being too low. This, although identifying a cause does not necessarily explain the root cause. A low product temperature in a particular furnace zone
may be due to many possible different root causes – faulty control thermocouple, burner, recirculating fan or even damage to furnace structure / insulation. The low product temperature may in some circumstances not be detected by onboard furnace controls and will require a deeper dive investigation. Identifying the root cause will require inspection at the source of the problem. This action is referred to commonly as “Going to Gemba” a Japanese word which means ‘the real place’. In this situation going to Gemba means investigating what is actually happening in the furnace in a particular zone, at the point of occurrence.
Root Cause Analysis – Controlled Aluminum Brazing (CAB) Example – Automotive Radiator Line Symptom High number of radiator rejects identified in QA Problem Poor product quality due to weak braze joints Cause
20 Furnaces International September 2020
www.furnaces-international.com
CAB Furnace
Fig 1. Thru-process temperature profiling system travelling through a conveyorized heat treatment furnace measuring product and or air temperatures providing a ‘temperature profile’ a thermal finger print for that product
From temperature profiles product braze temperature identified to be too low in Zone 4 Root Cause Recirculating fan fault in Zone 4 resulting in poor non uniform heat transfer to radiators Going to Gemba is not always the easiest of tasks especially when considering identifying the root cause of furnace problems. Any task involving the internal inspection of a furnace generally requires that the furnace is switched off, allowed to cool and then dismantled to allow access by operatives. Taking our aluminium brazing (CAB) example, internal inspection of the furnace is not a quick and easy task. Operating at 600 °C the cool down period is significant to allow engineers safe access for inspection and corrective action and then further delay to get the furnace back up to a stable operating temperature. Such maintenance action may mean one or two days lost production, from that line, which is obviously detrimental to productivity, meeting production
schedules, satisfying key customers and your bottom line. In addition to process temperature problems there are many other production issues that can be faced relating to the furnace operation and safe reliable transfer of the product through the furnace or oven itself. In the CAB process a day to day hazard of the process is the build up of flux debris. Flux materials used to remove oxides from the metal surface and allow successful brazing can accumulate within the internal void of the furnace. These materials are most problematic at the back end of the muffle section of the furnace where due to the drop in temperature, entering the cooling zone, materials condense out. Flux build up can create many different process issues including; � Physical damage to the conveyor belt or support structure requiring expensive replacement � Reduction in belt lubricity creating jerky movement and causing unwanted product vibration � Lifting of the belt mesh creating an uneven transfer of products causing possible excessive product movement, clumping or clashing. � Reduction in inner furnace clearance creating possible product impingement issues and blockages
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. Employing similar thermal protection technology ‘thermal barrier’ used in temperature profiling, in place of the temperature data logger a compact video camera and torch are used to record a video of what a product would see travelling through the furnace. The principle is just like your car’s dash cam, the only difference being that your journey is being performed in a furnace at up to 600°C. The resulting video “Optical Furnace Profile” shows 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. Benefits of applying the Optical Profiling principle in conveyorized furnace processes:
To prevent such problems, regular scheduled inspection and clean out of the furnace is necessary. This is not a pleasant, quick operation, and requires chipping away flux debris with pneumatic tools. Often requiring a furnace down time of 1 to 2 days, this task is only performed when essential. Leaving the clean-up operation too long though can be catastrophic causing dramatic deterioration in product quality or risk of mid production run stoppages. Until now there has been no easy way to see how your product travels through the furnace under normal operation conditions or means by which the need for furnace repair or clean down can be confirmed. A new technology called Optical Profiling changes all this and for the first time gives you the means to see what your product sees in production; a true products eye view!
� Damaged or Distorted panels / Sealing gaps / Corrosion � Build-up of dirt/flux/condensate or general processing debris – Contamination risk – identify need for critical cleaning action � Correct alignment adjustment of ducting to allow correct air flow / convective heat transfer � Identify ignition events or other safety related issues within the furnace
Optical Profiling – What is it? Optical profiling is a new complementary technique to that of ‘thru-process’ temperature profiling. The new technology allows for the first-time
Furnace Condition Check the condition of the internal walls of the furnace to ensure they are fit for purpose
Product Transfer Check that the product travels safely and smoothly through the process without conflict or obstruction � Conveyor belts run flat and product orientation is kept constant – No belt damage or distortion � No product vibration or excessive movement which may cause damage to product or affect processing step eg: brazing � Check that product is able to pass through without clashing with furnace furniture or product clumping
21 www.furnaces-international.com
Furnaces International September 2020
CAB Furnace
Fig 2. PhoenixTM Optical profiling ‘Optic’ System - High Temperature Thermal barrier used in the CAB brazing furnace protecting the video camera and dual torches
Condition & Operation of Key Furnace Features
Check that the process is being performed correctly where heat treatment action is physically visible � Bazing – Melt and Flow of filler metal
profile, process engineers can work with maintenance teams to not only Understand, Control, Optimize and Validate the heat treat process but also Maintain the furnace to protect productivity and quality. Employing the optical profile information preventative maintenance or furnace clean down can be scheduled with confidence, and when problems occur, rapid fault finding is possible. Furnace inspection as part of the production flow at temperature eliminates, days of furnace downtime, lost production and an interrupted product supply chain.
Summary
References:
‘Thru-process’ optical profiling is a new revolutionary technique for visually inspecting the condition of and also transfer of product through a continuous furnace. Combining such information with a product temperature
1. Aluminium International Today Magazine Set/Oct 2019 : Brazing Basics - ‘Thru-process’ Temperature Profiling a means to achieve process understanding, control, optimisation and validation. Dr Steve Offley PhoenixTM Ltd.
Check that key furnace features are working correctly and not damaged � Fans, Ducting, Control thermocouples, Gas Feed pipes, Zone separation curtains/brushes
Thermal Process Observation
22 Furnaces International September 2020
www.furnaces-international.com
CAB Furnace
OPTICAL PROFILING “GOING TO GEMBA” NEW TECHNOLOGY BENEFITS � Instant - View the inner workings of your furnace without need to dismantle the furnace or stop production. � New Understandings – See actual heat treat process if visual changes to product possibly for first time. � Production Conditions - See the operation of the furnace under actual production conditions fully loaded. � Time Saving - No delay to Cool, Disassemble, Reassemble as with normal inspection procedures. � Complementary - Run video profile simultaneously with temperature profile to combine Thermal and Visual information. The complete picture of your Heat Treat Process.
