HEAT PROCESSING Aluminium Recycling (Vorschau)

ISSN 1611-616X
VULKAN-VERLAG
Issue
2/2011
Special Issue:
Read all about the mega event
of the year from pages 117-142
http://www.heatprocessing-online.com
Recycling Plant
with Twin-Chamber
Melting Furnace TCF
Protecting
the environment
and cutting costs.
TCF (Twin-Chamber Melting Furnace)-Recycling Plant:
■ melting of contaminated scrap
■ TCF-Process
■ metal circulation system
■ automatic charging equipment
■ integrated control system
Benefits:
■ easy pouring
■ very safe operation
■ fully automatic operation
■ environmental friendly
■ reliable operation
Visit us:
Thermprocess Düsseldorf, Germany
Booth 9C62
28 June - 02 July 2011
LOI Thermprocess GmbH - Am Lichtbogen 29 - 45141 Essen / Germany
Phone +49 (0)201 1891.1 - Fax +49 (0)201 1891.321
info@loi-italimpianti.de - www.loi-italimpianti.com

6000 kg THROUGHPUT
18 % BETTER EFFICIENCY
1 TECHNOLOGY
18% reduction of energy cost – this is the
result of using the innovative Elotherm
iZone-Technology for the heating of bars
with 300 mm diameter and a throughput
of 6000 kg/h.
This example from a real operation shows
the potential for cost reduction due to iZone.
iZone automatically calculates the parameters
for the heating process using the
operator’s input of material and machine
data. Minimum energy consumption,
ideal through heating of the material and
reduced scaling – the key features of
Elotherm’s iZone.
MEETING your EXPECTATIONS
www.sms-elotherm.com

Editorial Reports
THERMPROCESS in combination with
GIFA, METEC and NEWCAST is again
the mega event of the branch
Optimism reigns for THERMPROCESS and the whole exhibition quartet in
Düsseldorf with the general motto “The Bright World of Metals”. CECOF
is actively supporting this exhibition, not only because it is taking place in
the heart of Europe but also due to the fact that the European suppliers
still dominate the world markets and are rightly claiming the international
technology leadership. This will for sure be proven again during THERM-
PROCESS 2011.
Particularly the number of exhibitors registered to date has increased
compared to 2007, showing a considerable shift towards international
exhibitors. This tendency also applies to the European exhibitor group being
represented by CECOF (the European Committee of Industrial Furnace and
Heating Equipment Associations).
This year’s THERMPROCESS is taking place in an economic environment which has brightened up for
most of the exhibiting CECOF member companies: the principal customer branches such as ferrous
and non-ferrous metals industry, the automotive industry, the machine and plant manufacturers,
aerospace and electrical engineering as well as all other metal using branches are investing again.
Therefore exhibitors and organizers in Düsseldorf hope that the number and internationality of the
visitors will increase as well.
One of the predominant themes – not only of THERMPROCESS – will be resource and energy
efciency. Even though energy eficiency has always been an important issue for the European
suppliers of thermo process technology and is therefore “old hat”, it is now of increasing importance.
The European Commission is looking at implementing regulatory instruments via the ErP Directive
2009/125/EG in order to move the European industrial furnace industry towards intensied efforts
to increase energy efciency even more. Against the background of the climate targets of the EU,
the industry is not rejecting this approach, only the right track is being discussed intensively. THERM-
PROCESS 2011 offers the chance – and the manufacturers will seize this opportunity – to show the
respective state of the art solutions.
The THERMPROCESS Symposium (organized by VDMA), where a large part of the lectures is being
held by European thermo process technology manufacturers, will mainly deal with these issues.
In this context it is anticipated that THERMPROCESS will – as in the past – prove its role as a platform
for trend setters and that the European suppliers of thermo process technology will remain in the
pole position.
Dr. Gutmann Habig
General Secretary CECOF
HEAT PROCESSING · (9) · ISSUE 2 · 2011 93

Official publication of
TABLE OF CONTENTS
Issue 2 · May 2011 · Volume 9
www.heatprocessing-online.com
INTERNATIONAL MAGAZINE FOR INDUSTRIAL FURNACES · HEAT TRATMENT PLANTS · EQUIPMENT
Reports
HEAT TREATMENT
Dominik Schröder, Hermann J. Meyer
Aluminium Recycling – Latest plant technology for
energy efficiency and environmental protection ......... 143
Aluminium recycling – Twin-chamber melting
furnace in progress
143
INDUCTION TECHNOLOGY
Stefan Beer
Use of induction systems for the production of extruded,
high-alloyed steel tubes ................................ 147
Martin Mach, Egbert Baake, Dietmar Köhler,
Thomas Walther
Extending the process limits of warm forging by
intermediate induction heating ......................... 151
MEASUREMENT & PROCESS CONTROL
Karl-Michael Winter
Soft optimization – How to increase the overall energy
efficiency by optimizing processes and material flows ... 157
Recuperative gas burner – New ceramic heat
exchanger with enhanced properties
184
BURNER & COMBUSTION
Sacha Scimone, Giovanni Carrara
Modern reheating practices focus on combustion
technology ............................................ 163
Sabine von Gersum, Wolfgang Adler,
Wolfgang Bender
Energy-efficient furnace heating – Regenerative
heat recovery with flat flame burners ................... 170
Val Smirnov, Ad de Pijper
Furnace burner delivers low NOx with high combustion
air temperatures ....................................... 175
Jörg Teufert, Stefan Baur
Regenerative burners for reduction of energy
consumption and emissions ............................ 179
Dimosthenis Trimis, Volker Uhlig, Robert Eder et al.
New ceramic heat exchangers with enhanced heat
transfer properties for recuperative gas burners ......... 183
126
THERMPROCESS SPECIAL: Read all about the
Hot Spot of the year!
VACUUM TECHNOLOGY
Uwe Zoellig, Klaus Buhlmann
Energy efficient vacuum solutions for
industrial furnaces ..................................... 189
94
HEAT PROCESSING · (9) · ISSUE 2 · 2011

News
Trade & Industry .......................................... 96
Diary Dates ............................................ 108
Events ................................................. 111
Book Review .......................................... 116
Thermprocess ‘11
SPECIAL
“Welcome to the most important trade fair”
Preface by Friedrich-Georg Kehrer, Messe Düsseldorf ........ 117
High-quality side program at the
„Bright World of Metals“
General information and map of the fairground ............. 118
THERMPROCESS Symposium 2011
Program, time table and speakers ......................... 122
“A globally unique opportunity of obtaining a
comprehensive overview of the industry”
Interview with Dr. Hermann Stumpp, Chief Executive
Officer of the LOI Thermprocess GmbH and chairman
of the exhibitors’ committee of the Thermprocess trade fair ... 125
Product Preview
See the latest innovations and products of the exhibitors ..... 128
Profile
COMPANIES PROFILE
M.E.SCHUPP Industriekeramik GmbH & Co. KG ....... 193
Are you playing it
safe?
Business Directory
I. Furnaces and plants for industrial
heat treatment processes .............................. 196
II. Components, equipment, production and
auxiliary materials .................................... 205
III. Consulting, design, service and engineering ............ 213
IV. Trade associations, institutes, universities, organisations .. 214
V. Exhibition organizers, training and education ........... 215
www.heatprocessing-directory.com
Columns
Editorial ......................................................................... 93
Index of Advertisers .......................................... Cover page 3
Imprint ............................................................ Cover page 3
Information about the functional safety of
thermoprocessing equipment can be found
here:
www.k-sil.de
Hall 9
Stand D22
Elster GmbH
Postfach 2809
49018 Osnabrück
T +49 541 1214-0
F +49 541 1214-370
info@kromschroeder.com
www.kromschroeder.de
HEAT PROCESSING · (9) · ISSUE 2 · 2011 95

News
TRADE & INDUSTRIY
Trade & Industry
Danieli Centro Combustion and Arvedi Group
finalized the contract for a new vertical furnace
Danieli Centro Combustion
(DCC) will supply a new vertical
furnace capable of matching
any market requirements
for different annealing cycles
to the Danieli Cold Mill Complex
at Acciaieria Arvedi, Italy.
In June 2010 Arvedi and DCC
nalized the contract for the
be performed in the rapid
close cooling section where
Jumbo power fans are foreseen.
Different strip widths
will be matched using a trimming
system, and maximum
heat transfer coefcients will
be ensured by positioning
special proled nozzles very
close to the strip. Strip tension
through this turbulent
passage is stabilized using up
and downstream helper rolls.
To increase the cooling effect
this section also is designed
to work with a H 2 content
of up to 25 %. Also, electric
heaters in the over-aging
chamber will maintain strip
temperature or slowly cool
it for a given time. Control
and instrumentation design
is based on state-of-the-art
concepts. Furnace control is
strictly linked to line control
and is capable of supervising
heating, soaking, and cooling
functions via software and/
or hardware, to ensure maximum
safety, thus respecting
increasingly stringent international
standards and regulations.
Arvedi Group and DCC
are condent that the good
teamwork established over
many years will guarantee
a positive outcome for this
ambitious project.
new vertical furnace that
includes engineering, supply,
installation, and supervision
at commissioning. Commissioning
is due to commence
in December 2011. To meet
the customer’s demand for
high performance but with
low investment costs, DCC
designed an exceptionally
compact furnace, complete
with heating, soaking and
cooling sections to allow for
any type of thermal curve,
which also will incorporate
different patterns. The number
of systems for each purpose
also has been increased
to permit short heat-up,
long soaking, slow cooling,
extremely rapid cooling and
extended over-aging time.
To further reduce investment
costs, flame-free tubes have
been substituted for radiant
tubes in the rst heating section.
From the environmental
protection point of view,
by reducing heat-transfer
time through installation of
high-performance process
machines we will obtain a
very low specic fuel and
electrical energy consumption,
resulting in a dramatic
slash in NO x emissions (< 100
mg/Nm 3 at 3 % O 2 in fllue).
Sections making up the furnace
also will include a freeflame
section equipped with
direct-flame burner zones fed
by hot air. A centralized recuperator
located in the waste
gas duct and a high impingement
premix burner zone fed
by cold air blown by a separate
dedicated fan will confer
strip heating to the maximum
allowable temperature in this
section. In the tube treatment
section heating is completed
and metallurgical transformation
at cycle temperature
is performed. The strip will
reach the required temperature
thanks to the use of 2P
Inconel, gas-ring radiant
tubes coupled with self-recuperative
burners. Jet coolers
in the slow close cooling section
will carefully reduce strip
temperature to values close
to AC1. Electric radiant tubes
also will allow for extended
soaking time. Cooling directly
from AC1 or cycle temperature
to zinc bath temperature
or lower (according to
process requirements) will
Mangels Aços expands HICON/H 2
® bell
annealer facility
Mangels Aços, a member of
the Mangels Ind. e Com. Ltda.
Group, placed an order with
Ebner in August of 2010 to
expand the existing HICON/
H 2
® bell annealer facility. The
order comprises four HICON/
H 2
® work bases, two heating
bells and two cooling bells.
The facility is equipped with
a Siemens S7 PLC control system
and the Ebner-developed
„Visual Furnaces 6“ process
International technology
Group Andritz has been
selected to provide a
gasication plant to Metsä-
Botnia’s Joutseno mill, Finland.
The 48 MW plant will
generate green fuel gas from
local biomass, thus making
the mill independent of fossil
fuels. After completion scheduled
for September 2012, the
mill will solely use renewable
fuels as energy sources and
fully replace all fossil fuels
in the mill’s lime kiln during
normal operations. Andritz’s
scope of supply includes engineering,
equipment, erection,
start-up, and optimization of
control system, based on an
SQL database. The facility
accommodates strip coils with
an outside diameter of up to
1.600 mm and a stack height
of 4.000 mm, representing
a max. net charge of 50 t.
Mangels Aços will start up
these facilities at the end of
2011, doubling the throughput
of material annealed with
HICON/H ® 2 annealing technology
to about 111,000 t/a.
Andritz provides a gasification plant in Finland
the entire gasication process.The
gasication plant
is based on the Circulating
Fluidized Bed (CFB) technology
of Andritz. Upon startup
of the plant, energy generation
at the Joutseno mill
will become carbon dioxide
neutral during its standard
production. Special attention
has been paid to availability
of the mill and environmental
factors. The fuel handling
system includes an innovative
dryer which utilizes the mill’s
excess heat for bark drying.
The gas produced is nally
burned in the lime kiln with a
burner developed by Andritz.
96
HEAT PROCESSING · (9) · ISSUE 2 · 2011

TRADE & INDUSTRIY
News
Cemented-carbide products manufacturer
orders furnaces
ALD Vacuum Technologies
GmbH, the Engineering
Systems Division of AMG
Advanced Metallurgical
Group N.V., will supply three
production-scale vacuum dewaxing
and high-pressure
sintering furnaces to Xiamen
Golden Egret Special Alloy
Co., Ltd., one of China’s
leading manufacturers of
cemented-carbide products.
These furnaces will provide
high-pressure sintering with
up to 100 bar argon gas pressure,
the nal step in the production
of high-quality hardmetal
products. The VKPgr
furnace combines the three
Bodycote upgrades furnace controls
main process steps in hard
metal production.
In the rst process cycle, the
cemented-carbide parts are
de-waxed. Next, the components
are vacuum sintered at
temperatures of about 1,400
°C (2,552 °F). In the nal
step, the components are
compacted under high gas
pressure to achieve a porousfree
material structure. The
high-pressure compacting
step is the key to securing the
highest mechanical properties
of the cemented-carbide
components for tools such as
drills or cutters.
Super Systems Inc. (SSi) supplied
Bodycote North America
with an automated nitriding
control system at its Highland
Heights facility outside
of Cleveland, Ohio. Highland
Heights upgraded the controls
on a gas nitriding pit furnace
to provide automated process
control for precise metallurgical
results and a traceable,
repeatable nitriding process.
The SSi nitriding system
includes a complete electrical
and flow-control system that
provides the furnace with the
ability to run recipes for oneor
two-stage gas nitriding
cycles and control all the necessary
parameters to achieve
precise metallurgical results.
EFD Induction lands brazing system order from
Andritz Hydro
According to Bodycote, the
new controls give Highland
Heights the ability to automatically
control Kn, temperature,
back pressure, soak time
and gas flows as well as data
log everything for complete
traceability. The investment
in controls and software has
created operational improvements
and plant-wide efciencies.
Austria-headquartered Andritz
Hydro has ordered a
Minac 25/40 twin induction
heating system from EFD
Induction. The system will
be used for copper brazing
at Andritz Hydro’s facility
in Weiz, Austria. “This
latest order means Andritz
companies have now purchased
about 25 Minac systems
from us over the past
two decades,” says Matthias
Gruber, managing director of
EFD Induction Austria. “And
that number does not include
ve Minac systems delivered
to Andritz Hydro in India during
the past two years, or the
four Minacs delivered to the
same customer in Brazil last
autumn.”
HÜTTINGER – power supplies
for innovative surface technology
Fascinated by process power
and what can be made of it
Our power supplies generate the power required for a great variety of coating processes. This includes plasma technology
that is indispensable to manufacture thin film solar cells, flat panel displays and micro chips. The generators are also used
in induction heating which increases hardness and wear resistance of driving shafts and spur gears. A leader not only in
the European markets, HÜTTINGER power supplies are also at the front of many industries worldwide.
Benefit from the experience of Europe`s best. www.huettinger.com
HEAT PROCESSING · (9) · ISSUE 2 · 2011 97