3.1
3.2
3.3
Contact: www.phoenixtm.com
Fig 3. PhoenixTM Optical Profiling System – Your Products Eye View in the operational Al CAB furnace. 3.1 Video profile screen shot – view down entire length of a single Furnace Zone 3.2 Video profile screen shot – exit of muffle furnace showing heavy flux build up. 3.3 Video profile screen shot – vacuum brazing furnace showing faulty IR heating element
23 www.furnaces-international.com
Furnaces International September 2020
Energy Efficiency
Hydrogen group aims to reduce emissions An industry consortium has been formed to increase the amount of hydrogen in energy- intensive manufacturing processes. The consortium was formed by Dutch glass company CelSian alongside engineering group DNV GL and consists of 30 project partners. While the consortium includes companies from other industries, such as Tata Steel, Shell and GRT Gas, the majority (40%) consists of glass manufacturers. These include the three largest container glass manufacturers O-I, Ardagh Glass, and Verallia, flat glass makers AGC, Saint-Gobain and Vitro Architectural Glass, specialist glass manufacturers Schott, Nippon Electric Glass and Owens Corning, pharmaceutical manufacturer SGD Pharma, tableware specialist Arc International, as well as furnace supplier Tecoglass. The use of hydrogen would reduce the amount of CO2 emissions in the glass manufacturing process. Project leader Lieke de Cock, of CelSian, said: “The major challenge now is to go CO2 neutral. Electric melting might not yet be a ready-made solution for the larger furnaces in the glass industry, so we are focusing on hydrogen.” Lab tests in the two-year programme are due to start next month at the DNV GL facilities near Groningen, Netherlands. Different burner types will be tested
and the considerations of switching from natural gas to hydrogen will be assessed. The aim is to develop burner technology
that allows the gradual transition from natural gas to hydrogen. “We will try to find an adaptive burner concept which enables the burning of 100% hydrogen but also a mixture of natural gas and hydrogen as well as the
ability to burn 100% natural gas, to give flexibility to the industry,” said Ms de Cock (pictured left). “It means the customer can run any mixture of natural gas and hydrogen safely, reliably and with low emissions.” CelSian will contribute to this study by applying CFD modelling of the combustion space and heat transfer of the H2-CH4 flames. Also, a CO laser sensor will be installed to adjust and control the burners with H2/CH4 mixtures. Once testing has been complete the aim is to try them out in an industrial context, probably in a year’s time. Ms de Cock said hydrogen offered a lot of potential to the glass industry. “If your furnace is located close to where hydrogen is piped into land then hydrogen conversion might be best for you. But if you are located close to a power source then electric melting might be more interesting to you, or a hybrid conversion. It depends on your location on what solution is best for you but it is important to explore all solutions such as hydrogen as well as electric melting.” Ms de Cock added: “The aim, in two years’ time, is to have all the knowledge that enables a successful roll out of hydrogen as a sustainable fuel and that we have all the knowledge we need to say we can use hydrogen with a certain type of burner that is sustainable and have a good rollout throughout the industry.”
CelSian, Eindhoven, The Netherlands www.celsian.nl
24 Furnaces International September 2020
www.furnaces-international.com
FIC ads 2019_Layout 1 15/11/2019 09:59 Page 1
, 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
www.fic-uk.com +44 (0) 1736 366 962
, The World s Number One in Furnace Technology
FIC (UK) Limited Long Rock Industrial Estate Penzance, Cornwall TR20 8HX United Kingdom
GLASS SERVICE
A Division of Glass Service
Emission Reduction
Can the glass industry meet emissio
Richard Stormont* says the answer to this question is YES, and the technology is already
The EU has set specific targets and a timetable for the reduction of greenhouse gas emissions. Many other organisations and governments around the world have set guidelines and adopted policies with the same aim. In the case of the EU a 20% reduction is called for by this year 2020, 30% by 2030, 40% by 2040, culminating in ‘net zero’ by 2050, all from a reference point of 1990 emissions levels. In glass melting and conditioning adopting electric heating technologies has long been seen as the way to minimise emissions. With an insulating layer of batch covering the surface of the glass in a continuous vertical melting process, a well-designed all-electric melter can have a thermal efficiency of 85%, close to twice that of even the most energy efficient fuel fired furnaces (Figure 1). Together with the absence of fossil fuel firing and having all the energy applied by means of electrodes immersed in the glass, emissions from the process are typically limited to any carbon dioxide released from raw materials - a small fraction of the emissions from .conventional fossil fuel fired melting. The difference becomes even greater when taking account of variations in the actual output of furnaces in relation to their nominal capacity. Such variations are almost inevitable due to product mix, market demand, machine maintenance and furnace age and condition. The thermal efficiency of the cold-top allelectric melter remains high even at reduced pull, in contrast to the fuel-fired furnace, in which thermal efficiency reduces sharply as output is reduced (Figure 2). While most glassmakers are well aware of the energy consumption and cost of their furnaces, many take little account of the fuel consumption and cost of conventional gas-fired forehearths and distributor channels. With small combustion chambers and limited scope for waste heat recovery, the thermal efficiency of gas heating
Figure 2
Figure 1
* Richard Stormont, Managing Director, Electroglass Ltd, Benfleet, UK. www.electroglass.co.uk/
26 Furnaces International September 2020
www.furnaces-international.com
Emission Reduction
on reduction targets?
y here.
Figure 1. The insulating batch blanket of a cold-top electric melter.
Figure 2 Two Electroflex container glass electric .
Figure 3. Control panels for three electric furnaces and their electric forehearths under assembly and test.
Figure 3
in forehearths, that is the proportion of heat energy transferred to the glass in relation to the total energy input, is typically extremely low. Electrically heated forehearths and distributors not only eliminate combustion gas emissions entirely, contributing significantly to the total emissions reduction target, but converting from gas to electrically heated can typically reduce operating energy costs by between 60% and 90%. This is a prime example of both operating cost and environmental benefit going hand in hand. Electric glass melting and conditioning are established technologies - the author has been involved with both for 50 years. It remains a fact however that the large majority of electric furnaces have been for so-called ‘special’ glasses, borosilicates, fluoride opal, lead crystal and specialist technical glasses. Generally, they have also been of modest size, mostly in the range of say 10 to 80 tonnes/day capacity. In contrast the majority of the world’s container glass, which accounts for some 50% of total glass production, is produced in furnaces with capacities of between 200 tonnes/day and 400 tonnes/ day, with some larger still. Successful designs of small and medium-sized electric melters cannot simply be scaled up, a process that is much easier to achieve with fuel-fired furnaces. In-depth understanding and great care in concept design are needed to ensure the energy and temperature distribution necessary for successful cold-top vertical melting in larger furnaces (Figure 3). There is already proven technology and operational experience of all-electric container glass melters of 200 to 250 tonnes/day and more, and Electroglass has well-developed concept designs for 300 to 350 tonnes/day melters. However scaling up the use of allelectric melting , both in terms of the capacity of individual installations and in rolling it out on a scale needed to match the world’s container glass demands alone will take more time than is available in respect of meeting the EU
27 www.furnaces-international.com
Furnaces International September 2020
Emission Reduction
Figure 4 Figure 4. A large all-electric container glass furnace under construction.
targets for example. Expansion of the use of electric melting in the 200 to 350 tonnes/day range for the container glass industry will continue, with key glassmakers taking the lead. However to stand a realistic chance of meeting many of the emission reduction targets and plans, a major focus for the next decade or two needs to be based on expanding the use of highly effective and proven technologies we already have - the most efficient electric boosting systems for essentially conventional fuel-fired furnaces. Electroglass’ CCC (Convection Current Control) boosting systems have, with constant development and refinement, been in use for some years and have an established reputation of delivering the highest energy efficiency combined with marked glass quality improvement. The average energy consumption is just under 20 kilowatts of continuous power input for each extra tonne/day over and above the unboosted output of the furnace concerned.
Less attention has been focused on the actual percentage of output increase this technology has delivered. Of course, some of these boost systems have been required to achieve only modest increases in furnace output, but many have increased output by 50% to 65%, and occasionally more, up to 100%. A 65% increase in output over the unboosted output of a furnace through electric boosting means that 40% of that furnace’s total output is being produced electrically. Leaving aside the undoubted improvements in the unboosted fuel efficiency and emissions reduction of furnaces from 1990 to now, that translates to a 40% reduction in combustion emissions per tonne of glass produced in that furnace. The fact that the above output increases have consistently been achieved while maintaining or improving glass quality shows that there is considerable scope for increasing these levels of electric boost, further directly reducing emissions per tonne of glass.
Boost design The boost design is crucial. Simply installing a high level of boost power is not only unlikely to achieve the desired output, but may well drastically reduce residence time, refining and therefore glass quality, even at substantially higher boost power inputs per tonne of glass. The zoning, number, size, positions, immersions and electrical connection arrangement of electrodes are critical. The study and understanding of each of these and other design variables, backed by decades of modelling, experience, practical application and proven results, are essential for success. While we continue with the development and application of larger all-electric melters, multiplemelter installations and other related approaches, existing electric boosting technology (and careful extension of it) and existing electric forehearth technology are already available to meet the immediate requirements for emissions reduction.
28 Furnaces International September 2020
www.furnaces-international.com
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
www.fic-uk.com +44 (0) 1736 366 962 ,
The World s Number One in Furnace Technology
FIC (UK) Limited Long Rock Industrial Estate Penzance, Cornwall TR20 8HX United Kingdom
GLASS SERVICE
A Division of Glass Service
Furnace of the Future
The Future of Glass Furnaces Stuart C Hakes*, Christoph Jatzwauk**, Erik Muijsenberg, Petr Jandacek and Hans Mahrenholtz*** ponder how furnaces will evolve in the post Covid-19 world. We have all learned that we live in a very strange and changing world due to the Covid-19 virus that is currently endemic around the world. Life has changed for most of us and the ramifications for the future are that there will be many structural changes. Notwithstanding the current pandemic, the glass industry has to change. Whether you believe in global warming or not, it has already been decided by many Governments and institutions that it is necessary to force industry to make changes and this has been enacted into legislation and targets. It may be that your own country is not following any of these dictats but nevertheless it will affect many glass manufacturers, because even if Government does not lead, your customers will start to demand it. Many customers, be it the public at large or institutions using glass will want to act as ‘green’ to their market in order to be seen as responsible citizens. This presents challenges for us all. It is well known that electric melters are considerably more efficient thermally (Table 1) and of course do not emit any CO2 apart from the raw materials (Table 2). For the purpose of this article I am ignoring the effects of carbon dioxide emissions on the production of refractories, steel, electricity etc. and only looking at the emissions in the glass plant itself. The problem with current electric furnaces is that they have a bad press. They are seen as having short lives although this is no longer the case. Typically we see lives of all-electric cold top melters of eight years and there is no reason to think that with
modern technology moving forward that this could not be extended.
Re-build cost In any case it is not necessarily disadvantageous, because the cost of a re-build of an all- electric furnace is considerably less than the re-build cost of a regenerative furnace be it endfired or side-fired and so two electric furnace campaigns will cost less than one conventional rebuild cost. They are also much quicker to re-build. The other problem levelled at electric melters is that they are inflexible, and this is indeed partially true. Cold top all-electric melters, which are the most thermally efficient, are generally limited to a range of pull of approx. 40% of maximum In fact there are only two down-sides to all-electric melting which really need consideration and that is that the current cost of electricity is generally much higher than other fuels and also that with current level of technology, electric furnaces are generally smaller than that is required of major manufacturers in containers and flat glass. This has changed, as I will explain later. It is quite likely that with legislation and the pressure on CO2 emissions, legislation will drive companies to look at alternative fuels which reduce CO2. There will be some move to biofuels on the basis that they are using renewable energy but this still does not fully address the CO2 emissions. Hydrogen burners are available and a sister company of FIC UK Limited (FlammaTec) has one
in operation. However, there are other issues with hydrogen which need to be overcome, particularly if the case of using oxy-hydrogen flames, remember this is the way rockets are put into space. The other problem with electric furnaces is that for some glasses, a cold top electric furnace is unstable, particularly of amber glass. This is currently solved by using semi hot-top furnaces for amber glass and this is technology which was
* FIC UK Limited, **FIC GmbH, ***Glass Service (Czech Republic) www.fic-uk.com www.gsl.cz
30 Furnaces International September 2020
www.furnaces-international.com
Furnace of the Future
proven in the 1970s when a number of electric furnaces were in operation making amber beer bottles.
Efficient The reason all-electric furnaces are efficient from a thermal point of view, is because of the low volume that needs to be heated. Most electric furnaces, except those making amber, are a cold top. This results in the heat in the furnace only melting the raw materials and refining them. The losses through the refractory are limited only to the glass bath as any superstructure is generally insulated by
the batch blanket. It follows therefore that all-electric furnaces are vertical melters, unlike conventional furnaces which are horizontal. Electric furnaces have been built up to 300tpd although almost without exception most are in the range of 50-200tpd. Whilst in theory it is technically feasible to produce a system to cover batch over a furnace melting between 600-1000tpd, the costs and operational difficulties are enormous. In addition, the depth of the glass to maintain vertical melting over such an area would again be technically challenging in terms of both refractory
design and more importantly furnace life.