News
TRADE & INDUSTRIY
The Minac is a versatile,
mobile induction heating
system available with various
output powers up to
a maximum of 220 kW
at intermittent operation.
Automatic output matching
– which ensures optimal
power output for different
heating operations, coils and
materials – is standard for all
Minac models. ‘Twin’ models
feature two independent
power outputs from a single
The company was founded
initially as M/s. Hans Hennig
VDI e.K. by Mr. Hans Hennig
in 1968. Then in 2009
the business partnership was
transferred into the Hans
converter, in effect offering
two heating systems in one.
“When a company such as
Andritz Hydro, with its stringent
standards in a demanding
industry, places repeat
orders for an equipment item,
then you know you’ve passed
a tough quality control test,”
says Gruber. “It proves just
how much value the Minac
can add to a company’s operations.”
Körting Hannover AG has acquired the company
M/s. Hans Hennig GmbH
Siemens to modernize continuous slab caster for
ThyssenKrupp Steel Europe
Siemens VAI Metals Technologies
received an order
from ThyssenKrupp Steel
Europe AG to install new
process-optimization models
in a continuous slab caster in
the Beeckerwerth steelworks
in Duisburg, Germany. The
process models will improve
the quality of the cast slabs.
The modernization of the slab
caster is scheduled to be completed
in the third quarter of
2011.
In order to further improve the
quality of its slabs, ThyssenKrupp
Steel Europe is upgrading
the cooling and cuttingplan
optimization models for
the 2-strand continuous slab
caster SGA2 in its Beeckerwerth
Works. Sie mens VAI will
develop and implement the
required process-control system
expansions. The dynamic
Simetal Dynacs secondary
cooling model is an important
part of this plant modernization,
and is designed to
operate with air-mist cooling.
The model includes a 3D temperature-prole
calculation.
The cut-length optimization
model automatically generates
settings for mold-width
adjustments. The scope of
supply also includes adapting
the basic automation to
the new process-optimization
models.
Siemens VAI is responsible
for the engineering and the
manufacture of all components,
and will carry out the
complete integration tests,
commissioning and customer
training. The slab caster
was originally supplied by a
third-party, and has been in
operation since 1980. The
ThyssenKrupp Steel Europe
oxygen steelmaking plant in
Beeckerwerth produces highquality
input materials for
high-tensile steel, vacuumdecarburized
and interstitialfree
(IF) steels, tinplate, thingauge
sheets, tube strip and
heavy plates.
Hennig GmbH. The company
has been active in the
section of industrial ring
technology for over 40 years
with the main area of focus
being metallurgy. At the
time being the company has
approximately 45 employees.
The acquisition of M/s. Hans
Hennig GmbH was a strategic
investment in the future.
Based on a formal agreement
with IUT Sweden, Seco/Warwick
has added continuous
aluminum log/billet homogenizing
to the scope of products
available to the global
extrusion market. This multizone
vertical airflow furnace
technology is flexible. The
furnace can process billets of
different alloys and diameters
The products of M/s. Hans
Hennig GmbH supplement
the products and services of
the company division Industrial
and Process Heat, Firing
Technology of Körting Hannover
AG. It is to be expected
that the established market
access of M/s. Hans Hennig
GmbH will also set positive
accents for Körting Hannover
AG, as Hans Hennig GmbH
has a customer basis at its disposal
which leads to expectations
concerning a mutual,
goal-oriented development
of future prospects.
Seco/Warwick adds continuous aluminum billet
homogenizing to portfolio
without leaving empty saddles.
The control system manages
the walking-beam cycle
time and air temperature set
points to ensure that furnace
throughput is optimized and
required product quality is
achieved. The fully equipped
plant consists of the furnace,
cooling section and loading/
unloading equipment.
AFC-Holcroft supports the wind energy market
with a new furnace
AFC-Holcroft is pleased to
announce the receipt of
a new furnace order for a
sealed quench furnace line
that will be used to process
specialized components utilized
in the wind energy market.
The furnace line is based
on AFC-Holcroft’s standard,
modular UBQ (Universal Batch
Quench) family of products,
but was modied to optimize
its efciency for the mix of
products required by this customer.
Brevini Wind, headquartered
in Italy, is expanding
their facility in Indiana, USA
where the equipment will
be installed. AFC-Holcroft is
pleased to be part of the premium
Brevini supplier base as
they expand their business
units around the world. AFC-
Holcroft’s European branch
ofce spearheaded this project,
although equipment for
the project will be built in
North America. “We believe
the time is right to invest in
additional capacity, in North
America specically,” explains
Jacopo Tozzi, President of
Brevini Wind and CEO of
Brevini Wind. “The UBQ furnace
t our needs for today,
and allows the flexibility of
future expansion as the wind
energy sector continues to
grow. We are thrilled to add
Brevini to the list of global
manufacturing suppliers who
have chosen AFC-Holcroft
and our UBQ furnaces for
their operations,” says Marc
Ruetsch, Director of European
Operations at AFC-Holcroft.
98
HEAT PROCESSING · (9) · ISSUE 2 · 2011

EBNER
HICON/H 2
®
Heat treatment furnace
facilities for the steel
industry
S. C. Otelinox, Romania
throughput:
7.7 t/h
Cr/CrNi Strip
strip width:
max 1300 mm
stripthickness : 0.1 - 1.5 mm
• Professional project consultation
• Highly skilled in-house fabrication of key
components
• Expert installation and commissioning of
facilities
• Theoretical and practical training of
customer’s personnel
• Extensive after sales support
• Ongoing research and development
• Customer support in the development of
new products
• Optimization of process technology
Visit us at
THERMPROCESS 2011
Hall 9, Booth 9A38
28.06. - 02.07.2011
Germany
Bright annealing lines for
high- alloyed steel strip
• Bright, oxide-free surface for cold-rolled
stainless steel strip
• Dewpoint in atmosphere below -60°C
• No damage to strip surface
• Best strip shape and no strip breaks
• Precise temperature control
• Reduced fuel gas consumption
• Reduced H 2 consumption
www.ebner.cc
EBNER
EBNER Industrieofenbau GmbH
Ruflinger Strasse 111
4060 Leonding / AUSTRIA
Tel.: (+43) 732 68 68
Fax: (+43) 732 68 68 1000
e-mail: sales@ebner.cc
Subsidiaries: USA, CHINA, INDIA
Service Points: Brazil, Japan, Taiwan

News
TRADE & INDUSTRIY
Keramischer Ofenbau puts the shuttle kiln
in Portugal into operation
The company CERISOL Isoladores
Cerâmicos SA, Portugal,
is a manufacturer of a
wide range of ceramic insulators
(IEC solid core post, hollow,
line, and traction insulators).
The insulators have
got dimensions of up to 2.3
m length and diameters up
Tenova revamps two push pull pickling lines for
Ternium Mexico
Tenova Strip Processing
received a contract from Ternium
Mexico to modernize
two existing push pull pickling
lines. The main targets of this
investment are to improve the
strip quality, to increase the
plant productivity from 0.8 to
1.2 t/year and to enhance the
operator safety.
In particular, the upgrading of
the Pickling line no. 1 mainly
consists in the modernization
of the existing plants in
order to increase the production
and to guarantee better
quality to the nal product.
The existing entry section
will completely be replaced
by a new one composed by
doubled pass-line and sophisticated
equipment such as
stitcher & notcher units and a
tension leveller/scale breaker;
in the exit section a new side
trimming unit (turret type)
to 600 mm and weights up
to 1 t. The plant is designed
as shuttle kiln with a setting
volume of 61 m 3 . The gas
consumption is approx. 25
% lower than that of comparable
kiln
plants in the
same factory.
More outstanding
features
of this kiln are
the extremely
flexible ring
curves by
using a hightech
ring system
as well as
the very good
temperature
distribution
even with dif-
cult settings.
This shuttle kiln
type is available designed as
„down-draught system“ and
as “up-draught system”.
will replace the existing one,
all based on Tenova proprietary
design. The Tension
Leveller and the Side Trimmer
turret type are of the latest
generation featuring complete
automatic equipment
set-up and control. The high
strip elongation applied to
the strip and the very good
flatness are reachable thanks
to the Tenova Tension Leveller-Scale
breaker, leading to
an increase of the line productivity,
reducing the acid
consumption and improving
the strip running into the
process tanks and in the side
trimmer. The rotating feature
of the Tenova Side Trimmer
allows the blade changing in
half minute minimizing the
line stop time, the machine,
designed with stiff design and
tight mechanical tolerances,
guarantees precise and reliable
strip cuts.
Curtiss-Wright acquires surface technologies
business from BASF
Curtiss-Wright Corp., the
parent rm of Metal Improvement
Co., signed a denitive
purchase agreement to
acquire the assets of BASF’s
surface technologies business
from BASF Corp. The
surface technologies business
is a leading supplier of
metallic and ceramic thermalspray
coatings primarily for
the aerospace and powergeneration
markets. Thermalspray
coatings are utilized to
protect and enhance a wide
variety of critical components
used in the aerospace, automotive,
diesel, power-generation
and medical markets.
These coatings provide thermal
barrier protection, abrasion
and erosion resistance,
high-temperature oxidation/
corrosion resistance and
the capability to serve as a
replacement of hard-chrome
plating.
BASF‘s surface technologies
business applies several different
types of thermal-spray
coatings, including highvelocity
oxygen fuel (HVOF),
plasma spray and flame-spray
coatings, which can all be
tailored to the specic enduse
application. According to
Curtiss-Wright, thermal-spray
coatings are synergistic with
its current offering of highly
engineered metal-treatment
services.
Fives Stein won a new contract for ATI Allegheny
Ludlum in USA
Fives Stein has been selected
by Allegheny Technologies
Incorporated (ATI) to design,
engineer and supply on a
turn-key basis the two walking
beam furnaces which are
part of the contract received
by Siemens VAI Metals Technologies
(Siemens Industry
Inc.) for the new advanced
speciality metal hot rolling
and processing facility to be
built for ATI Allegheny Ludlum
in Brackenridge, Pennsylvania,
U.S.A.
As part of a strategic investment
to enhance the metal
processing capabilities, the
two new walking beam furnaces
of Fives Stein’s Digital
Furnaces ® technology will be
capable of reheating a wide
range of stainless steels and
other specialty alloys with
the highest quality requirements.
Each of these Digital
Furnaces ® is designed to
reach unrivalled ultra low NO x
performances combined with
high energy efciency solutions
for the full operating
range of production. The furnaces
will be equipped with
the latest generation of Fives
Stein’s low NO x Advantek ®
MWF modulating wide flame
burners. The associated pulse
ring combustion system of
the Digital Furnace ® technology
gives the best flexibility
of operation and allows the
production of the various specialty
metals and slab dimensions
of the product-mix at
high productivity and quality
levels.
The project scope for Fives
Stein comprises design, engineering,
manufacturing and
supply of the complete furnace
equipment, the slab
handling and the electrical
and automation systems. The
level 2 process automation
features a HOS (Heating Optimizing
System) and is aimed
at meeting the mill requirements
while maximizing the
furnace productivity and the
product quality. Supervisory
services are also being provided
for installation, start
up, commissioning, technical
assistance and training.
100
HEAT PROCESSING · (9) · ISSUE 2 · 2011

TRADE & INDUSTRIY
News
First aluminium foundries introduce
low-emission and energy-saving melting furnaces
from ZPF therm
China is on the brink of an
industrial revolution: the
emissions of CO 2 are planned
to be reduced by 45 % until
2020 and the consumption
of energy is supposed
to decrease in all sectors. In
many places plants have to
be equipped with expensive
lters in order to avoid severe
sanctions. In the economic
region of Shanghai rst
foundries take a step forward
and invest in modern furnaces,
which satisfy even the
strictest regulations without
any lters at all and, at the
same time, save material and
energy. The melting furnaces
are a product of ZPF therm
from Germany – the country
whose emission directives
served as one of the models
for the new legislation.
The reduction of energy consumption
and thus of CO 2 -
emmissions is a stated aim
of the coming ve-year plan.
Until 2020 the CO 2 -production
is supposed to decrease
by 40 to 45 % with reference
to the gross domestic product,
as stated the government
in late 2009. The problem of
water, air and soil pollution
shall be approached and the
change of climate is meant
to be combated. To that end
new limits for nitric oxides
and ammoniacal nitrogen will
presumably be introduced.
In the region of Shanghai
alone, in which roughly 70 %
of the foundries are seated,
about 500,000 t of aluminium
are melted every year. During
that process both gaseous
pollutants as well as solid
particles emerge, which have
to be removed from the emis-
sions according to the new
regulations. Interceptors and
lters are not sufcient, additional
condensers, adsorption
and absorption systems are
necessary. The acquisition
costs of an appropriate facility
for a single melting furnace
as generally used here range
from $ 70,000 to 140,000.
Against the background of
these costs and of the legal
pressure rst foundries have
now decided to solve the
question of efciency and
the waste gas problems in
the long run, by investing in
modern, eco-friendly facilities.
By now, four companies
in Shanghai have introduced
furnaces by the German manufacturer
ZPF therm who has
dealt with green technologies
for the past 15 years. The furnaces
which were designed
for the ideal use of raw materials,
low energy consumption
and the protection of the
environment are now coming
onto the market under the
slogan “EfficientTechnologies“.
Twelve furnaces by ZPF therm
are already in use in the
wider area of Shanghai. The
prospect of using less energy
permanently, of reducing the
running costs and of meeting
the new legal conditions
makes the furnaces very
interesting for the whole aluminium
industry – despite the
necessary initial investment.
As with most investments in
eco-friendly techniques the
expenses are put into perspective
by the cost-saving
opportunities in the long run.
According to that, the expert
on economy, Cheng Siwei
explained as a reply to the
question, whether the latest
trend would threaten the
prot of companies that for
a short time companies may
lose money during the adjustment
to a sustainable business
model, however, in the
long run it is cost-effective.
JASPER
Setting The Standards For Highest
Efficiency In Thermal Processing
2011
Hall 10
10A19
Aluminium Melting Furnace after Revamping,
Performance: 150 to per day, Capacity: 83 to,
equipped with 10 MW EcoReg® System
Gesellschaft für Energiewirtschaft und Kybernetik mbH
Bönninghauser Strasse 10 - D-59590 Geseke / Germany
Tel.: +49 2942 9747-0 Fax.: +49 2942 9747-47
INTERNET: www.jasper-gmbh.com
HEAT PROCESSING · (9) · ISSUE 2 · 2011 101

Inductoheat supplies induction forging system
The international magazine
for industrial furnaces,
heat treatment plants and
equipment
The technical journal for the entire fi eld of industrial
furnace and heat treatment engineering, thermal
plants, systems and processes. The publication
delivers comprehensive information, in full technical
detail, on developments and solutions in thermal
process engineering for industrial applications.
Now
also available
as epaper
Inductoheat, Inc. shipped a
single-module, 500 kW/3
kHz InductoForge ® induction
forging system and material-handling
equipment to
a supplier of hardware and
hand tools. This machine is
designed for heating a wide
range of billet diameters and
lengths to 2,250 °F. This
forging line begins with a
6,500-pound-capacity automatic
bin tipper with automatic
rell, which dumps
carbon steel billets into a
rotary feeder. The rotary
feeder continuously feeds billets
end to end using a start/
stop motion sensor and supplies
a pinch-wheel in-feed
system that precisely delivers
billets through the induction
coils on heavy-duty skid rails.
The power module supplies
two in-line forging coils and
accurately heats the billets to
2,250 ºF at a nominal rate of
300 pieces/h. Process control
is enhanced by IHAZ (induction
heat-affected zone) temperature-modeling
software,
which allows for customized
billet temperature prole to
best suit the customer’s ideal
billet heating specications.
After billets are heated to
the ideal temperature prole,
they exit the induction coil
on a fast extractor conveyor,
while the infrared temperature
pyrometer activates the
over and under accept/reject
system.
Samsung Electronics purchases vacuum furnace
VAC AERO International sold
a vacuum furnace to Samsung
Electrics to be used for hardening
captive press and plastic
die molds used in the manufacture
of mobile phones,
refrigerators and washing
machines. The furnace will
be housed in Samsung’s new
state-of-the-art facility in
Gwangju Metropolitan City,
Korea. The VAH6660 HV-6 is
equipped with VAC AERO’s
Honeywell HC900 interactive
control system with complete
network integration capabilities
and remote monitoring
and control.
The hot zone measures 48
inches wide x 48 inches
high x 60 inches deep and is
comprised of high-efciency
graphite felt, carbon composite
and curved graphite elements.
The furnace operates
at temperatures up to 2,400
°F. The vacuum pumping
system includes a diffusion
pump for high-vacuum applications
to 10-5 torr. Delivery
is scheduled for this summer.
Make up your mind on how to subscribe!
· The printed volume suits the classic way of reading.
· The epaper issue offers the modern way of receiving informationon
a computer, tablet pc or smart phone.
· The printed volume + epaper issue combine the best of both
worlds.
For more information on subscription details,
please check our online-shop at
www.heatprocessing-online.com
Nitrex Metal completes major expansion
program in China
Nitrex Metal completed Phase
2 of a four-phase nitrocarburizing
project for Chinese
industrial gear maker Nanjing
High Speed & Accurate Gear
Co. (NGC). The project is part
of NGC’s major expansion
program, which the company
embarked on in 2008 when
it opened two new largescale
manufacturing facilities
for the expanded production
of its high-speed and heavyduty
gears. Nitrex’s scope of
supply includes multiple nitrocarburizing
systems based on
a common horizontal-loading
chamber furnace platform.
Phase 3 will be fully completed
in 2011.
Vulkan-Verlag GmbH
www.heatprocessing-online.com
HEAT PROCESSING is published by Vulkan-Verlg GmbH, Huyssenallee 52-56, 45128 Essen

To date, eight turnkey systems
have been successfully
installed and commissioned
at the Nanjing
plant. Nitrex’s involvement
is in the front-end engineering
phase of the project,
including system and
process control design,
licensing of Nitreg ® -C
nitrocarburizing technology,
and on-site operation
and testing of the systems.
Nitreg ® -C technology was
chosen by NGC for its compliance
to AGMA 923 metallurgical
specication for
steel gearing. In addition,
NGC chose the Protherm
9800 production management
software supplied by
Marathon Monitors Beijing,
a member of United Process
Controls, to perform
data acquisition, recipe
management and monitoring
of the Nitrex nitriding
systems as well as three
preheat ovens and two
parts washers.
Nevada Heat Treating increases capacity
Nevada Heat Treating,
Nevada, U.S.A, is pleased
to announce that orders
are placed for two new
advanced heat treating
furnaces. This represents
a capital investment of
approximately $ 500,000
in the Nevada facility.
These furnaces will allow
to increase the production
throughput and decrease
lead times while maintaining
the high quality levels.
The new furnaces are
scheduled to be installed
and operational in spring
of 2011.
Latrobe Specialty Steel expands in Ohio
Latrobe Specialty Steel
was awarded a Contingency
Grant from the Ohio
Department of Development,
U.S.A., for creating
31 new full-time jobs and
retaining existing jobs at its
Wauseon plant. The company
will use the grant to
purchase new equipment
for its growing precision
wire manufacturing business
at Wauseon. According
to Latrobe Specialty
Steel, the company will further
expand capacity this
summer with the installation
of technologically
advanced hydrogen atmosphere
furnaces. The expansion
will cost approximately
$ 3 million at Wauseon.
Latrobe makes two product
groups: Edge wire and precision
stainless steel wire.
The industrial bimetal saw
market buys Edge wire,
an enhanced value-added,
small-diameter, rectangular,
high-speed-steel wire.
The market, previously
served by European producers,
includes manufacturers
of band saws, hacksaws,
reciprocating saws,
hole saws and utility knives.
Latrobe sources the highspeed
steel from its Pennsylvania
steel mill. For precision
stainless steel wire,
Latrobe melts the stainless
steel in Pennsylvania, ships
it to Wauseon and then
draws the wire to the exact
standards demanded by its
customers in the market
for implantable medical
devices.

TRADE & INDUSTRIY
News
Krautzberger receives the 2011 Hermes Award
The Hermes Award is one of
the most prestigious international
prizes for technological
achievement, and this year’s
winner is Krautzberger GmbH
based in Eltville. The company
received the award for
an innovative steam spraying
system. With this technology,
atomization is effected
by steam instead of the more
conventional compressed
air. Krautzberger’s adoption
of steam as the atomizing
medium for paints, adhesives,
glazes and varnishes is a
world rst. The use of steam
results in a smoother, more
even coating with reduced
overspray, giving a higherquality
nish combined with
signicant savings in coating
material (up to 25 %)
and energy consumption (up
to 50 %). At the same time
operating personnel benet
from the reduced noise levels.
Furthermore, the drying
process takes less time, resulting
in a further reduction in
energy costs. Altogether it
amounts to a big step forward
in environment-friendly
production processes. As well
as conserving resources, the
new technology also poses
less of a health risk to the
paint shop operatives.
This year’s Hermes Award
was presented on 3 rd April
2011 at the opening ceremony
for Hannover Messe by
Dr. Annette Schavan, Federal
Minister for Education and
Research. In her speech the
Minister praised the SME sector
as the driving force behind
so much technological innovation
today: “Krautzberger
GmbH is a perfect example
of a relatively small company
driving technology, which
despite the economic downturn
has managed to stay on
course with good ideas, disci-
pline and a real commitment
to business success. And
today that company has been
awarded this distinguished
prize for a uniquely innovative
technology with great
commercial potential.”
The winning company,
Krautzberger GmbH of Eltville,
was competing against
four other nalists for this
year’s Award. The other
nominated companies were:
FerRobotics (Linz, Austria),
Omega Air (Ljubljana, Slovenia),
Tailorlux (Steinfurt, Germany)
and Wenglor Sensoric
(Tettnang, Germany).
Qatar Steel expands steelmaking capacity
Qatar Steel plans to build
a new steelmaking facility
adjacent to existing plants in
Mesaieed. It is expected to
be commissioned by the rst
quarter of 2013. The new
1.1 million t/year plant will
comprise a Siemens VAI ultrahigh-power
110 t electric arc
furnace, 110 t ladle furnace
and 6-strand high-speed billet
caster coupled with fumeextraction
system for zero
emission. The expansion will
help Qatar Steel respond to
steel demand in the local and
GCC market. The plant will
be designed according to Siemens
VAI’s technology in the
eld of steel plant machinery,
equipment and automation.
The engineering design of
the planned equipment will
be designed to assure maximum
safety. Special attention
will also be paid to standardization,
interchangeability
of the various components
and minimizing the need for
maintenance and access.
Energy optimization for future-proof energy efficiency
• Avoiding energy peaks
• Collection of all electrical parameters
• Central storage in database for evaluation
• Online view of selected measurement values
• Analysis of historic data to present load profiles
• Simple integration in existing process control and PLC systems
Come visit
us at the
Thermprocess.
Hall 9 / Booth F02
Elektronik GmbH
STANGE Elektronik GmbH • Gutenbergstrasse 3 • 51645 Gummersbach
Fon: +49 2261 95790 • Fax: +49 2261 55212 • E-Mail: info@stange-elektronik.de
Internet: www.stange-elektronik.com
Elektronik GmbH
Heat-Processing.indd 1 13.05.2011 15:08:59
HEAT PROCESSING · (9) · ISSUE 2 · 2011 105

News
TRADE & INDUSTRIY
Siemens supplies turnkey AOD converter to
producer in China
Siemens will be equipping
Yunnan Tiangao Nickel
Industry Co., Ltd. (Tiangao),
a producer in China, with a
turnkey AOD converter. The
contract is the rst of this
type awarded to Siemens by
a private Chinese producer.
The order volume amounts
to several million Euros and
the project is scheduled to be
completed at the beginning
of 2012.
the tilting unit and tuyeres,
top lances, valve stations and
a transfer car. The electrical
equipment is comprised of
the basic automation system,
user software for the basic
and process automation systems,
and instrumentation.
Siemens will also supply the
drive system for the converter
tilting unit, the drive for the
oxygen lance and a motor
control center (MCC).
Emerson gets certified for fire safety system
Emerson Process Management’s
DeltaV SIS process
safety system has received
certication from TÜV Rheinland,
a German organization
similar to Underwriters
Laboratories in the United
States. Based in Cologne,
TÜV is a product safety and
quality assurance testing rm
for North America, Europe
and Asia. It has certied the
DeltaV SIS system as meeting
the requirements for the following
three burner-management
standards:
• National Fire Protection
Association, NFPA 85:
Boiler and Combustion
Systems Hazards Code.
• European Standard, EN
298: Automatic Gas Burner
Control Systems for Gas
Burners and Gas Burning
Appliances with or without
Fans.
• European Standard, EN
50156: Electrical Equipment
for Furnaces and
Ancillary Equipment.
All the standards cover the
design and installation of
fuel-burning equipment and
their associated systems.
“With many existing DeltaV
SIS installations already being
used in burner-management
applications, the NFPA 85,
EN 298 and EN 50156 product
certications give users
additional assurance“ that
their systems are well-suited
for use with red equipment,
says Emerson’s Mike Boudreaux,
Delta’s brand manager.
The AOD converter of Tiangao,
with a tapping weight
of 120 t, is being erected in
the southern Chinese city of
Qujing, Shizong county in the
province of Yunnan. Siemens
is responsible for the plant
engineering and supply of the
entire mechanical and electrical
systems. The mechanical
equipment includes the converter
vessel, the suspension
system, the trunnion ring,
Lakeside Steel build heat-treatment facility
in Alabama
Lakeside Steel Inc. selected a
site in Thomasville, Alabama,
U.S.A, to build a $ 7.5 million
state-of-the-art heat-treatment
and end-nishing facility.
The new facility will enable
Lakeside Steel to upgrade
and process the high valueadded
American Petroleum
Institute-certied J, L, N and
In addition, Siemens will be
providing consultation services
for the erection and
will carry out the startup and
commissioning of the converter.
The project at Yunnan
Tiangao is the rst contract
for an AOD converter
from a private producer and
is the rst in China in which
Siemens will be assuming
the entire responsibility for a
turnkey plant of this type.
P grades of OCTG products
that it produces and which
are required throughout the
majority of drilling operations
in North America. The plant
will be located approximately
ve miles from the company’s
new casing mill currently
being constructed in Thomasville.
4 new members join the Association of European
Distributed Energy Resources Laboratories
The Association of European
Distributed Energy Resources
Laboratories (DERlab e. V.)
has accepted four new institutes
from Belgium, Finland,
Luxembourg and U.S.A. at its
general assembly in Roskilde,
Denmark. DERlab e. V. was
founded in 2008 as an nonprot
association of independent
world-class laboratories
for the grid-integration of
decentralized power generation.
Since then, the twelve
members have, for example,
prepared an international
white paper for the standardization
of grid inverters and
developed interconnection
requirements for decentralized
energy resources (DER)
as well as testing procedures
for power system services.
“DERlab aims to cluster the
best European DER laboratories
from each EU member
state and is now starting to
involve institutes from other
continents as well”, says Dr.
Philipp Strauss, the immediate
past spokesperson of
DERlab´s board. “The new
members will bring all their
valuable technical expertise
to the network.”
The standardization of the
grid properties of distributed
generators, storage units and
controllable loads is an urgent
matter, because such units
are expected to deliver ancillary
system services for electricity
grids in the near future.
These network services have
to be delivered in a coordinated
way so that they are
able to take over tasks that
today are mainly performed
by bulk power plants. DERlab
e. V. will help to accelerate
this harmonization process
and to develop appropriate
test procedures that can be
applied to guarantee the necessary
quality assurance.
106
HEAT PROCESSING · (9) · ISSUE 2 · 2011

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The advanced, high efficiency recuperator design incorporates a
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June 28-July 2, 2011
Düsseldorf, Germany

News
DIARY
108
HEAT PROCESSING · (9) · ISSUE 2 · 2011

TRADE & INDUSTRIY
News
California Brazing awarded AS9100
accreditation
California Brazing, U.S., is
pleased to announce their
ofcial accreditation to the
AS9100 international aerospace
quality standard. The
scope of this accreditation
includes heat treating,
machining, brazing, and
contract manufacturing. This
certication reflects California
Brazing’s ongoing commitment
to continuous improvement,
along with their desire
to meet and exceed the
increasingly stringent industry
requirements for aerospace
related products and services.
The AS9100 certication will
strengthen California Brazing’s
competitive position
in the aerospace market,
and will also benet their
non-aerospace customers in
the semiconductor, medical,
and energy management
markets.
SMS Elotherm supplies quench & temper line for
bar mill to Bhushan
For its new bar mill in Orissa,
the Indian steel producer
Bhushan Power & Steel Limited
has ordered a quench &
temper line from SMS Elotherm
which enables Bhushan
in the future to quench and
temper or solution-anneal
(homogenize) bars of alloyed
steel and stainless steel. The
plant will be equipped with a
multi-zone converter whose
major benet is its high flexibility
for the material to be
treated as well as for the nal
product.
The line mainly comprises an
inductive heating and cooling
zone and downstream
tempering induction coils.
The heating coils are divided
in three and the tempering
coils in two zones which
can be separately controlled
and the multi-zone converter
allows bar temperatures up
to 1,100 °C whereby bars
can be treated from most
different materials i.e. from
stainless duplex steel (dualphase
steel) up to stainless
steels. Regarding the dimensions
of the feed tubes the
customer will also be flexible:
quick-change connections for
power and water make sure
that the induction coils which
are arranged on stainless steel
frames can be changed in a
few minutes. The control via
a central computer ensures a
Schmidt + Clemens
Devilishly good when hot
S+C can supply highly heat resistant materials
for almost any task in the area of high temperature.
For example: Our material Centralloy ® 60 HT R, which combines
heat resistance of up to 1,250 °C with extreme durability.
So when the ideal material solution is a burning issue
to you please get in touch with us.
You can get further information on our website:
schmidt-clemens.com
Visit us at Düsseldorf
28 th June - 02 nd July 2011
Hall 09, Booth 9E34
Schmidt + Clemens GmbH + Co. KG
Edelstahlwerk Kaiserau · Kaiserau 2 · 51789 Lindlar (Germany)
Phone: +49 2266-92 507 · Fax: +49 2266-92 538
HEAT PROCESSING · (9) · ISSUE 2 · 2011 109

EVENTS
News
repeatable and reliable operation.
A major bene compared
to conventional combustion
furnaces: with the quench &
temper line Bhushan is able to
set new parameters for development
and trial orders in an
easy and quick manner. The
heating behavior changes as
soon as the control recipe is
adapted. In this way, Bhushan
can test new materials and
carry out reference orders
for new customers without
signicant interruptions of
normal production.
Only a few weeks after supply
of the line in Q3 2011, the
facility is expected to already
produce the rst salable end
products. Quick assembly
and commissioning can be
primarily achieved due to the
modular design. Every year,
Bhushan produces roughly
2.3 million t of steel for flat,
round and long products covering
the entire value-adding
chain from coal via pig iron
and steel production up to
the nished products such as
precision tubes, cables or wire
rod.
Settlement of disputes
The copyrighted/competitively conict caused
by the change of two employees from Andritz
MAERZ GmbH to Küttner Non Ferros GmbH
has been amicably settled.
Küttner Non Ferros regrets this conict.
Events
International exhibitors rush to register for EMO
Hannover 2011
After a four-year gap, the premier
trade fair for the world‘s
metalworking sector is being
held once again in Hannover,
from 19 th to 24 th September
2011. International manufacturers
of production technology
are eagerly awaiting this
event, with demand concomitantly
high. At the beginning
of the year, 1,500 exhibitors
from 36 different countries
had already registered,
occupying a new exhibition
area of around 140,000 m 2 .
„We‘re extremely gratied by
the flood of inquiries“, says
Dr. Detlev Elsinghorst, General
Commissioner of EMO
Hannover 2011. It shows that
production technology manufacturers
worldwide are once
again very optimistic about
the ongoing year. As in the
past, manufacturers are once
again hoping for investment
to be signicantly boosted at
the EMO in Hannover.
For trade visitors and production
experts, Elsinghorst is
predicting a veritable Eldorado
of innovations and new
technical solutions. He is quite
certain that the EMO Hannover
will once again live up
to its reputation in this eld as
well. After all, manufacturers
of technology for metalworking
applications everywhere
in the world have ground
to make up. „Many vendors
have utilised the downturn
period to develop new products
and services“, reports
Elsinghorst. They want to hit
the ground running, and are
using the EMO in Hannover
Küttner GmbH & Co. KG
45130 Essen, Germany
Phone: +49 (201) 72930
info@kuettner.com
www.kuettner.com
ANDRITZ Maerz GmbH
40215 Düsseldorf, Germany
Phone: +49 (211) 38425 0
welcome-maerz@andritz.com
www.andritz.com
Unbenannt-2 1 08.03.2011 09:22:40
for this purpose. Customers
are focusing, for example,
on issues like exceptionally
flexible machinery concepts,
creative service capabilities,
sustainability in production
operations or intelligent, customised
production solutions,
to name only a few keywords.
All this will be on show at
EMO Hannover under the
slogan „More than machine
tools“.
The world‘s premier trade fair
for the metalworking sector
will be showcasing the entire
bandwidth of modern-day
metalworking technology,
the heart of every industrial
production operation. It will
be showcasing the very latest
machines, plus efcient
technical solutions, productsupportive
services, sustainability
in the production
process, and much, much
more. The EMO‘s principal
focus is on cutting and forming
machine tools, production
systems, high-precision
tools, automated material
flows, industrial electronics
and accessories. The trade
visitors to the EMO come
from all major industrial sectors,
like machinery and plant
construction, the automotive
industry and its component
suppliers, aerospace technologies,
precision mechanics
and optics, shipbuilding,
medical technology, tool and
mould building, steel and
lightweight engineering. The
EMO Hannover is the biggest
and most international
meeting point for production
technology anywhere in
the world. It is organized by
the VDW (German Machine
Tool Builders‘ Association)
on behalf of the European
Association of Machine Tool
Industries (CECIMO). For further
information please virist:
www.emo-hannover.de.v
HEAT PROCESSING · (9) · ISSUE 2 · 2011 111