Pooled resources As a consequence of this limitation FIC UK Limited and Glass Service (Czechia) pooled their resources to look at how this might be overcome for the majority of furnaces in the world. We have modelled our proposals using existing furnaces as a base case e.g. a 350tpd container furnace and a 600tpd float furnace and modelled the changes and have shown that our thinking is workable and produces the same quality glass as the original base case furnaces. This represents a
31 www.furnaces-international.com
Furnaces International September 2020
Furnace of the Future
TABLE 1
Table 1
significant breakthrough as we have determined that the existing footprint of a container furnace or float furnace can be maintained. This is a considerable saving on the capital cost. FIC UK Limited and Glass Service (Czechia) recognise that there is a tremendous leap from the existing furnace to these large all-electric furnaces but have devised a pathway allowing companies to move slowly in this direction. These pathways are grouped under two headings, superboosting as an initial step leading to a Hybrid furnace.
Superboosting Superboosting is a term used when taking an existing furnace, with or without a small amount of electric boost, and progressively adding more boost to the furnace and steadily reducing the amount of firing. This is relatively easy TABLE 2 to do on an end port furnace as typically used on container furnaces and is easily possible on float furnaces, however, in the case of a float furnace it really requires individual chambers grouping either the port singly, or in pairs. This approach allows customers, at an appropriate time, either at a re-build or by hot drilling the furnace on-the-run to add more boost progressively and reduce the amount of fuel in the furnace accordingly. Theoretically, 1kW electric boost in the glass should save 2kW of natural gas but in reality we have found in practice that this figure is not reached. The increase in power of an existing zone or zones or the addition of other zones in the melter upstream of the hot spot (uprise position for float furnaces) is a simple pathway. We
have found from our modelling that it is possible to put in over 50% of the energy by boost whilst maintaining glass quality and output. In some furnaces much more than 50% of energy in the form of boost can be improved but it depends on furnace design. We have also modelled using high levels of cullet (up to 80%). After the saturation point of the furnace at the 50% (or more) level then changes need to be made to the furnace as we start to go into the Hybrid phase.
Modelling From our modelling it is clear that adding more power means that we can go to a maximum of 80% of the energy supplied by in-glass electrodes. Our modelling has found that we do need some top heat to maintain glass
quality. Our modelling also shows that these hybrid furnaces can operate from 15% electric mode up to 80% electric mode so can be operated flexibly depending upon the fuel availability and fuel costs. As I stated previously, the hybrid furnace pretty much follows the existing footprint of the furnace reducing the capital costs. Another point to remember is that although we have said there is top heat required, (and this could be natural gas if available or bio-fuel), but can also be by electricity. The above-glass electrical heating can take two forms – either by preferably molybdenum disilicide elements or less favourably silicone carbide, or alternatively the electricity could be used to generate hydrogen and oxygen onsite by electrolysis and burn this in the furnace. The use of top heat in this hybrid furnace also eliminates one of the limitations of conventional all-electric melters, namely turn down ratio and amber glass production. The hybrid furnace is thus flexible and can operate from zero to maximum pull and melt any colour or tints. It is thermally more efficient than existing melters and is lower capital cost. I hope to show by this presentation that there is a pathway to large all-electric melters which is surely the way forward in the next 10-20 years. Extensive modelling has been carried out to give some confidence and assurance to those contemplating this move. The future of glass is in all probability electric.
0.50
(0 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0.45
[t/t]
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00 regSP
Table 2
regEP
regEP, EB
â– Combustion
regEP, EB, CP
regEP, EB, BCP
Melting
rec, EB
AOF
HybridM
AEM
â– Direct (Comb. + Melting)
32 Furnaces International September 2020
www.furnaces-international.com
Furnaces International brings readers a selection of technical features focusing on all aspects of the international furnaces market, as well as industry news, events, and regular columns from the British Industrial Furnace Constructors Association (BIFCA).
Published quarterly in a digital format, Furnaces International magazine is sent straight to the inbox of over 50,000 professionals from across the aluminium, steel, and glass industries.
SIGN UP TO RECEIVE YOUR FREE COPY
Contact us now: Nadine Bloxsome
Nathan Jupp
Esme Horn
Manuel Martinquereda
Editor
Sales Manager
International Sales Executive
+44 1737 855115
+44 (0) 1737 855027
Glass & Primary Metals Department Co-ordinator
nadinebloxsome@ quartzltd.com
nathanjupp@ quartzltd.com
+44 1737 855136 esmehorn@quartzltd.com
ManuelM@ quartzltd.com
+44 (0) 1737 855023
BUSINESS MEDIA
WWW.FURNACES-INTERNATIONAL.COM Untitled-3 1
05/09/2018 13:37
Melting Solutions
Fives: melting solutions for industria Remi Pujol* outlines the variety of melting options available to glassmakers from the container and float sectors. Fives isan international engineering group that has served the glass industry for decades supplying solutions for glassmakers. Its glass melting technologies are designed for maximum longevity, optimum efficiency and with the environment in mind.
Figure 1
Figure 2
Figure 3
Figure 4
Figure 1. Electric furnaces (Fig 1) are a green alternative to traditional fossil fuel-fired glass melting. Figure 2. Oxy-fuel combustion increases furnace efficiency, reduces emissions and improves glass quality by creating a more stable process. Figure 3. Flexible hybrid furnace: up to 80% electric boosting with air/oxy-gas combustion for low emissions production of container glass. Figure 4. Produce high quality automotive and architectural glass with Prium Melt Float, the float glass furnace with Low Energy Melter for maximum efficiency.