News
EVENTS
The European Powder Metallurgy Summer School
The European Powder Metallurgy
Association (EPMA)
is planning a Powder Metallurgy
Summer School, which
will take place in Dresden,
Germany. The course consists
of a 5-day training course
from Monday, 27 th June to
Friday, 1 st July 2011.
The EPMA Summer School
is particularly designed for
young graduate designers,
engineers and scientists
drawn from a wide range of
disciplines such as materials
science, design, engineering,
manufacturing or metallurgy.
The course will offer them an
advanced teaching of Powder
Metallurgy’s advantages
and limitations by some of
the leading academic and
industrial gures in Europe.
Powder Metallurgy (PM) is
the generic name for a series
of related processes where
powders are compacted into
components of the desired
shape and then the compacts
are strengthened by sintering
at high temperature in excess
of 1,100 °C.
The participation fee for the
whole event is a very reasonable
€ 425 per person.
For this non-refundable fee
participants will receive all
relevant course documents
plus refreshments, meals and
accommodation. The course
is open to graduates under
the age of 35 who are citizens
of a European state. The
deadline for applications is
31 st March 2011. For further
information and to register
for the PM Summer School
please go to: www.epma.
com/summerschool.
The 3 rd international conferences on distortion
engineering
The various causes for distortion
can be found in every
step of the manufacturing
process. Based on that
the control of a components
distortion only can be
achieved by an interdisciplinary
approach starting at the
design phase of a part up to
the nal heat treatment. The
International Conferences on
Distortion Engineering (IDE)
2005 and 2008 in Bremen
have shown that this systemoriented
point of view is necessary
for the full understanding
and solution of distortion
problems. The 3 rd IDE, which
takes place from 14 th to 16 th
September 2011 in Bremen,
Germany.
The main objective of the IDE
2011 is again to discuss on an
international level the state of
the art of understanding basic
mechanisms and interactions
between different production
steps leading to distortion
and the measures to control
changes in shape and dimensions
including modeling and
simulation in industrial production
processes. Of primary
interest are production processes
of metallic parts, which
are manufactured by forming
and machining operations
and heat treatment. Contributions
which are focused
on distortion phenomena in
thermal joining operations
are also welcome.
The conference will be a
forum for engineers and
researchers from universities
as well as industry who are
dealing with distortion phenomena
in the whole process
chain experimentally or by
modeling and computer simulation.
The conference also
addresses experts who are
engaged in measurement and
control of distortion relevant
parameters or who are looking
at the eld of distortion
from a production management
perspective. The conference
is organized by the SFB
570 in close cooperation with
the Foundation Institute of
Materials Science (IWT, www.
iwt-bremen.de), sponsored
by the DFG and the University
IFHTSE – 19 th International Congress 2011
The International Federation
for Heat Treatment and Surface
Engineering Congress
will be held in Glasgow,
United Kingdom, on 17 th to
20 th October 2011 in the
Grand Central Hotel. The
international series began
thirty years ago with no. 1
held in Warsaw, Poland, in
1981. The international subject
scope will be broad and
will cover the whole eld of
industrially critical heat treatment
and surface engineering
practice, technology and science.
The 19 th congress will
addresses the current concerns
of energy management
and environmentally benign
processes (and the science
EXPOGAZ – Benchmark in the gas industry for
over 30 years
EXPOGAZ is the trade show
for the gas industry that brings
together all the major players
in the profession in Europe,
every two years. 6,000 m 2
of exhibition space showcase
150 important accounts and
brands: suppliers, producers,
operators, distributors and
service providers from the
natural gas, liqueed natural
gas, vehicle natural gas
and liqueed petroleum gas
markets. The show offers the
5,000 expected visitors:
• An innovation competition
that will present awards
to winners in three categories:
Technical development,
energy saving and
environmental protection,
of Bremen and supported by
the German Association for
Materials and Heat Treatment
(AWT, www.awt-online.org)
and the International Federation
of Heat Treatment and
Surface Engineering (IFHTSE,
www.ifhtse.org).
and technology response)
as well as the increasingly
important aspects of heat
treatment and surface engineering
in the non-ferrous
industry. The congress plans
to make better links between
materials and mechanical
engineering – especially tribology
aspects – in component
design.
This congress will be attended
by specialists from throughout
the world and will provide
a fantastic opportunity
for your company to gain a
high level of exposure with
the delegates. For further
information please visit the
Congress website:
www.ifhtse2011.org.
and lastly, safety and prevention.
• Throughout the three days
of the show, a presentation,
in partnership with
the COPAGAZ association,
of historical equipment
from the heritage of gas,
focusing on the evolution
of devices for detecting
leaks.
• An open-to-the-public
technical day on September
13 rd , organized in collaboration
with the AFG.
The day will include round
tables moderated by specialists
and will tackle the
topic of “Gas line work”
and all the new elements
to the DICT Decree, and
112
HEAT PROCESSING · (9) · ISSUE 2 · 2011

PM in Barcelona - Expanding PM Possibilities
International Congress
and Exhibition
TECHNICAL PROGRAMME
AVAILABLE NOW
An all topic powder metallurgy event focusing on
Conventional PM
Metal Injection Moulding
Including Special Interest Seminars on:
Functional Surfaces in Hard Materials
Metal Injection Moulding of Applied Functional Materials
PM Biomaterials Design and Biofunctionality
Hard Materials & Diamond Tools
Hot Isostatic Pressing
Organised & Sponsored by
9th - 12th October 2011
CCIB, Barcelona, Spain
www.epma.com/pm2011

EVENTS
Heat_Proc_89x62mm_E_pfade.ai 1 70.71 lpi 45.00° 5/19/2011 3:24:38 PM
Prozessfarbe Schwarz
News
along with that, “The
2012 thermal regulations
and innovative gas solutions”.
Alongside the show, on
Wednesday, September 14 th
and Thursday, September
15 th , the Congrès du Gaz,
organized by the AFG, will
be held. A privileged space
for debates and exchange, it
remains a unique chance for
everyone in the gas industry
to participate in current
C
events talks, round tables and
M
workshops, and to meet hundreds
of national and inter-
Y
CM
national participants, experts
MY
and high-level managers in
the energy and gas sector. CY
AMMONIA
SUPPLY
PLANTS
TECHNOLOGY
SERVICE
ACCESORIES
CMY
K
ALUEXPO 2011 offers a golden chance and
platform of cooperation and exchange
ALUEXPO 2011 is the second
aluminium technologies,
machinery and products trade
fair that will be organized on
13 rd to 16 th October 2011
in Istanbul, Turkey, at the
Expo Center Halls 9, 10 and
11. The trade fair for aluminium
industry is already on
exhibition cover; suppliers for
aluminium industry and aluminium
products: mainly raw
materials, primary metal products,
semi nished products,
aluminium production technology,
machinery and equipments,
surface treatment,
services, consultancy and
ment for aluminium processing
and manufacturing. Lightmetals
trade, consultancy and
expert opinions. Professionals
and decision makers are from
the industries of aluminium
manufacturing and processing,
building and construction,
automotive and transport,
packaging, plant and
machinery manufacturing,
metalworking, as well as
the electronic industries. As
part of the Industrial Materials
China Events and Global
Aluminium brand organized
by Reed Exhibitions,
Aluminium China uniquely
provides access to business
opportunities. The fair trade
will held at the new International
Expo Centre from
July 13 rd to 15 th , 2011. For
further information please
visit:
www.aluminium china.com.
the path to success almost
ve months before it opens.
AUEXPO 2011 is an exclusive
forum that will bring together
the leading names of the aluminium
industry from all over
the world. Activities of the
companies represented at the
information technologies.
This exhibition is designed
to highlight the present and
future scenario of aluminium
industry, showcasing products
and latest technologies
to around 10,000 visitors.
Aluminium China – The world’s leading
aluminium gathering in 2011
Located at the very heart of
iLocated at the very heart of
industrial Asia, Aluminium
China 2011 in Shanghai is
the world‘s leading aluminium
trade fair dedicated to
the whole supply chain in
the aluminium industry and
its major application elds.
Gathering elites from the
global community and facilitating
world class trading,
networking and educational
activities in the world‘s most
dynamic aluminium market,
China, the event in its 7 th presentation
will showcase the
latest innovations in products
and cutting-edge technologies
to seamlessly combine
the mighty demand existing
in Asia and the fast development
in emerging aluminium
consumers.
It is the international platform
for suppliers of aluminium
raw material, semi-nished
and nished products, surface
treatment and producers of
machinery, plant and equip-
ISIS.2011 – Automatic surface inspection
13 exhibitors and 230 participants
show that the international
surface inspection summit
was received very well by
all the companies. The unique
event for surface inspection
systems in the metal industry
took place on 23 rd to 24 th
March 2011 in Düsseldorf,
Germany. 230 visitors from
25 countries and 32 speakers
exchanged views on the current
status of automatic surface
inspection. An exhibition
as well as an evening event
completed the program.
The „Surface Inspection 3D“
and „From data to quality“
sessions in particular showed
the direction the demands
in the application of surface
inspection systems will take
in the future. Among others,
the topic quality assurance
for long products in aluminum
and in slabs was taken
into account. With its 118 m 2
of net exhibition space, the
ISIS.2011 exhibition exceeds
its predecessors. The feedback
was very positive, and
the opinions were unanimous
that the time was right for an
International Surface Inspection
Summit on European
soil after a three year break.
The next International Surface
Inspection Summit will take
place in February 2012 in
Mumbai, India. India became
the 4 th largest producer of
crude steel in the world in
2010 as against the 8 th position
in 2003 and is expected
to become the second largest
producer of crude steel in
the world by 2015. India also
maintained its lead position
as the world’s largest producer
of direct reduced iron
(DRI) or sponge iron. For further
information please visit:
www.isis-world.com.
HEAT PROCESSING · (9) · ISSUE 2 · 2011 115

News
BOOK REVIEW
Book Review
Flat-Rolled Steel Processes: Advanced Technologies
by Vladimir B. Ginzburg
CRC Press, London, New York
372 pages, Hardcover, 1 st Edition (2009) $ 174.95
ISBN 978-1-4200-7292-1, www.crcpress.com
Considered one of the major
innovators in the flat-rolling
of steel, Vladimir
B. Ginzburg holds
more than two
dozen patents in
the industry. In this
volume, Ginzburg
brings together
other industry pioneers
to define
the latest developments
in flat-rolled
processes. This includes the
revolutionary introduction
of computer-based technology
in both new and existing
conventional rolling mills.
Each section provides
a brief topic
summary and
then goes on to
describe the latest
advances specific
to that area. Main
subjects include
advanced hot rolling
mills, advanced
cold rolling mills,
control systems, and the
production of advanced flatrolled
steel products.
energy-efciency. The „Industrial
Burners“ chapter outlines,
with detailed examples,
the essential types of industrial
burners and their integration
into the extremely diverse
range of modern furnacesystem
concepts. This is then
followed by chapters on standardization
and legal requirements,
more specialized and
detailed literature, relevant
research institutions, and an
annex containing the relevant
physical data. The book discusses
the present-day state
of technological development
Inductive Melting and Holding
in a practically orientated
manner. The reader is provided
with a detailed view of
all relevant principles, terms
and processes in industrial
combustion technology, and
thus with important aids for
his or her daily work. This
compact-format book, with
its plethora of information,
is an indispensable reference
source for all persons who are
professionally involved in any
way at all with the heating
and combustion-systems of
industrial furnaces.
by Erwin Dötsch
Vulkan Verlag, Essen
266 pages, Hardcover, 1 st Edition (2009) € 60.00
ISBN: 978-3-8027-2380-3, www.vulkan-verlag.de
Handbook of Burner Technology for
Industrial Furnaces
by Joachim G. Wünning, Ambrogio Milani
Vulkan Verlag, Essen
218 pages, Hardcover, 1 std Edition (2009) € 90.00
ISBN: 978-3-8027-2950-8, www.vulkan-verlag.de
The demands made on the
energy-efficiency and pollutant
emissions of industrial
furnaces are rising continuously
and have high priority in
view of the latest increases in
energy prices and
of the discussion of
climate change for
which CO 2 emissions
are at least
partly responsible.
Great importance
is now attached to
increasing energyefciency
in a large
range of industrial
sectors, including
the steel industry and
companies operating heattreatment
installations. This
work is intended to provide
support for those persons
responsible for the clean and
efcient heating of industrial
furnacesThe initial chapters
of the “Handbook of Burner
Technology for Industrial Furnaces”
deal with the indispensable
theoretical principles
of combustion theory,
fluid mechanics
and heat transfer.
Only those
aspects which are
of importance for
burner technology
are examined.
The succeeding
chapters then proceed
on to burner
technology as
such, and focus on
combustion-system concepts,
analyze pollutant generation
and reduction, and discuss
the recovery of heat for use
in combustion-air preheating,
the most important provision
for the enhancement of
The book presents the current
state-of-the-art of inductive
melting technology as it
is deployed in manufacturing
and processing metal. Nowadays
the energy efciency of
process heating plants is the
new challenge for
industrial furnaces.
The work focuses
mainly on the metallurgical
processes
involved in melting,
holding and pouring
using induction
systems. The fundamentals
of inductive
power transmission
and the
design of induction plants are
described to the extent necessary
to understand the production
process. Color images
illustrate the topics. The book
provides support not only for
the specialists, but also for
students in research, development
and practical applications.
Contents: Introduction; Fundamentals;
Inductive Power
Transmission; Induction
Furnace Structural Shapes;
Induction Crucible Furnace;
Induction Channel Furnace;
Components of a Crucible
Furnace Plant; Furnace Body,
Power Supply, Peripherals,
Overall Layout; Components
of Channel Furnaces; Furnace
Vessel, Inductors, Power Supply.
Cooling Devices; Electromagnetic
Stirrers
and Pumps; Furnace
Design and
Energy Requirements;
Melting
Metallurgy of
Iron and Non-iron
Materials; Cast,
Cast Shell, Aluminium,
Copper
Materials; Operation
of Induction
Plants in Iron Foundries; Melting
in Induction Crucible Furnaces;
Duplication, Holding
and Combined Holding/Melting
in the crucible furnaces;
Holding in the Channel Furnaces;
Pouring with Pressure-
Actuated Pouring Furnaces;
Continuous Supply of Molten
Iron; Melting Cast Steel in
Induction Crucible Furnaces;
Induction Crucible Furnaces
in Mini Steel Works; Induction
Systems in the Aluminium
Industry. Induction Systems
for Copper Materials; Induction
Plant for Melting Zinc.
116
HEAT PROCESSING · (9) · ISSUE 2 · 2011

www.thermprocess.de
Welcome to the most
important trade fair
for industrial furnaces
and heat treatment
processes
Düsseldorf,
Germany
28 June –
02 July 2011
THERMPROCESS in Düsseldorf this
year is bigger and more international
than ever before. Almost
50 % of the companies exhibiting
in 2011 are coming to THERMPRO-
CESS from European and overseas
countries and will be presenting a
show here about industrial furnaces
and heat engineering production
processes that is unique anywhere
in the world. With 312 exhibitors
who have booked 9,762 m 2 of stand space, the trade fair
is bigger than it has ever been before in its almost 40-year
history – much to the satisfaction of Messe Düsseldorf
and the VDMA e.V. association responsible for it (thermo
process and waste technology).
In the alliance with the GIFA, METEC and NEWCAST
trade fairs that are taking place at the same location,
THERM PROCESS is also considered to be the technological
link between the different events. Everything at the trade
fair revolves around industrial heat treatment and thermal
processes. Components, equipment, furnace construction
materials, gas generation, melt treatment components or
pumps play a major role in the exhibitors’ portfolio too,
however. In addition to this, state-of-the-art solutions
relating to process-integrated occupational health and
safety, ergonomic workplaces or energy and resource input
minimisation in the companies’ programmes reflect the
systematic focus on innovative developments and the la
test technology at THERMPROCESS.
All in all, more than 1,900 exhibitors will be presenting their
products and services on almost 78,000 m 2 of stand space
at the “Bright World of Metals”, as we like to call our four
technology trade fairs too, is a record for GIFA, METEC,
THERMPROCESS and NEWCAST.
I would be delighted if reading the special THERMPROCESS
publication inspired you to make a visit to the trade fairs in
Düsseldorf.
We are looking forward to seeing you!
Welcome to the 10 th International Trade Fair and
Symposium for Thermo Process Technology!
Here you will find the latest state-of-the-art
technology for successful business including
industrial furnaces, industrial heat treatment
systems, test technology and refractory
construction, as well as the Symposium for
Thermo Process Technology.
The focus is on innovations in energy and
resource efficiency as well as sustainability,
especially true for exhibitors of the ecoMetals
initiative.
Friedrich-Georg Kehrer
(Messe Düsseldorf)