Electric melting furnaces Electric furnaces (Figure 1) are a green alternative to traditional fossil fuel-fired glass melting, offering better thermal efficiency, lower emissions and the potential for advanced automation. With a reliable supply of renewable energy, electric furnaces have the potential to reduce combustive emissions from glass melting to zero. Electric furnaces are especially suited to manufacturing lines melting one glass type under a stable load. Capacities as little 10 tpd and as much as 150 tpd have been successfully in operation, and this could be increased to 300 tpd. Example applications include: pharmaceutical, container, tableware, perfumery and cosmetics, opal glass, tubing for pharmaceutical and lighting applications, fibers, HV insulators, and coloured glass (float/rolled). One of the advantages of electric furnaces is the straightforward layout, which enables it to be almost fully automated. Automation further increases
efficiency, but is also a safety benefit, keeping personnel out of danger. In electric melting the raw materials are distributed evenly over the top to form an insulating batch layer in a cold or semihot top vertical process. The materials are melted and refined as they are drawn down through a deep melting tank to exit at the throat. This process ensures minimal heat loss – in fact, electric furnaces can reach thermal efficiency of up to 85% dependent on capacity. This high thermal efficiency and the system’s energy efficiency are one of the main reasons why glass manufacturers choose electric furnaces.
The Prium E-MELT series Fives offers cold-top and mixed-melt electric furnaces, as well as electric boosting, in its Prium E-MELT range. � The Prium E-MELT cold-top vertical melter (CTVM) offers a cost-effective option to produce a range of glass types. The deep-CTVM format will produce exceptional quality glass with low fault
concentration and high homogeneity. This solution is particularly applicable to glasses with volatile constituents such as lead, boron and fluorine but can equalling be applied to standard soda-lime glasses for container applications. � Prium E-MELT mixed-melt furnaces offer an alternative for situations in which cold-top operation isn’t possible due to high-gassing of melting reactions (e.g. carbon-sulphur amber) or when greater output flexibility is required. It uses a low-power combustion system to heat the crown and electrodes for the rest. It extends the benefits of an electric furnace to situations in which electric melting would not previously have been feasible. Fives is continuously striving for increased efficiency and a lower total cost of ownership (TCO). We use physical and computer-based modelling techniques to design and evolve power systems, furnace geometry and process control systems. Our control systems utilise technology incorporating touch screens, PLC’s,
*Sales Manager-Glass, Fives, Didcot, UK https://glass.fivesgroup.com
34 Furnaces International September 2020
www.furnaces-international.com
Melting Solutions
al projects specialist software and computer equipment from various manufacturers. Solutions are tailored to each individual project based on the technical complexities of the installation and the requirements of the customer. Oxy-fuel furnaces designed for greater efficiency Oxy-fuel combustion (Figure 2) increases furnace efficiency, reduces emissions and improves glass quality by creating a more stable process. The addition of oxygen to the fuel almost eliminates nitrogen from the oxidiser, which greatly reduces the mass flow rate of flue gas leaving the furnace. Melting efficiency is increased and the environmental benefits have made oxyfuel combustion a preferred technology for many customers and even a requirement in some applications. Further adding to the advantages of oxy-fuel furnaces, Fives has developed the Heat Recovery Area (HRA) system. This proprietary system reduces the crown height at the back of the tank to optimise the radiative exchange between the flue gas and the batch blanket and reduce the temperature of flue gas leaving the furnace. The result is a 5 – 10% reduction in energy consumption.
Prium Oxy Melt with Heat Recovery Area The flue gas in oxy-combustion tanks is usually evacuated by openings in the breast walls of the furnace. These flue gas outlets are placed in the batch area to reduce the temperature of the flue gas leaving the tank. However, this design is inefficient, as it allows an uncontrolled recirculation of flue gas between the hot (central) zone and the colder zone above the batch blanket. Furthermore, the semi-transparency of the flue gas allows an intense radiative exchange between flue gas, walls and batch surface, thus levelling out the desired temperature drop of the flue gas towards the outlets. The new proprietary design of HRA technology from Fives solves this problem by a controlled, even flow of the flue gas in counter-direction to the batch blanket flow. This is achieved by a reduction of the crown height. Previously, the high level of the crown and a large flue gas volume were believed to be compulsory for an
intense radiative emission towards the batch surface. However, Fives discovered that a much lower crown level optimises the radiative exchange between flue gas and batch blanket. In addition, size and orientation of the flue gas outlet minimise radiative losses by the hot crown and flame radiation.
An evolution in hybrid furnaces Fossil-fuel driven furnaces are emissions intensive. Electric boosting can help reduce the furnace’s carbon footprint, but the balance of energy efficiency has typically been lost at around 30 -50% electrical input – until now. Fives has designed a new type of hybrid furnace, incorporating its Heat Recovery Area (HRA) technology to achieve up to 80% electric boosting, which could reduce emissions by up to 60% (Figure 3). Container glass production goes green The Eco-Flex hybrid furnace from Fives addresses the disadvantages of gas combustion, while mitigating the limitations of all-electric furnaces. By replacing up to 80% of the natural gas with green electricity, furnace emissions are dramatically reduced, but the additional benefit of this system is the ability to use high rates of recycled glass (up to 80%). For every 10% of cullet added to the mix, CO2 emissions are reduced by 5% and energy consumption falls by 3%. These savings are not possible with electric furnaces, which cannot use large quantities of cullet. The hybrid furnace is designed for all types of container glass production.
Flexible electric boosting Eco-Flex is designed to operate with the same quality level, from 15 – 80% electric boosting. It’s not simply a case of fixing on a number and continuously operating at, say, 50% electric boosting – you can change the boosting ratio on the fly, without a production stop, down to a minimum of 15%. Previously, hybrid furnaces were limited by three things: 1. High electrical energy ratios require a lower temperature above the batch layer. 2. Separation of melting and refining, and effective degassing of the melt, require higher temperature above the fining section (with free glass surface). 3. High boosting input increases need for a strong thermal barrier (division between melting and refining).
This implies the need for a temperature gradient within the combustion chamber, which is difficult to achieve in a single combustion zone, especially with the burner/combustion configuration in an air-gas end-fired port furnace. Low temperature regions of the crown are prone to volatile attack and it can be difficult to control temperatures in an optimal way. The Eco- Flex uses proprietary Heat Recover Area (HRA) principle to overcome these limitations. HRA technology lowers the crown height over the preheat zone to maximise the heat transfer between waste gas and the batch surface. In a conventional oxy-fuel furnace, this creates an energy saving of 8 – 10% and reduces waste gas temperatures, benefitting secondary heat recovery and simplifying exhaust handling. The HRA zone length can be adapted to suit your needs and the whole system can be scaled to suit any capacity and container glass type/cullet ratios. Combustion can be adapted to either oxyfuel or air-gas.