Thermprocess 2011
GERNERAL INFORMATION
High-quality side program at the
“Bright World of Metals”
An extensive, attractive side program
with numerous seminars and trade
symposia, special shows and technical
forums as well as international congresses
and lecture series is being organized
again for the “Bright World of
Metals” this year, which is being held
in Düsseldorf from 28 th June to 2 nd July
2011. The focus is on information about
current developments in research projects,
with particular emphasis on energy
efciency and resource minimization.
This means that the four metal trade
fairs have excellent additional benets
to offer trade visitors: alongside the
comprehensive demonstration by the
exhibitors of their particular achievements,
GIFA, METEC, THERMPROCESS
and NEWCAST are providing the best
possible basis for constructive dialogue
between industry professionals.
Furthermore, 20 institutes from Germany
and other countries will be demonstrating
their comprehensive scientic
capabilities in the context of “Science
Street” in Hall 7. Research facilities from
such countries as Germany, Poland,
Switzerland, Slovenia and South Africa
will be presenting their research and
development ndings and operations.
There is no doubt about it: the number
and quality of the events combined with
the comprehensive range of products
and services presented by the exhibitors
will once again make Düsseldorf the
meeting place and focal point for the
international trade and research community
from the foundry technology,
castings, metallurgy and thermo process
technology industries.
“GIFA-Treff” and WFO
Technical Forum
The “GIFA-Treff” organized by the
National Association of the German
Foundry Industry (bdguss) will again be
inviting experts to come and exchange
ideas and information right at the heart
of the trade fair in Hall 13. Thematic displays
will be providing detailed information
about such subjects as the energyefcient
production of castings or the
118
HEAT PROCESSING · (9) · ISSUE 2 · 2011

Thermprocess 2011
GERNERAL INFORMATION
use of discharged heat in the context
of a special exhibition about “energyefcient
foundries”. The WFO (World
Foundrymen Organization) Technical
Forum in Hall 13 from 28 th June to 1 st
July will once again be acting as a source
of ideas and an opportunity to discuss
Title of event THERMPROCESS 2011
GIFA 2011
METEC 2011
NEWCAST 2011
International trade fairs for thermo process technology,
foundry, metallurgical and precision castings
Show venue
Düsseldorf Fairgrounds
Date 28 th June - 2 nd July 2011
Opening hours
Tickets
daily from 9 am until 6 pm
Day Ticket*
€ 50.00 (at the cashiers / exhibition ground)
€ 40.00 (via Online Shop)
Season Ticket*
€ 120.00 (at the cashiers / exhibition ground)
€ 100.00 (via Online Shop)
Day Ticket* for Students
€ 15.00 (at the cashiers / exhibition ground + Online-Shop)
(bring your identication pass for reduced fee)
*Admission tickets include free round trip transportation to the trade
fair on the Regional Transport Networks Rhein-Ruhr,VRR (DB 2nd
class, trains without supplement only). Ticket shop opens in spring
2011.
Catalogues Single catalog: 35.00 €
All four catalogs: 75.00 €
Organizer
Messe Düsseldorf GmbH
Messeplatz
Stockumer Kirschstraße 61
D-40474 Düsseldorf
Tel.: +49 (0) 211 / 4560 01
Infoline: +49 (0) 211 / 4560 900
Fax: +49 (0) 211 / 4560 668
Internet: www.messe-duesseldorf.de
trends when the international experts
analyze the progress made in casting
technology and indicate how foundry
engineering can be optimized. The focus
throughout the lecture program is on
energy efciency and the responsible
use of resources. Specialists from Brazil,
Denmark, Germany, Finland, France,
Great Britain, India, Italy, Japan, Canada,
Austria, the Netherlands, Switzerland
and South Africa will be demonstrating
impressively how practical applications
know-how can be transferred internationally.
METEC – InSteelCon 2011
and EMC
METEC InSteelCon 2011, that is being
organized by the Steel Institute VDeH,
combines no fewer than four different
trade congresses for the international
steel industry at one location from 27 th
June to 1 st July: ECIC (6 th European
Coke and Ironmaking Congress), ECCC
(7 th European Continuous Casting Conference),
STEELSIM (4 th International
Conference on Modelling and Simulation
of Metallurgical Processes in Steelmaking)
and EECRsteel (1 st International
Conference on Energy Efciency and
CO 2 Reduction in the Steel Industry). The
events are being held at the Düsseldorf
Congress Centre, directly on the exhibition
site. More than 600 presentations
– all of them in English – underline the
outstanding global signicance of this
occasion. The European Metallurgical
Conference (EMC) 2011 promises to be
excellent, too. The organizer, the Society
for Mining, Metallurgy, Resource and
Environmental Technology (GDMB), has
chosen “Optimization and improvement
of resource efciency in the nonferrous
metals industry” as the issue to focus on
in the high-quality event this year.
NEWCAST – forum and award
NEWCAST will be featuring the “NEW-
CAST Forum”, that will be presenting
the latest casting developments in interesting
panel discussions and lectures
by experts. The main subjects covered
here will again be material and energy
efciency as well as innovative rapid
manufacturing systems. The forum is
being organized by bdguss.
For the second time Messe Düsseldorf,
bdguss and Verein Deutscher Gießereifachleute
e.V. (VDG) are presenting the
prestigious NEWCAST Award for the
most innovative and outstanding castings
in the following three categories:
best substitution of a different manufacturing
process, best function integration
and best casting solution (extending the
boundaries of casting engineering). The
winners are being announced shortly
before the trade fair, so that the companies
can already exhibit their prizewinning
products at the fair.
ecoMetals – focus on energy
efficiency and resource
minimization
When asked what issues will interest
visitors to their stands at GIFA, METEC,
THERMPROCESS and NEWCAST most,
there is a denite trend in the answers
given by exhibitors: energy efciency
and resource minimization in production
processes. As the organizer of the four
120
HEAT PROCESSING · (9) · ISSUE 2 · 2011

GERNERAL INFORMATION
Thermprocess 2011
technology trade fairs, Messe Düsseldorf
was quick to respond to this trend and
already launched the “ecoMetals” campaign
a year ago now. Relevant solutions
and processes exhibitors have to offer
are being showcased specially under the
subtitle “Efcient Process Solutions”.
Participants have had an opportunity
to register for “ecoMetals” by sending
a detailed description of their processes
and products to Messe Düsseldorf. The
exhibits submitted had to meet one of
the following requirements, however:
they had to save energy or deploy materials
and other resources efciently in
production, make climate-compatible
use of renewable energies or involve
optimized energy controlling and innovative
technologies.
The companies participating are identied
specially not only on the websites www.
gifa.de, www.metec.de, www.therm-
process.de and www.newcast.de but
also in the printed trade fair catalogue
and on the stands at the fairs. Messe
Düsseldorf is also publishing a separate
brochure about the ecoMetals campaign
with the names of the exhibitors and
the descriptions of their energy-efcient
solutions. There is a handy pocket guide
with which anyone can nd out particularly
quickly which exhibitors he wants to
visit during the trade fairs.
Achieve great things –
the THERMPROCESS 2011
The 10 th THERMPROCESS 2011 is
focused completely on providing exhibitors
and visitors technical trends and
solutions to the most important questions
connected with the manufacture
and use of industrial ovens and heat
production plants. The THERMPROCESS
is the world’s most important platform
for the presentation of highly innovative
technology and environmental concepts
for industrial thermal processing plants
– it is both the guidepost and point of
reference. Sustainable solutions will be
displayed in the international context of
all industries concerning the subject of
thermal processing plants. Maximization
of efciency, reduced CO 2 emissions and
sustainable climate protection are the
issues that are dening the market.
Technology with future
Especially in the eld of thermal processing
technology, research in the past
few years has become intensive and very
much orientated on industry realities –
with future-dening results. As a result,
the high technical and economic level of
plant technology could be maintained.
Until 2011, at the centre of the research
will be analysis in the elds of heat
conduction, process management and
procedures for combustion. The most
sensible option of reducing energy consumption
in a thermal processing plant is
the internal use of the waste heat from
one process stage to heat another process
stage. In this way, resources can be
used efciently and the climate can be
protected effectively. The focal points
are the issues of energy saving, resource
recovery, closed loop recycling management,
CO 2 and NO x reduction and the
optimization of combustion processes.
Almost 40 % of the energy used globally
in industry is used by thermal processing
plants. Therefore, the central concern
of the plant designer is to considerably
reduce energy consumption. The
THERMPROCESS 2011 is characterized
by technical innovations. Process optimizations
and increases in efciency for
industrial ovens contribute signicantly
to saving fuel. It is the ideal platform
for exhibitors to present new procedure
technology and plant optimizations. The
central factors of modern thermal processing
plant technology include higher
levels of efciency with considerably
lower energy consumption, a signicant
reduction in CO 2 , increase in production
flexibility and maximum protability.
THERMPROCESS symposium
THERMPROCESS symposium and the
FOGI special exhibit will also be dealing
with and discussing current issues relating
to energy efciency and sustainability
of process heating plants. Both subjects
represent a new challenge for plant
designers. In the past years, thermal
processing plants have come increasingly
under the scrutiny of the public as
they are one of the major energy consumers
in terms of process technology.
In the manufacturing industry, energy
consumption is increasingly becoming a
critical competitive factor. Consequently,
efciency in thermal processing plants is
a central theme. Combustion and ring
systems, oven insulation, integrated
energy use in processes, waste heat
usage and a reduced consumption of
electricity are the focus of the THERM-
PROCESS 2011.
HEAT PROCESSING · (9) · ISSUE 2 · 2011 121

Thermprocess 2011
SYMPOSIUM
THERMPROCESS –
SYMPOSIUM TIME TABLE
Chairmann: Dr. Klaus Lucka
Session 1 – Wednesday, 29 June 2011
Chairmann: Prof. Dr. Eckehard Specht
122
HEAT PROCESSING · (9) · ISSUE 2 · 2011

SYMPOSIUM
Thermprocess 2011
THERMPROCESS –
SYMPOSIUM TIME TABLE
Chairmann: Dr. Franz Beneke
Session 2 – Thursday, 30 June 2011
Chairmann: Prof. Dr. Bernard Nacke
Industrial furnaces Microwave heating Precision fine casting Spectroscopy Induction heating
Thermprocess
Düsseldorf
28.6.-2.7.2011 • 10B66
www.linn.de
HEAT PROCESSING · (9) · ISSUE 2 · 2011 123

Thermprocess 2011
SYMPOSIUM
THERMPROCESS –
SYMPOSIUM TIME TABLE
Chairmann: Dr. Volker Uhlig
Session 3 – Friday, 1 July 2011
Chairmann: Prof. Dr. Herbert Pfeifer
THERMPROCESS 2011
DÜSSELDORF
28. Juni - 2. Juli 2011
Visit HEAT PROCESSING
in Hall 9, booth 9B52
KNOWLEDGE
for the
FUTURE

INTERVIEW
Thermprocess 2011
„A globally unique opportunity of
obtaining a comprehensive overview
of the industry“
Dr. Hermann Stumpp, Chief Executive Officer of LOI Thermprocess GmbH
and chairman of the exhibitors‘ committee of the THERMPROCESS trade
fair talks to HEAT PROCESSING (HP) on the globally leading technical fair
for industrial furnaces and thermal production processes, the international
ranking of German thermal process technology, and future trends,
sales markets and challenges in this industry.
HP: Dr. Stumpp, the „quartet“
of trade fairs – the GIFA, METEC,
THERMPRO CESS and NEWCAST –
in Düsseldorf from June 28 th to July
2 nd is this year, yet again, the top
event for all international specialists
in these elds.
Where do you, as the chairman of
the exhibitors‘ committee for the
THERM PROCESS 2011, see the
benets of parallel timing of these
four technology fairs under the title
„The bright world of metals“?
Stumpp: As the title says, the focus
of these four fairs is on production
technology for metals. The special
feature of this combination of fairs
is the fact that the processes highlighted
at the METEC and also, on
the other hand, at the GIFA, are
always combined, in industrial production,
with a signicant proportion
of thermal-processing facilities. The
holding of these four fairs simultaneously
is, for all specialists concerned
with metals production, a globally
unique opportunity of obtaining
a comprehensive overview. This is
expressed neatly and succinctly by
our title, „The bright world of metals“.
The GIFA, METEC and NEWCAST
fairs concentrate virtually exclusively
on metals, but we should remember
that the THERMPROCESS 2011
will also feature thermal processes
for other industrial applications, for
production of materials such as glass,
ceramics and cement, for example.
HP: Energy efciency and conservation
of resources has been the dominant
topic in this industry for years. The Messe
Düsseldorf exhibition corporation also
features the subject in its „ecoMetals“
(Efcient Process Solutions) campaign.
What is behind this name, and what
should exhibitors and visitors expect?
Stumpp: The two main topics on which
our industry is focussed at present are,
on the one hand, Innovative Heat Treatment
Processes for Innovative Materials,
orientated, in particular, around energysavings,
emissions reduction and the
conservation of resources and, on the
other hand, enhancement of energyefciency,
and emissions reduction, in
the thermal-processing systems themselves.
In line with the great topicality you
mention, these innovative materials are
spotlighted in the „ecoMetals“ campaign.
Among the most interesting of
these materials are, in the eld, rstly,
of energy-generation and energy-transmission:
• Grain-oriented and non-oriented electrical
steel, which is needed to permit
the transformation and transmission
of electrical energy with the lowest
possible losses, and also for conversion
of electrical to mechanical energy
and vice versa. The special feature of
these materials is the fact that they
need as many as four or even ve
heat-treatment stages.
• Quenched and tempered (QT) steel
pipes for the increasingly difcult eld
of oil prospecting and production.
In the eld of transport:
• New, specialised materials for hybrid
engines and electric motors – the
electrical steels we just mentioned are
also used here
• High-tensile steel strip, tailored by a
large range of diverse provisions to
have the minimum possible weight,
for use in automotive engineering
• Wheelsets for high-speed trains – a
sector which is expanding particularly
fast in China at present
and, in structural engineering:
• Heavy plates, mainly in steel, but also
in aluminium, adjusted to maximum
load-bearing capacity in a thermal
process which includes water quenching,
and thus permitting lowest possible
installed component weights.
Thermal-processing facilities, by their
very nature, require high flows of energy.
Predominantly fossil fuels are used. Optimisation
of combustion processes and
the implementation of energy recovery
HEAT PROCESSING · (9) · ISSUE 2 · 2011 125