Float glass furnaces With environmental concerns at the forefront of glass manufacturer’s minds, reducing energy consumption is a priority. Less fuel means less emissions, but ordinarily it would also mean lower temperatures and reduced quality and efficiency. To overcome this, Fives developed its proprietary Low Energy Melter (LEM) technology for use with the Prium Melt Float furnace (Figure 4). The LEM improves melting efficiency while reducing energy use down to 1200 kcal/kg (5 GJ/ton). Float glass furnace from Fives is designed to produce architectural and automotive glass with the highest clarity and quality according to ASTM and EN standards. When combined with the Prium Bath and Prium Lehr, the Prium Melt Float is an energy efficient float glass line solution for flat glass measuring 2 – 15 mm thick. The furnace design, together with our advanced control systems, ensure guaranteed flatness and optical characteristics, as well as automatic glass flow regulation. Our tailor-made designs are made possible thanks to our wide technological knowledge and our innovative mindset. Every glass manufacturer deserves a glass melting line that is tailored to their requirements.
35 www.furnaces-international.com
Furnaces International September 2020
Life after Lockdown
SmartMelter Inspections during and What will life be like for glassmakers after the lockdown? Fred Aker* discusses how manufacturers can assess their furnaces in the most challenging of circumstances.
Glass melting furnaces continue to wear and degrade during a crisis and won’t wait for lockdowns and travel bans to pass. In contrast to repair and construction companies who must be on-site to perform their services, SmartMelter has given customers the flexibility to conduct self-performed repeat inspections to monitor refractory corrosion for years. Most repeat customers make use of this option. Covid-19 has produced unique challenges to SmartMelter, as it has to every business. One of these challenges is that customers have less personnel in their facilities as they try to to keep as few employees in the factory as necessary. This means engineers and hot maintenance personnel who are not directly involved in daily production are working reduced hours or remotely. Those employees who are still showing up are working in staggered shifts and maintaining physical distance to reduce the chance of infections.
22kg Compact rolling case containing two sets of equipment
*Vice President Sales & Marketing at PaneraTech, Chantilly, Virginia, USA www.smartmelter.com
36 Furnaces International September 2020
www.furnaces-international.com
Life after Lockdown
d after Covid-19 Lockdowns The new challenges also include: � Getting to customers – especially first-time customers – to label the furnace and train plant personnel. � Helping customers who can’t perform their own furnace scans during times of lockdowns. For the first challenge of getting to customers, we have developed a new self-inspect programme to equip initial customers to be self-sufficient. Under this scenario, we send the equipment (a single 22kg rolling case) to customers and teach them how to label the furnace and use the equipment. This is done via videoconference and training videos we have developed for this purpose. These customers have a SmartMelter coach available during all working hours in their time zone to assist on the phone. Daily check-ins are conducted as well to review the progress and data collected. We also give these customers longer equipment lease periods to allow them to inspect at their own pace or with limited personnel. This new variation on firsttime inspections has already been sold to customers on three continents. One of these inspections led to the customer having to cancel a marketdriven colour change to flint and will affect the scope and timing of an upcoming intermediate repair. For the second challenge, which is helping customers who can’t scan the furnace themselves due to dire circumstances, we get creative. PaneraTech has field engineers on three continents who can at a minimum serve customers in the country where they live. Our Certified Partner, Fosbel, expands this reach even further. Customers who are near a Fosbel technician have the option to receive a comprehensive furnace audit that includes a SmartMelter report and targeted recommendations. For standalone SmartMelter inspections, we also have access to contract technicians who are geographically close to customers and can operate our equipment. Our practice has always been to teach the customer to be self-sufficient
37 www.furnaces-international.com
Furnaces International September 2020
Life after Lockdown
Poor monitoring of a glass furnace. Courtesy of the Millville, NJ Fire Department.
at data collection. Even during the initial inspection, we have typically shared the burden of collecting data with the customer. It has always been a partnership. Now, with physical distancing so important, we can offer to perform the entire inspection. There is no need for the technician to interact with the plant personnel or touch the customer’s computer to upload data. All we need is WiFi access or to tether to a mobile phone. The customer receives an email from us with a link to install the SmartMelter XSight software. From there, he can monitor the inspection progress remotely. Again, no interaction with plant personnel is necessary. We managed to conduct this type of inspection for the Italian manufacturer Vetrerie Riunite during the darkest hours of the Coronavirus crisis in northern Italy without endangering the plant personnel or our field engineer. Our inspection revealed that the throat needed to be overcoated immediately. These inspections that require us to do everything through a third party or our own field engineer are more costly. Pricing is also being updated to reflect the savings when customers scan the furnace themselves. What happens to the industry after lockdowns are lifted? We hope lockdowns are a thing of the past by the time this article is printed. Depending on how long the ‘newnormal’ takes, things are going to get complicated. Will there be mandatory quarantines when crossing borders? If so, the measures addressed above will address this situation for SmartMelter. For customers who need other services, things will get complicated. � They may continue to not have access to specialised furnace repair and maintenance skills. Especially in less developed countries. � Repair and furnace construction companies need to catch up for the weeks/months that they lost. Due to this backlog of work, rebuilds and repairs will need to be delayed. � Supply chains have been interrupted. While specialised equipment such as IS, ware handling, and inspection
Marked up photo to help label the furnace.
38 Furnaces International September 2020
www.furnaces-international.com
Life after Lockdown
This will lead to further delays and require furnaces on their last legs to operate longer than planned. How can SmartMelter help with these challenges? SmartMelter can determine what maintenance is immediately necessary and what can wait. Our experience has been that many companies are too conservative with maintenance. They overcoat more than is necessary and before it is necessary/prudent to do so. We can help customers make condition-based decisions. We can also monitor the insulation for early glass or metal penetration, giving manufacturers the confidence to possibly operate a furnace for a year or longer than planned. We can detect and quantify problems long before there are thermal or visual indications through the insulation. This will be especially important for certain sectors of the glass industry. On one end of the spectrum, we have pharmaceutical glass producers who will be especially critical for providing ongoing medical supplies. To quote the New York Times from May 2, 2020: “Bill Gates, the Microsoft founder, whose foundation is spending $250 million to help spur vaccine development, has warned about a critical shortage of a mundane but vital component: medical glass. “Without sufficient supplies of the glass, there will be too few vials to transport the billions of doses that will ultimately be needed.” While we respectfully disagree with Mr. Gates or New York Times categorisation of glass as ‘mundane’, we do agree that pharmaceutical glass will continue to play a life and death role in this crisis. Depending on the vaccine developed, 7-14 billion doses will need to be administered. These critical infrastructure operations cannot afford any unplanned or avoidable downtime. On the other end, we will have especially hard-hit glass segments. These include tableware makers who are primarily selling into the hospitality industry (restaurants, hotels, bars). Tableware producers were already living on razor-thin margins before Covid-19. Anything they can do to extend the life of
Where do we expect SmartMelter services to develop in the future? We expect more customers to perform their own data collection with our easy to operate equipment. This will save money on inspections while reducing the number of outsiders entering plants. The turnaround time on this equipment including shipping will be much slower than if PaneraTech or our certified partner Fosbel is hand-carrying equipment to the plant and leaving with
www.furnaces-international.com
MOTING PRO TH
Summary
the equipment following completion of the data collection. We have prepared for this by building additional sets of our proprietary hardware and making it even easier to use. No matter how the industry wants to execute inspections, SmartMelter will be available through multiple channels to serve the customer’s needs. This may be through our Certified Partner, Fosbel, self-service, contract technicians or PaneraTech field engineers. It is not important how the data is collected. The value we provide is in the analysis of that data and the resulting reports and recommendations. This allows customers to plan the life cycle of their furnaces with deterministic data.
INIUM IN LUM D EA
30 YEA R
S
N HA
their assets while reducing the probability of a catastrophic leak may be necessary for their survival. This holds true for any low margin glass sector.
FOR MOR ET TRY US
machines have continued to be produced during lockdowns, the specialists from Europe and the USA have not been able to travel to customers to install and commission this equipment.
CONNECTING THE INTERNATIONAL ALUMINIUM INDUSTRY RY FOCUS
Aluminium International Today is an English language journal
SPANISH INDUST
G
MINING & REFININ
EXTRUSION
TION PRIMARY PRODUC
dedicated to the production and processing of aluminium.
day.com l.31 No.1
miniumto
www.alu ebruary 2018—Vo January/F
It contains a digest of global news, events, and statistics as
NAL THE JOUR
NIU OF ALUMI
CT M PRODU
PROCESS ION AND
ING
& Aluminaium Alumin nik h c Te
well as more detailed technical articles, company and country profiles, conference reports and regular regional economic briefings. Published six times a year, Aluminium International Today reaches more than 3,000 aluminium industry professionals, and is read in over 85 countries worldwide. d competitive g force behin n. The drivin productio aluminium d 1 1 1-18 COVER.ind AIT jan feb.indd 7x210-05-0 t-Today_29
CLP_Alu-In
Claudius n: Publicatio Insert Date:
16/01/2018
15:51:15
05/01/2018
Peters
nal Today
Internatio Aluminium 2018 Jan/Feb
05-01-18 Copy Date: m 297x210m Ad Size: Peters Ref: Claudius Booking
11:54
t, g this documen 761212. arise concernin +44 (0)1582 If any problems Studios on Oyster please contact COVER 4813 10_05-01-18 Job Number: Today_297x2 CLP_Alu-IntFile Name: 05-01-18 Last Updated: 1 Proof Stage: by: Approved
SIGN UP TO RECEIVE YOUR FREE COPY Furnaces International brings readers a selection of technical features focusing on all aspects of the international furnaces market, as well as industry news, events, and regular columns from the British Industrial Furnace Constructors Association (BIFCA). Published quarterly in a digital format, Furnaces International magazine is sent straight to the inbox of over 50,000 professionals from across the aluminium, steel, and glass industries. Sign up at www.furnaces-international.com to receive your free copy.
Join the Aluminium International Today Group
AIT_Furnaces_A5_Ad.indd 1
@AluminiumToday
WWW.ALUMINIUMTODAY.COM 14/05/2019 11:44
Furnaces International September 2020
39
Company Profile
Continuus-Properzi’s new look The size of a company is not measured solely on the magnitude of its revenue but above all on its ability to evolve, to change, and to continuously improve. Over the years, Continuus-Properzi has expanded its product range so that it can offer its customers complete systems: from furnaces to coilers, from the new IULIUS4.0 applied technology to the new Technical Consultancy Service available in three versions. The latest ContinuusProperzi innovations have been focused on our furnace technology that is divided according to the material to be processed, starting from furnaces for copper scrap to those for copper cathodes and then passing to those for Aluminium. To optimize and support this division, the Continuus-Properzi Board of Directors decided to improve and implement its engineering expertise by dedicating a Research and Development team to the study of Properzi technology applied in the design and realization of Furnaces. Here is a chart (right) showing the complete typology of Properzi furnaces that we are going to highlight
Vert-melt furnace set for aluminium lines Today, in the modern globalized world, large Aluminium CCR rod lines may require a Furnace Set (Melting and Holding) with production rates above 5.0 tph up to 8.0 tph and higher, and, at the same time, that provide a modest investment cost, a compact lay-out, low maintenance, and low gas consumption. Taking advantage of 30+ years of experience with Shaft Furnaces, only Continuus-Properzi can currently offer a precise answer to this market demand that is the Vert-Melt family of furnaces. The Vert-Melt furnace is a combination of a vertical (shaft) melting furnace with a static receiving/holding chamber.
Main advantages � Very high production rate � The skip charging machine is virtually automatic � Constant melting rate not disturbed by charging operation � Energy efficiency is approximately 25% higher than any Reverberatory Furnace with regenerative burners
Vert-Melt Furnaces Set for AL Lines
� Metal losses are more than three times less compared with a Reverberatory Furnace: 1.5% versus 5% � Easy operability and low maintenance � Low emissions � Possibility of continuous production of alloys by feeding two Holding Furnaces: one for alloying practices and one to feed the casting machine � Vert-Melt Technology does not require sophisticated and energy wasting
stirring systems nor delicate maintenance and spare parts for regenerative burners and tabular alumina The charging system is very reliable and permits loading either ingot bundles or compressed bundles of pure aluminium scrap. The charging system is equipped with the following safety devices: � Overload protection, to prevent operation exceeding the maximum admissible charging load
40 Furnaces International September 2020
www.furnaces-international.com
Company Profile
� Surrounding protections properly interlocked � A closed circuit TV and camera system which monitors the charge position inside the Shaft The advantage of this continuous charging system is that heat loss is minimal and the furnace walls are not subjected to any thermal shock.
Furnace set for copper lines The variety of the Properzi family of furnaces extends, as we have indicated above, to furnaces suitable for the completion of plants for the production of copper wire rod starting from two types of products: cathodes or scrap (with different percentages of copper), or even for plants that can process both materials. Let’s start with continuous refining from scrap.