Thermprocess 2011
INTERVIEW
are the main lines of advance essentially
being pursued at present in fuel-heated
furnaces, in order to enhance energyefciency
and minimise losses and emissions
in industrial installations. Computer-assisted
optimisation systems are
being introduced, mainly in electrically
heated, but also in many fuel-heated,
furnaces, in order to reduce energy input
to the minimum absolutely necessary for
the instantaneous process situation.
HP: The last THERMPROCESS 2007 took
place against the background of enormously
increased demand around the
globe for steel, non-ferrous metals and
other materials, whereas this year‘s fair is
opening just at the end of a severe economic
recession.
How do you view the economic situation
in general now, and where do you see,
under these circumstances, the current
challenges for suppliers and operators of
thermal-processing plants?
Stumpp: More than 60 % of all industrial
furnace installations are supplied
to the steel industry, and this sector
was expanding extremely rapidly in the
years before the crisis. Within just a
few years, China had raised its domestic
capacity to more than 500 million t/
year, and very high investment was also
observable in other regions, including
Russia and Eastern Europe. Many of the
plant-engineering companies
thus entered the crisis
with their order books
full to bursting. Despite a
number of cancellations
and postponements, the
plant suppliers in question
still required a long period
to work through all these
orders. Now, despite the
crisis, a certain saturation
of steel capacities is apparent
in China. In addition,
consolidation of the still
extremely segmented, and
in some cases obsolete,
capacities in that country is
also now imminent. Other
regions, such as Russia,
were directly hit by the
effects of the nancial crisis,
however. India continues
to grow, but at a lower
level. We will, therefore,
need to adjust to a lower
level of demand, compared
to the pre-crisis period, for
the foreseeable future. There will also be
intensied price competition.
A second major market for industrial
furnace installations is the automotive
industry and its suppliers. Growth
here was more restrained before the
crisis. Demand for equipment declined
extremely steeply when the crisis broke,
and the furnace-engineering industry,
with its predominantly shorter delivery
times, was particularly badly hit.
Now, demand for equipment is rising
extremely rapidly, with China playing an
important role.
Demand is also growing considerably in
other regions, such as South America
and the Middle East, at present.
The last THERMPROCESS fair was
in 2007, in a period dominated by
extremely rapid expansion of steel
capacities in Asia, and also by large
investments in plant capacities in other
regions. This initially almost unchecked
growth came to an abrupt end when the
nancial crisis broke - in China, in particular
- and we are now observing, on the
one hand, a shift to other areas in China
and, at global level, the emergence of
other regional focuses, such as India and
South America, for instance.
HP: What expectations do you and the
exhibiting companies have for this year‘s
THERMPROCESS lead fair?
Stumpp: I‘m also expecting equipment
makers from the countries I‘ve mentioned
to use these four fairs even more
intensively as a platform to highlight
themselves at international level. All in
all, I‘m anticipating a signicant reorientation,
which should indicate the trends
for future years.
HP: The THERMPROCESS symposium is
also being held in parallel to the fair.
What will be its thematic focuses?
Stumpp: A number of focal topics have
been selected for the symposium: from
the energy-efciency of thermal-processing
facilities, life-cycle costs, new safety
concepts, special processes, components
and applications, the latest trends in
heating and burner technology, up to
and including cooling, quenching, and
heat recovery, visitors to the fairs will
have the opportunity at the symposium
of learning about the technical innovations
achieved by the companies exhibiting
and presenting papers.
HP: From what industries are you expecting
the most visitors?
Stumpp: In line with the orientation of
this „alliance“ of four fairs, the majority
of visitors will be from the steel-producing
and steel-using industries. We
have, for a number of years now, been
observing considerable efforts in China
at organising fairs and exhibitions. I‘m
quite sure that we can expect large numbers
of visitors from India, the Middle
East and a number of growth regions in
the west.
HP: Where do you see the future sales
markets for German and European thermal
process technology?
Stumpp: There‘s no doubt in my mind
that we will be seeing European and
German thermal process technology in
the lead globally for the present and for
the foreseeable future. Signicant competitors
are already emerging in China,
however, although only to a much lesser
extent in other regions.
HP: Where do you perceive a need for
action to ensure that Germany will be
able to defend its „global exports champion“
title successfully in the future?
Stumpp: We in Germany must, both in
general, and in the case of the industries
126
HEAT PROCESSING · (9) · ISSUE 2 · 2011

INTERVIEW
Thermprocess 2011
represented at the four THERM PROCESS,
METEC, GIFA and NEWCAST fairs, in
particular, get accustomed to the fact
that it is vital to locate signicant portions
of the value chain in the regions
of the main sales markets. The engineering
business has always necessitated a
certain regional differentiation between
the performance of the conceptual and
„know-how input“ work, on the one
hand, and production and installation,
on the other. All the major companies
in our industries have more or less
already adjusted to this, by globalising
their structures. We need to concentrate
on ensuring that we continue to supply
adequately innovative technology in a
competitive form from the competence
centres in Europe, and that we remain
able to sell it, on currently shifting markets,
by means of globally flexible overall
organisation. We must never forget
that signicant innovations are, in fact,
frequently suggested by our customers
themselves, and can only be implemented
together with them. Experience
shows that, in the mid-term, innovation
occurs mainly in growth regions with
correspondingly bold and enterprising
customers.
HP: You are a physicist by education
and training. Do you think there will still
be great technological advances in this
industry? What will be the research topics
of tomorrow?
Stumpp: As in past years, the main challenges
for our industry will be found in
the drafting of further contributions to
thermal process technology for the conception
and production of even higherperformance
materials. The increasing
scarcity of resources will make this vital.
In the last few years, the main emphases
in development in the plants and
components supplied by our industry
has been on optimisation of heating systems,
and both enhanced efciency and
reduction of the various emissions have
been achieved simultaneously. I‘m not
expecting any more „quantum leaps“ in
this eld at present. Instead, the focus
will move increasingly to „holistic“
observations of processes, in which not
only the heating arrangements and computer-assisted
process simulations, but
also all the other design criteria which
have essentially continued unchanged
for many years, will need to be critically
re-examined.
Dr. Hermann Stumpp:
Hermann Stumpp was born in Hirrlingen/Tübingen on December 19, 1948. After
nishing secondary education at the Eugen-Bolz grammar school in Rottenburg
am Neckar, he studied physics at the Eberhard-Karls University, in Tübingen. He
received the Dr. Friedrich-Förster Prize for his degree and doctorate thesis in the
eld of electron optics and electron-beam technology in 1984. Dr. Stumpp also
completed a six-term university course in business administration.
Also in 1984, Dr. Stumpp joined Leybold-Heraeus GmbH, Hanau, as a
project engineer. After working as a product-sector manager, he was ultimately
appointed Head of the Vacuum Metallurgy division.
Dr. Hermann Stumpp moved to LOI, Essen, in 1991, and was appointed chairman
of the management board of LOI Thermprocess GmbH in 1994. The company‘s
globally leading position was consolidated and further expanded under
his management, with the acquisition, inter alia, of Belgium‘s DREVER group.
Dr. Stumpp is the chairman of the specialist „Thermal Process and Waste Technology“
association within the „VDMA“ German Engineering Federation, and
of the exhibitors‘ council of the THERMPROCESS trade fair.
Dr. Stumpp is married, and has three children.
HP: In addition to your work as chairman
of the exhibitors‘ committee of the
THERMPROCESS fair, and of the Specialist
Association for Thermal Process and
Waste Technology of the „VDMA“ German
Engineering Federation, you have,
most particularly, been successful in
business for many years as the CEO of
LOI Thermprocess GmbH.
How, in your opinion, should a company
be managed and positioned nowadays,
to achieve market success?
Stumpp: I can‘t really give you a generalised
answer to that question here. In
our company, we have concentrated on
maintaining the most complete possible
spectrum of knowledge for the eld
of heat treatment of metals, ranging
from metallurgy, via process-engineering,
automation and including all the
other disciplines necessary, in the form
of a highly capable and relatively large
team, which probably no other supplier
in this eld can claim in this breadth.
This enables us to react at any time to
new, and even major, requirements and
challenges set by the market. We have,
correspondingly, managed to achieve
outstanding market positioning with a
number of our products, and this will
probably continue to be the case. These
capabilities are backed up by a global
organisation, and by our own subsidiaries
on the most important markets. This,
combined with our dependability, which
is absolutely vital for our customers, convinces
us that we are well equipped for
our future tasks.
HP: What advice would you give young
people starting out in working life, in
view of the ever more globalised world,
with its rapid technological progress?
Stumpp: I‘m repeatedly extremely
impressed by the commitment and motivation
with which young people – with
the support of their parents – approach
working life and a professional career
in countries like China and India. This is
not always the case in Germany. Nonetheless,
we manage, again and again,
to integrate young new employees into
teams with older and more experienced
colleagues, and implement outstanding
key projects and generate the very highest
levels of motivation. I love, under the
motto „Yes, we can!“, demanding a lot
from young people – with their furtherance
as the reward.
HP: Thank you for this interesting interview,
Dr. Stumpp.
HEAT PROCESSING · (9) · ISSUE 2 · 2011 127

Thermprocess 2011
PRODUCT PREVIEW
New generation of thyristor power controllers
Just in time for the 50 th anniversary
of their power controllers,
AEG PS has launched
a new generation of thyristor
power controllers that feature
many new standard-setting
highlights.
The new Thyro-A series supports
voltages of 24 V to 600
V offering a unique product
range of 2 A up to 1,500
A, available as one, two and
three-phase units. Via Flex-
Connect, the power controllers
can be connected from
either the top and/or the bottom.
Celebrating a premiere
with its full-graphics touch
display, the new power controller
allows for extremely
intuitive handling, thereby
offering new opportunities
with regard to visualization
and parameter setting. Set
and actual values, as well as
operating modes are displayed
in plaintext with operating
modes also being indicated
via color-changing backlights.
In addition to Ethernet, USB
2.0 is now also included as a
Metal oxide fibres for temperatures up
to 1,370 °C
3M Nextel Ceramic Textiles
are made out of continuous
polycrystalline bres,
which are manufactured
by the Sol-Gel process. The
transparent nonporous multi-
standard interface by which
parameters can be set in the
power controller even when
disconnected. As an alternative
browser-based option,
parameters can also be set
and visualization effected via
an integrated web server.
Communication-enabled and
in combination with master
control systems in the process
and automation environment,
optional bus modules
are now available for TCP/IP
– based communication
such as
Pronet, Modbus
TCP and Ethernet
IP – in addition
to the traditional
field bus protocols
DeviceNet,
Modbus RTU, Pro-
bus und CANOpen.
The new
range also offers
a sophisticated
cooling concept
enabling the units
to be operated via
water cooling as an alternative
to traditional air cooling.
A further operating mode is
available via water-cooled
rear panels. Another characteristic
feature of the new
generation is its use of intelligent
and advanced technologies
that include network
interference reduction
and mains load optimization
to help reduce costs, energy
consumption and CO 2 emissions
during operation.
AEG Power Solutions GmbH
www.aegps.com
Hall 10 / Booth C66
laments have a diameter of
10 to 12 µm. The continuous
form, high strength and the
flexibility of the metal oxide
bres enable production of a
textile production with con-
ventional weaving and braiding
technologies. Rovings are
converted into plied twisted
yarns out of which a variety
of textiles e.g. fabrics, tapes,
sleevings and even sewing
threads can be made. Excellent
convertibility together
with a high abrasion resistance
make it possible that
Nextel metal oxide bres can
be used in applications up to
temperatures of 1,370 °C.
Integration of case hardening into the
manufacturing-line
For many years the gear
industry has addressed the
challenge to produce high
performance components in
a cost-efcient manner. To
meet quality-specifications
the components need to be
heat treated, which traditionally
takes place in a central
hardening shop. However
this separation between
machining and heat treatment
results in high costs for
transportation and logistics
within the production-plant.
Therefore since many years
it is being discussed to integrate
heat treatment into the
manufacturing line.
Applications for Nextel metal
oxide fibres include industrial,
aerospace and outer
space applications up to the
development of reinforced
Ceramic Matrix Composites
(CMC), Metal Matrix Composites
(MMC) and Polymer
Matrix Composites (PMC).
3M Deutschland GmbH
www.3m.de/Nextel
Hall 9 / Booth A28
In order to totally integrate
heat treatment into the manufacturing
line and in order to
synchronize heat-treatment
with machining, ALD Vacuum
Technologies GmbH has
developed a new heat treatment
cell. Following the philosophy
of „One Piece Flow“
the parts are:
• taken one by one from the
soft machining unit
• heat treated in time with
the cycle-time of soft
machining (“Synchronized
heat treatment”)
• passed down one by one
to the hard machining
unit.
To allow for a
rapid case hardening,
the components
are low
pressure carburized
(LPC) at
high temperatures
(1,050 °C)
followed by
high pressure
gas quenching
(HPGQ). In
addition to the
cost-savings for
logistics the new
concept in equipment
offers the
following advantages:
• individual processes
customized
for each
gear-component
128
HEAT PROCESSING · (9) · ISSUE 2 · 2011