Continuous copper scrap refining
third one may be required. Main advantages: � Increased thermal efficiency � Longer refractory life and very short downtimes � Easier slagging and refining � Easier fumes filtration � Cheaper refining process with less additives � Improved final chemistry of the molten copper
Production range The Vert-Ref System is very flexible and offers many possibilities taking into consideration that the downstream casters may be continuous or discontinuous, therefore dozens of configurations of the production plant are possible.
Properzi Vert-Ref System
When scrap has Cu content ≥ 97%, an even more efficient technology has been developed. In this case the Properzi Vert-Ref technology is applied.
The vert-ref system for copper scrap recycling The new Vert-Ref Process is an evolution of the well-known Cosmelt System supplied by Continuus-Properzi based on 20+ years of experience. The Vert-Ref Process facilitates the melting, slagging, refining and homogenization of copper scrap in a continuous or batch operation in order to obtain molten copper with a controlled content of impurities for the production of copper ingot, copper rod, or other copper products. The Vert-Ref System consists of a special shaft furnace where a skip-hoist machine charges the scrap that is melted and starts the refining process. There are one or more refining chambers at the bottom of the shaft furnace where additives are added and some slagging is done. At the exit from the last chamber the melt has been refined but is still too high in oxygen content. The reduction operation is accomplished in the downstream holding furnace by tuyeres or porous plugs. For continuous operation a second holding furnace is needed and, in some cases, a
The Vert-Ref melting shaft furnace is suggested in the range 5-12 tph while the total annual production may vary from 8,000 up to 40,000 tpy and higher with different arrangements of casters for rod, billet, ingot or other products and with different quantity and size of holding/ reduction furnaces installed within the system. Always beginning from the melting of copper scrap, another typology of furnaces is the reverberatory scrap refining furnace.
Reverberatory scrap refining furnace Recycling of copper scrap is not only environmentally friendly, and an example of a circular economy, but provides a good opportunity for a prosperous business. Continuus-Properzi introduced an
important evolution of the old model of reverberatory furnaces that were tiltable on wheels or rollers and were developed during the second part of the 20th century for the steel and copper industries. The general geometry of the old reverberatory furnaces was always similar except for the size and the different brands. The charging door(s) and the slagging door were on one lateral side while the pouring spout and the tuyeres were on the opposite side. The main burner(s) and the fumes exit were located on the shorter sides of the furnace opposite to one another. Continuus-Properzi patented a new design in 2010 where, as a major difference, the charging door was located on the roof of the furnace thereby allowing a faster, simpler, and more automatic charging operation. The loading system can be accomplished via a skip charging machine or an industrial belt conveyor. The latter system is the most advantageous for larger size furnaces allowing many tons of scrap to be charged in just one minute. Continuus-Properzi provides Reverberatory Refining Furnaces that cover all the different sizes of Copper Casting Lines from small ones, which produce 10,000 tons per year, up to large ones producing 75,000 tons per year. The first 250ton capacity Refining Furnace using this new roof top charging concept has been in operation in the USA since 2012 with excellent results. Top-charging 100 ton and 150-ton capacity Reverberatory Refining Furnaces followed. The refining know-how developed and optimized in many installations during the last 25 years is the key to the profitable operation that Properzi can offer to Clients worldwide. The Reverberatory Refining Furnace can be fed with 100% copper scrap with minimum 94% Cu content that could be a mix of many different kinds of copper scrap thereby saving hundreds of dollars per ton on the raw material! This technology is designed and capable to process copper scrap into liquid metal with a controlled content of impurities. The production of this molten copper is suitable to produce FRHC (Fire Refined High Conductivity) copper rod, strip, billets, or copper ingot. We will now move on to the furnaces
41 www.furnaces-international.com
Furnaces International September 2020
Company Profile
designed for the production of wire rod that starts from the melting of cathodes; in this case the most suitable Properzi furnace set will be shaft + holding.
Shaft + holding for copper cathode Properzi has 40+ years of experience in designing such furnaces and was the first to develop the pre-mix burner system that today is adopted by all furnace producers.
� Expected yearly output: from 25,000 to 58,000 tons Medium output rate � Production rate: from 12.5 to 20 tph � Expected yearly output: from 61,000 to 115,000 tons
Various size options:
Large output rate � Production rate: from 25 to 40 tph � Expected yearly output: from 125,000 to 250,000 tons
Small output rate � Production rate: from 5 to 10 tph
The cathodes, and up to 15% clean copper scrap, are loaded automatically
and scattered inside the shaft furnace in order to increase melting efficiency thus reducing fuel consumption and refractory wear as well. The melting rate and the combustion quality are strictly controlled by Properzi’s state-of-the-art burner combustion system, where the combustion air-to-fuel ratio of each burner guarantees consistent melting at the desired value. The optimal combustion parameters, so maintained, facilitate optimization of flame quality, negligible dissolved hydrogen (gassy-copper), improved refractory service life, and, last but not least, fuel savings. The thermal
42 Furnaces International September 2020
www.furnaces-international.com
Company Profile
consumption of a Properzi Shaft Furnace is the lowest in this type of application and the quality of the liquid copper, collected in the Holding Furnace, is suitable for the most severe applications and meets the most stringent standards. Moreover, we provide the maximum flexibility in terms of design, configuration, and scope of supply, from just the technological package to a complete supply on an EPC (Engineering, Procurement, Construction) basis so that our customers can be only minimally involved with the installation of the plant. This flexibility is a distinctive characteristic of our company. In the end, it is important to underline that any facet of Properzi technology which is utilized by our customers will always be supported by specialized aftersales service and assistance. The advantage of having Properzi as your equipment and technology supplier/ partner for the complete development and lifetime of any project is the strength of the company itself which can offer highly specialized technical consultancy services (for all Properzi users) through three different options: 1. E-mail Consultancy - a fast “problem solving” approach based on information exchange via e-mail. The Customer will detail the issue to consultancy@properzi.it. Properzi will deploy its dedicated and qualified engineering/process team until problem resolution. 2. Remote Assistance - it is a direct point-to-point connection between Properzi’s control room and Customer Line PLC. To enable the Remote Assistance Service a communication module has to be installed and connected to the Internet. Opposite page: An example of Reverberatory Refining Furnace - 250 Ton
3. Technical Audit at Customer Site - This requires dispatching Properzi’s specialist(s) to site in order to assist the customer in resolving the most critical issues, those which cannot be addressed by mail and require Properzi’s physical presence on the Line.
Above: Shaft and Holding Furnaces - Properzi CU Lines 12.5 tph
We are always a step ahead in finding continuous innovation and new solutions to make life easier and more economical for all our customers.
Left: Cathodes Loaded Automatically
43 Furnaces International September 2020