PRODUCT PREVIEW
Thermprocess 2011
• homogenous and quick
heating of the components
and therefore low
spread of distortion
• homogenous and controllable
gas quenching and
therefore low spread of
distortion
EZ-Lynks ® is a series of modular
equipment optimized
for the movement, heating
and quenching of very large
parts, such as those used in
the wind turbines and earthmoving
product segments.
EZ-Lynks is designed to
improve the effectiveness of
heat treating large parts over
traditional pit furnace designs
– making the entire process
easier – by employing three
important advantages:
1. Flexibility of equipment
location – no quench pits
• environmentally friendly
carburizing and quenching
• compact and space-saving
heat treat unit.
ALD Vacuum Technologies
GmbH
www.ald-vt.de
Hall 9 / Booth E20
Modular equipment optimized for the movement,
heating and quenching of large parts
required and low height
option
2. Part specific fluid flow
quench patterns – minimizing
distortion for gears
and shafts
3. Rotating transfer car provides
multiple quench
options such as press
quenching, water or polymer
quenching, even salt
quenching
Large gears can be processed
in a layers to allow horizontal
quench oil flow that will eliminate
trapped vapor between
the gears, thereby improving
distortion and reducing the
grind allowance, resulting
in less processing after heat
treating. Elimination of extra
trays and xtures improves
the quenching speed and
reduces the amount of heat
normally transferred to the
trays and xtures.
Handling of the part is done
by use of a rotating transfer
car, similar to AFC-Holcroft’s
well-known product, the UBQ
(Universal Batch Quench) furnace.
The transfer car eliminates
the possibility of human
error caused thru the use of
overhead crane and chains
to lift and carry the part to
the furnace and quench,
and improper handling of
the part. The transfer car has
the ability to rotate the load
180 degrees on the car itself,
thus saving in floorspace and
allowing maximum equipment
congurability. In situations
where ceiling height is
limited, the equipment door
motions can be altered to
allow placement almost anywhere
within a typical industrial
plant.
AFC-Holcroft
www.afc-holcroft.com
Hall 9 / Booth E03
Medium and low frequency induction generators
Ambrell is proud to announce
new members of our EKO-
HEAT family of precision
induction heating systems!
Get deeper heating for your
larger parts with the precision,
repeatability and reliability
for which the EKOHEAT
family is known. With these
enhancements to our portfo-
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(EUROPA) GMBH
Phone: +49(0)211 500 91-0
info@bloomeng.de
www.bloomeng.de
1150 ULTRA 3 LOW NOx
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Thermprocess 2011
PRODUCT PREVIEW
Mobile gas analyzer tests protective gases and
indicates deficiencies
lio of solutions, we are better
positioned to address process
and power needs for:
• forging
• heat treating
• pre-heating
• crystal growing
• hardening
• brazing
and other applications requiring
a clean, precise, energyefcient,
non-contact source
of heat.
Visit Ambrell at THERMPRO-
CESS to see representative
examples from various power
levels of our EKOHEAT line
as well as our renowned
EASYHEAT line up to 10 kW.
Speak to one of our induction
experts for more information.
AMBRELL - Precision
Induction Heating
www.ambrell.com
Hall 9 / Booth A37
Leaky pipes, moisture, not
reacted protective gas: there
are numerous sources of deciencies
for the composition
of the atmosphere in heat
treatment shop furnaces. In
the best case the workpiece
becomes stained, at worst the
workpiece will not show the
desired features after the heat
treatment. Either way, the
entire batch is scrap. This is
why the Avion Europe GmbH
& Co. KG will present innovative
gas analyzers which
point out flaws like these at
an early stage at this year’s
Therm process in Düsseldorf.
Apart from a highly resistant
oxygen probe for stationary
measuring systems, Avion
will also present a completely
mobile NDIR analysis system.
Among other things the
portable device even allows
for the meeting of the strict
requirements of the new CQI
color touch screen on which
the results are displayed in
real time. Due to the fact
that the device is additionally
equipped with a pump
of its own and is operated by
rechargeable batteries it can
be used everywhere irrespective
of the existing infrastructure
in the plant. Its application-oriented
construction
makes it ready for use within
just a few minutes.
Via the enclosed flexible silicone
tube, a gas sample is
channeled from the release
valve of the furnace into the
measuring device where it is
tested for its different components.
For CO, the test spectrums
range from 0 to 100
%, for CO 2 they range from 0
to 2 % and optionally up to
20 %, for CH 4 they range
from 0 to 100 % and for
O 2 from 0.1 to 25 %. As an
New ceiling radiation burner for the steel and
non-metal industry
The new Maerz burner (since
2010) is the successful implementation
of a highly environment-friendly
technology.
Andritz Maerz has developed
and successfully tested a
new ceiling radiation burner
for use in heating furnaces
for the steel and non-metal
industry.
This burner concept is
based on the Coanda effect
together with partial separation
of the combustion air
supply. In conjunction with
gas injection, the ceramic
burner stone and the swirl
element for the combustion
air have been rated and specially
designed to generate
multiple recirculation of the
exhaust fumes in the burner
head. This newly developed
radiation burner operates
with the normal gases used
in the steel industry (natural
gas, coke-oven gas, converter
and mixed gas) and has even
been optimized for operation
with LPG. Under the normal
production conditions for an
industrial furnace, the flame
produced by this burner
is stable over a very large
control range. The selected
technology and the optimization
attempt have generated
excellent results with regard
to NO x formation (NO x < 200
mg/Nm 3 at 5 % O 2 , 500 °C
air pre-heating temperature
and 1,250 °C furnace chamber
temperature).
Andritz MAERZ GmbH
www.andritz-maerz.com
Hall 9 / Booth E22
9-guideline of the automobile
industry – without additional
effort of installation.
The entire portable measuring
system ts into a hard
shell case which also protects
the system against shocks and
damages during transport.
Apart from the analyzer, the
case contains an integrated
800 x 480 mm sized multioption,
it is possible to measure
the H 2 -content between
0 and 100 %. From these
gures, the device calculates
the amount of carbon in
the atmosphere of the furnace
precisely from 0.1 to 2
%. Thereby the gas analyzer
by Avion Europe meets the
quality assurance requirements
for a redundant measuring
system according to
130
HEAT PROCESSING · (9) · ISSUE 2 · 2011

ANDRITZ Maerz:
100 Years of engineering arts.
When Johannes Maerz constructed the first Siemens-
Martin furnace in 1911, his dream was to make efficient
use of the forces of nature while giving his customers
the greatest possible satisfaction in meeting their
requirements. This vision is our motivation. As one of
the world’s leading suppliers of furnace installations for
complex thermal process technology in the steel and
copper industry, ANDRITZ Maerz stands for excellent
engineering arts, quality and tradition. We develop
solutions for tomorrow that offer greater energy
efficiency while keeping pace with market dynamics.
Please visit our booth at THERMPROCESS 2011
from June 28 – July 02, 2011 at hall 09, booth E22.
ANDRITZ MAERZ GmbH
Corneliusstraße 36, 40215 Düsseldorf, Germany
Phone: + 49 (211) 38425-0
welcome-maerz@andritz.com
www.andritz.com
AndritzMaerz_GB_AZ_100J_Messe_182x255_RZ.indd 1
HEAT PROCESSING 12.04.2011 · (9) · ISSUE 17:37:41 2 · 2011 Uhr 131

Thermprocess 2011
PRODUCT PREVIEW
the CQI 9. The test results
can be evaluated as tables or
graphs directly on the screen.
Signicant deviations of the
carbon graph may, for example,
indicate a crack in one of
the pipes. All measurement
results are automatically
The novelty in thermodynamic
models used for online control
of reheating furnaces will
be presented by celano GmbH
at the THERMPROCESS. In a
multiannual research project,
supported by the Federal
Ministry of Economics and
Technology, the theoretical
approach has been successfully
put into practice. Since
the 1970s furnace control systems
are assisting the operation
of heat-treatment plants.
Low memory and calculation
capacity of older PCs leaded
to a lot of simplifications
concerning the algorithm as
well as the modelling. Stricter
environment regulations and
higher energy costs are pushing
this old concepts to their
limits.
The new approach celFcsRht,
a three step procedure, does
away with these simplications.
Instead of considering
individual elements (like
critical materials), the furnace
load as well as the future load
is observed for both the prognosis
and the optimization,
saved in the device, but can
as well be transferred to a PC
via USB or an Ethernet connection.
Avion Europe GmbH & Co. KG
www.avion-europe.de
Hall 9 / Booth C55
Thermodynamic models – the new unique
approach
thus optimizing the quality.
As regards memory requirements
and computing power
the coding of this procedure
is comparable to NP-equivalent
issues of computer science
and is one of the more
complex optimizing problems.
To ensure online compatibility
despite the complexity
the whole software has
been designed with a parallel
processing approach on
multiprocessing computers.
Furthermore, a flexible evolutionary
algorithm – also using
parallel processing – was
implemented to reach the
varying optimization goals.
Energy savings and improvement
of product quality will
be achieved by this innovative
furnace control system especially
for frequently changing
thermal properties and
smaller lot sizes (e.g. different
quality and dimensions) and
waiting times.
celano GmbH
www.celano.de
Hall 10 / Booth E41
New self-recuperative direct-fired burner
Eclipse, Inc. has introduced
the TJSR v5 self-recuperative
burner for direct-red furnace
heating applications. The
advanced burner design combines
a high velocity flame
with fuel saving recuperation.
A space saving integral eductor
pulls the furnace exhaust
through an internal ceramic
recuperator. The recuperator
preheats the incoming combustion
air to very high levels,
which improves furnace
operating efciency to reduce
fuel usage by as much as 50
% over typical ambient air
burners. The TJSR v5 design
eliminates the need for the
hot air ductwork required by
external recuperators, providing
savings in hardware and
installation. The internally
insulated heat exchanger
section and exhaust housing
hold heat in the recuperative
section, adding to
the heat recovery efciency.
This also keeps external temperatures
very low, providing
better operator comfort and
reduced thermal wear on
associated equipment outside
the furnace shell. The
integrated gas and air orices
simplify burner piping, set-up
and adjustment. There is no
guesswork with input levels
or burner capacity settings at
startup.
The new burner housing
design is up to 40 % lighter,
making furnace structural
changes and installation simpler,
with no fear of high
stress mounting areas. Internal
components are made
of space age silicon carbide
materials, built to deliver
excellent heat transfer and
extremely long burner life.
Installation, operation, and
maintenance are simplied
and less costly. And the fuel
savings are constant, with no
degradation of the exchanger/
recuperator section, even
after years of use. TJSR V5 can
be red on natural gas, propane
or butane. The burner is
available in three sizes, with
a maximum capacity ranging
from 200,000 to 600,000
BTU/h. (60 to 175 kW). With
the TJSR v5, you can light anywhere
in the ignition range,
with no pilot required. The
TJSR v5 is capable of ring at
High/Low/Off. On-ratio ring
and excess air ring can also
be accomplished. With the
highest flame speed in the
industry, TJSR v5 delivers a
stable flame throughout its
full input range.
Eclipse, Inc.
www.eclipsenet.com
Hall 09 / Booth C10
Vacuum carburizing with oil or gas quenching
capability
Industrial furnaces are widely
used in the metallurgical sector,
but by no means limited
to this industry. One of the
household names in the production
of vacuum furnaces is
ECM Technologies. The company
develops and produces
standard and customized
industrial furnaces.
Vacuum carburizing with
either oil or gas quenching
capability has demonstrated
its excellent cost effectiveness
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Thermprocess 2011
for gear heat treatment, and
its implementation continues
to grow rapidly. The benets
of low pressure vacuum
carburizing are outstanding
in terms of global quality.
Today’s managers want the
heat treating operation integrated
into the production
line, just in time, and vacuum
furnaces combined with gas
quenching, easily suit this
concept.
ECM Technologies’ solutions
have indeed proved extremely
useful for applications such
carburizing solutions. It is
based on the patented Infracarb
® heat treatment process,
a reference in the world
of heat treatment, which
guarantees drastic cycle time
reduction, absence of oxidation,
perfect control of metallurgical
performances and
environment friendly conditions.
All ICBP ® components
are designed as modules so
as to allow a flexible architecture,
maximum process
efciency and short return on
investment. ICBP ® can simul-
ELINO has long-term experience
and can offer various
designs for the processes
under ambient air atmosphere
and for special gastight
designs with process
gases, e.g. argon, N 2 , H 2 ,
flammable gases or vapour.
Rotary tube furnaces and
rotary drum furnaces made
by ELINO provides for a high
technological standard and
allow for very long lifetimes.
Depending on the process
conditions, heat treatments
of up to 2,200 °C can be carried
out. Product-specic various
components can be integrated
in the process chamber
to allow for optimization
of the thermal and chemical
processes.
On the basis of the single
product transport, these
plants meet the demands
of many applications in the
chemical and powder producing
industry. ELINO provides
a large number of plants for
oxidizing and reducing atmosphere.
Calcination, prereduction,
and carburization
of metal powder in the rotary
drum furnace are delivered as
complete systems, as desired.
Pyrolysis, synthesis and gasication
plants on the basis
of ELINO drum furnaces are
used in the eld of alternative
energies. On the basis
of the process parameters
determined in our pilot plant,
ELINO can scale up the system
for industrial plants.
ELINO Industrie-Ofenbau
GmbH
www.elino.de
Hall 10 / Booth A66
Modular machine for induction hardening
automotive crankshafts
as car transmissions (manual,
automatic, CVT, double
clutch and others), drive lines
(axles, CV joints), diesel common
rail (injector, pumps) and
power steering.
ICBP ® is the name of our patented
family of low-pressure
taneously carry out different
treatments in different cells,
extra treatment cells can be
added rapidly to face a sudden
increase of production.
ECM Technologies
www.ecm-furnaces.com
Hall 10 / Booth A74
Furnace technology for a number of different
applications
Rotary tube furnaces are generally
equipped with burners.
The burner is used to
input energy direct onto the
product and therefore burns
directly in the process tube.
The tube itself is insulated on
the inner surface. In principle,
drum furnaces are indirectly
heated. The process chamber
of these plants consists
of a heat-resistant metallic or
ceramic tube. Energy is indirectly
introduced in the product
process from the outside
through the tube wall. The
indirect heating ensures separation
between the atmosphere
of the heating room
and of the process chamber
thus providing for an oxygen-free
atmosphere for the
product. Drum furnaces can
optionally be heated using
an electrical heating or a gas
burner.
The hardening machine Elo-
Crank originates from the
reengineered ModuLine
series and stands out due to a
compact design and reduced
energy consumption.
Owing to the flexible machine,
the crankshaft manufacturers
are able to react
very quickly to
modified crankshaft
geometries.
Equipped with a
novel converter
technology which
allows an individual
control of
the heat output
on each single
bearing, the new
EloCrank can
harden also crankshafts with
radii. In general, crankshafts
with radii in bearings provide
a very compact conguration
and additionally withstand
higher mechanical pressure
in the engine. With these
measures, car manufacturers
ultimately achieve a reduction
of the vehicle weight and the
specied gasoline consumption.
The trend-setting and also
functional machine tool
design from SMS Elotherm is
convincing. The fully enclosed
machine allows a perfect
view into the process and at
the same time a comfortable
access for the service staff.
SMS Elotherm GmbH
www.elotherm.de
Hall 9 / Booth A63
HEAT PROCESSING · (9) · ISSUE 2 · 2011 133

Thermprocess 2011
PRODUCT PREVIEW
Compact and full integrated solution for mobile
or stationary inductive heat treatment
Due to the integration of
an induction heating generator
and a corresponding
active cooling system into
one cabinet, our compact,
easy going/handling and on
your demand mobile device
New furnace protective control unit
With the new furnace protective
control unit FCU 500,
Elster Kromschröder is offering
a comprehensive allround
package for the implementation
of current safety
standards. The unit allows
essential functions of the
central protective system pursuant
to EN 746-2:2010 to
be implemented in multiple
burner applications. Thanks
to the appropriate Kromschröder
sensors and actuators,
the FCU module meets
assures you a high quality in
processes such as:
• Brazing (pneumatic or
manual operated)
• Hardening (edge of cutters,
difcult contours or
proles)
• Heat treatments (annealing,
coating, remove of
coating) and much more.
The operation of the MICO
is very simple by a state of
the art operation-panel with
touch-screen, oriented on
the “I-Pod generation”. The
MICO-Line can be delivered
with a power range of 15 kW
up to 70 kW, medium or high
frequency.
eldec Schwenk Induction
GmbH
www.eldec.de
Hall 9 / Booth F21
the requirements of EN 298,
EN 62061 up to SIL 3 and EN
ISO 13849 in accordance with
Performance Level PL e.
The new furnace protective
control unit monitors various
safety conditions such
as minimum and maximum
gas pressure and air pressure,
and carries out a standard-compliant
pre-purge. At
the same time, an extended
tightness test function monitors
the main valves and carries
out a system tightness
test during system start.
A special algorithm allows
time-saving testing in the
case of large test volumes.
For increased operational
safety, high temperature
monitoring can be performed
in conjunction with
Kromschröder burner control
units using a twin thermocouple
to be directly
connected.
The functions combined in
the FCU 500 can be pre-
cisely adapted to the requirements
of the respective heating
equipment using parameterization.
The furnace
protective control unit has
been specially developed for
installation in control cabinets
and features tried-and-tested
operation on the unit and an
optical interface for programming
and diagnostics using
the PC software BCSoft. In
addition, the FCU 500 can be
directly controlled from the
control cabinet door with the
help of a separate operatorcontrol
unit.
The new Internet-based system
planning platform KST is
available as planning support
for the protective system as
well as for the design of the
entire heating equipment.
KST offers many tools for the
effective and safe implementation
of heating equipment.
Elster Kromschröder
www.kromschroeder.com
Hall 9 / Booth D22
Iron reduction in blast furnaces with natural gas
In many countries of the
world, the iron reduction will
be done mainly in blast furnaces
with coke as reduction
source. In countries however,
where coke and coal are not
available, or very expensive,
but natural gas is a cheap
source and available (Middle
East, South America, Australia,
India). The acceptation of
Direct Reduced Iron (DRI) and
its equipment is increasing.
During the “Direct Iron
Reduction”, iron Oxide pellets
will be converted in pure iron
by a reducing gas produced
from natural gas or coal. The
reducing gas is a mixture
majority of Hydrogen (H 2 )
and Carbon Monoxide (CO)
which acts as reducing agent.
These reducing agents can be
produced from natural gas in
cheap and reliable methods.
During the process i.e. start
or shut down of the complete
unit and during troubles of
the reaction unit,
the whole reaction
source unit
of the system can
create high risk
due to an explosive
mixture. In
case of eventual
arising extensive
malfunctions of
the system, the
risk of destroying
of the whole system
is in the worst
case possible.
Especially during
shut down, heat
up phase and
shut down of the
reformer, trouble
can come up. In
such a case, huge amounts of
Inert gas must be available in
a short time. The FK Inert gas
system will be used in the following
cases:
• Leakage of explosive gases
from the shaft furnace
during operation
• Removal of combustible
gases and backwash of the
system during shut down
of the system
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PRODUCT PREVIEW
Thermprocess 2011
• To pressurize the system
(lling of the system with
inert gas) during start up
process of the system.
• To keep a positive pressure
in the reactor unit (filling
with inert gas) during
standstill of the system in
order to prevent re-oxidation
of the still hot product.
Oxygen and natural gas will
be mixed in a burner especially
designed for the purpose.
The Oxygen/natural gas
mixture will be blown into a
double walled, water-cooled
Stainless Steel combustion
chamber. The ignition of the
burner will be carried out by
Endogas plants with a performance
of 200 Nm 3 /h
Gebrüder Hammer GmbH is
awarded the contract to supply
three large endogas plants
each with a performance of
means of a high voltage electrode.
Flame control during
the burning process will be
done by a UV. Diode(optical
flame control). The whole system
operates fully automatically
by means of Inert gas
analysis control – operators
are not required. In just 30
min (from start up till production)
is a respective big Inert
gas amount available (i.e.
3.500 Nm 3 /h). During the
operation the Inert gas generator
adjusts itself with regard
to the requested amount of
Inert gas.
FK Industrieofenbau + Schutzgastechnik
GmbH
www.industrieofen-schutzgas.de
Hall 9 / Booth B22
200 Nm 3 /h. The customer has
once again chosen electrical
heating for endogas generation.
The special requirement
placed on the endogas plant
was that the endogas is provided
with an exit pressure of
900 mbars (ü). With suitable
furnace design, the operator
can forego the circulation
of the endogasthrough
fans in the thermoprocess
plant, thereby minimising the
service costs of the furnace
system. The pressure of the
endogas is increased inside
the endogas plant before
the actual generation and is
therefore achieved without
downstream condenser. This
makes the pressure increase
interesting also for energy
reasons. Gebrüder Hammer
GmbH has therefore once
more been able to prove its
innovative strength in the
area of process engineering
for gases, and in particular in
the eld of endogas generation.
Gebrüder Hammer GmbH
www.hammer-gmbh.de
Hall 9 / Booth C64
Heat treatment of big size centrifugal cast
iron pipes
The heat treatment of cast
iron pipes with a diameter of
1.200 up to 2.600 mm and
a length of up to 8.000 mm
require an annealing furnace
in special design. Since the
4 th quarter 2010 the by IOB
developed furnace plant is
successfully in operation in
Saudi Arabia.
The furnace plant consists
out of two bogie hearths
onto one displacement trolley
which is installed in front of
the furnace. Hence the loading/unloading
of the bogie
hearths and the annealing
is taken place in cycles. The
three to four pipes are placed
in upright position onto the
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Thermprocess 2011
PRODUCT PREVIEW
New safety temperature limiters (STB) and
monitors (STW)
The new safety temperature
limiters (STB) and monitors
(STW) from JUMO representing
the latest state of the art
meet technical and economical
requirements in the eld
of functional safety and reliability.
The use of the compact
and freely congurable
STB / STW tted on top hat
rails allows early, safe and
reliable recognition of hazards
that could lead to injury,
environmental damage or to
the destruction of production
respective bogie hearth and a rotary hearth furnace out equipment and goods. The
during the annealing process of the special scope of supply primary task of safety temperature
limiters is the reli-
they will be constantly rotated it being used instead of the
using their single rotary disc, bogie hearth furnace plant. able monitoring of technical
and thus deformation at the Pipe tilting devices and pipe heat processes and switching
equipment to an opera-
pipes is avoided. Various transport units complete the
burner zones, as well as horizontal
as also vertical, deal
entire line equipment. tionally safe condition in the
event of a malfunction.
with the different amount of IOB Industrie-Ofen-Bau GmbH The devices come with
material over the pipe length. www.iob.de
approvals as per DIN EN
With bigger required capacity Hall 10 / Booth D42
14597, SIL, PL (perfor-
HeaPre_DEUTSCHLAND_GG3406011_EMO Hannover 2011 18.04.11 09:54 Seite 1
mance level ), UL, and GL,
which shorten the users‘ own
approval processes. All calculation
values required for this
purpose, for instance MTTfd,
PFD, SSF, DC, λ dd, λ du in
FIT are made available in the
familiar manner.
The high standards of DIN
EN 61508 or DIN EN 13849
are met by a device concept,
the 1oo2D structure of which
guarantees the safe recognition
of errors and faults. As
such, it can also be used for
applications subject to the
new 2006/42/EC machinery
directive. Safety and reliability
were the key features during
the development of the
devices. Simple commissioning/start-up
was also a focal
point.
A mini USB plug at the
front permits conguration
through a PC or laptop. Light
The world of metalworking
INFO:
VDW – Generalkommissariat EMO Hannover 2011
Verein Deutscher Werkzeugmaschinenfabriken e.V.
Corneliusstrasse 4, 60325 Frankfurt am Main, GERMANY
Tel. +49 69 756081-0, Fax +49 69 756081-74
emo@vdw.de · www.emo-hannover.de
136
HEAT PROCESSING · (9) · ISSUE 2 · 2011

PRODUCT PREVIEW
Thermprocess 2011
diodes show whether or not
the device is functioning perfectly
or if a pre-alarm or a
limit value alarm has been
triggered. The measuring
input with a large number
of linearization can be freely
congured for RTD temperature
probes and thermo-couples
and for current measurements.
In the event of faults/
errors, two relay outputs (prealarm
and limit value alarm)
switch the process into a
HWG Inductoheat is the company
to feature an inverter
with a stepless frequency
setting in its product range.
safe condition.
With regard to
the limiter function,
the device
is released again
by an internal or
external unlocking
key. Process
values can be
transmitted to a
recording device
or a controller or
a higher-ranking
control system
via the series
analog output. Additional
features, such as a password
controlled access and a settable
level locking increase
operating safety and process
reliability. Voltage supplies
of AC 110...240V (-15 %/
+10 %), 48…63Hz or AC/DC
20...30V, 48..63Hz are available.
JUMO GmbH & Co. KG
www.jumo.net
Hall 10 / Booth H58
Inverter with stepless frequency setting
Statitron IFP now makes it
possible to use the same
inductor to create different
hardening depths in different
places on a workpiece – in a
single uninterrupted process.
This innovative inverter allows
users to control the amount
of electricity they apply when
hardening workpieces. Users
can harden different areas
of a workpiece with custom
depths ranging between 0.5
mm. Retrotting is no longer
necessary because the workpiece
is completely hardened
in a single, uninterrupted process
using the same inductor.
HWG INDUCTOHEAT GMBH
www.hwg-inductoheat.de
Hall 10 / Booth B24
Straight thermocouple in a testable design
By the straight thermocouple
in a testable design, the
HERTH elektrische Temperaturgeber
GmbH makes it
possible, to discover the deviation
of the operating thermocouple
against a reference
element during the process
in the course of the DIN ISO
9000 ff (e.g. at heat-treating
furnaces). The thermocouple
in a testable design will be
supplied as a single or double
exchangeable measuring
insert. The terminal block has
a centre hole which enables
The new CellaTemp PA Pyrometer
series was launched on
the market one year ago.
The series has now been
expanded to include a new
version which measures temperatures
using a two-colour
or ratio technique. Even
when the signal is weakened
due to ambient
dust, steam or
a dirty lens, this
pyrometer, which
detects radiation
at two different
wavelengths,
will continue
to produce reliable
temperature
data. CellaTemp
PA has a special
function which
monitors the
amount of dirt
the customer to locate a
calibrated reference sensor
directly near the tip of the
operating thermocouple in a
testable design, in order to
compare its value by a digital
thermometer. The thermocouple
corresponds to the
demanded tolerance according
to DIN EN 60584 and can
remain or must be replaced.
HERTH elektrische
Temperaturgeber GmbH
www.herth.de
Hall 9 / Booth A25
New ratio pyrometer with a built-in video camera
obstructing the view of the
sight glass.
CellaTemp PA features two
analogue outputs. This lets
you, for example, analyse
both the single-wavelength
and the dual-wavelength
(ratio) temperature data
HEAT PROCESSING · (9) · ISSUE 2 · 2011 137

Thermprocess 2011
PRODUCT PREVIEW
simultaneously. Of special
interest is CellaTemp PA’s
ability to detect emissivity
using this second output. This
enables the user to quickly
respond to emissivity variations.
CellaTemp PA is available
with one of ve different
optical systems to choose
from. The pyrometer can thus
be used with tiny targets as
small as 0.3 mm as well as
with applications requiring
measurement at distances as
far as 30 m.
The pyrometer comes with
either through-the-lens sighting
or a laser to indicate the
target spot. The latest CellaTemp
PA model features
a built-in video camera,
enabling the target to be
viewed remotely from the
control room. Automatic
exposure compensation
ensures that a high-contrast
image is produced, regardless
of the lighting conditions
in the surrounding area. The
multifunctional CellaTemp PA
offers a variety of conguration
options for superior
versatility. These include a
congurable error correction
curve, a setting for transmissivity
of the protective windows
and ATD (Automatic
Temperature Detection) for
discontinuous processes. The
two-colour (ratio) version of
CellaTemp PA is available in
16 different models to cover
a wide range of temperature
applications from 500 to
3,000 °C.
KELLER HCW GmbH - Division
MSR
www.keller-msr.de
Hall 9 / Booth A12
temperatures: quartz T max
< 1,100 °C, powder metalalloy
< 1,300 °C, ceramic
< 1,700 °C.
Electrically heated rotary tube
furnaces are used for continuous
drying, oxidizing of
chemicals, reducing of metal
SECO/WARWICK is introducing
a new line of equipment,
the CaseMaster EvolutionTM
universal batch
furnace for low pressure
carburizing equipped with
an oil or gas quench. These
systems provide a technically
advanced alternative to
traditional integral quench
furnace systems for many
oxides, calcinations and sintering
of ceramic powders
and granules, metal heat
treatment etc.
Linn High Therm GmbH
www.linn.de
Hall 10 / Booth B66
Universal batch furnace for low pressure
carburizing
rizing cycle. The LPC systems
is supported with the proprietary
SimVac simulation software.
The CaseMaster EvolutionTM
system offers many
process advantages:
• Cost and time reduction of
carburizing process using
FineCarb ® technology
compared with conventional
technologies
Rotary tube furnace up to 1,600 °C
Linn High Therm presents
high quality rotary tube furnace
for special heat treatments
of e.g. powders and
granules with ceramic or
metallic rotary tube (inner
diameter = 99 mm, length
= 2.500 mm, heated up to
1.500 mm).
Adjustable rotation speed of
the insert tube is from 0.5 up
to 5 rpm and the adjustment
of inclination via rack winch is
up to 10°. The 3-zone heating
is available in the following
versions: Fibrothal tubeheating
module with embedded
heating coils, T max 1,200
°C or Kanthal Super heating
elements T max 1,600 °C. The
water cooling is located on
the insert tube of screw conveyor.
Furthermore, there are
many options available: protective
gas, screw conveyor,
thermal post-combustion,
multideck sieves, cooling
zones, vibration feeder etc.
The use of different insert
tubes withstand different
applications including: Aviation,
Automotive, Machine
Tool, Bearings, Commercial
Heat Treating. This single system
is capable of performing
low pressure carburizing (LPC
by FineCarb ® ), LPC with prenitriding
(PreNitLPC ® ), bright
hardening (oxidation in preheat
chamber), annealing
and tempering. PreNitLPC is a
new technology that provides
process integrity at higher
temperatures, saving process
costs by reducing the carbu-
• High quality (clean and
bright) parts following
heat treatment
• Reliability
• Consistent process repeatability
• No load decarburization or
oxidation
• No CO 2 emissions
• Optimal processing gas
consumption
• Full automation & visualization
of the HT processes
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PRODUCT PREVIEW
Thermprocess 2011
• Data archiving and reporting
system
• Nominal temperature up
to 1,320 °C, ± 5 °C in the
heating chamber
• Vacuum 10 -2 mbar, (10 -5
option)
• Charge transport to the oil
– less 20 s
The SimCarbTM module is
available to design and simulate
carburizing processes
New multi-purpose pyrometers
Compact infrared temperature
sensors are ideal for
harsh industrial environments
that require EMI immunity
and high-speed response
times. LumaSense Technologies,
Inc. has introduced two
multi-purpose infrared temperature
sensors to its line
of compact pyrometers. The
IMPAC IS 320 and IGA 320
prior to running trials. By modeling
processes in advance,
process parameters can be
checked, saving process
time and avoiding scrapped
parts.The furnace operation
will meet AMS 2750D, AMS
2759, BAC 5621, PN-EN
98/37 and PN-EN 746-1 standards.
SECO/WARWICK S.A.
www.secowarwick.com.pl
Hall 9 / Booth C22
are the latest additions to
LumaSense’s broad portfolio
of gas and temperatures sensing
solutions, which include
infrared thermometers, ber
optic sensors and gas measurement
instruments, as well
as pyrometers.
The IS 320 and IGA 320 sensors
offer features such as
small form-factor, digital and
analog outputs, high-speed
response times, exchangeable
cable connections and
LED sighting technology.
Both pyrometers are ideal for
a wide range of applications
that require highly accurate
non-contact temperature
measurements including
metal, ceramic or graphite
processing plants.
Both compact, stainless
steel sensors are EMI safe,
specically designed for
use in applications such
as tempering, preheating,
annealing, welding,
forging and hardening.
Built-in LED pilot lights allow
plant engineers to easily align
and focus the instrument to
the measurement target.
Enhanced optics allows areas
or objects as small as 1.2 mm
to be measured, and 2-millisecond
response rate makes
the sensors ideal for fast,
high-dynamic processes such
as sintering, melting, soldering
and brazing.In addition to
the sensors’ ruggedness and
accuracy, the IS 320 and IGA
320 are easy to install with
simple connection cables
as opposed to xed cables,
as well as sub-ranging and
adapted analog outputs that
enable users to configure
their instruments and easily
connect pyrometers to PCs.
Both the IS 320 and IGA 320
also include the InfraWin software
for easy instrument setup
as well as intuitive graphical
temperature displays.
LumaSense Technologies
GmbH
www.lumasenseinc.com
Hall 9 / Booth B05
Visit us
at the Thermprocess
hall 9, booth E20!
© appeal 042 105
Hardness which pays off
The technology of ALD´s ModulTherm ® heat treatment system for hardening and case hardening of
serial parts has been successfully used for many years, worldwide. The new model ALD ModulTherm ® 2.0
offers optimum process fl exibility, reduced manufacturing costs as well as environmental compatibility.
First class service allows for smooth continuous operation.
For more information please contact us!
ALD Vacuum Technologies GmbH
Wilhelm-Rohn-Strasse 35
63450 Hanau, GERMANY
Phone +49 (0) 6181 307-0
Email info@ald-vt.com
Internet www.ald-vt.com
HEAT PROCESSING · (9) · ISSUE 2 · 2011 139

Thermprocess 2011
PRODUCT PREVIEW
Mirror dew point measuring system with
high accuracy
As a result of permanent
improvements and optimizations
the company MESA
Electronic GmbH presents the
further development of their
dew point measuring device
Dewchecker 1.0. The measurement
principle of the new
The mirror dew point checker
Dewchecker 1.1. is characterized
mainly by the fact that
the temperature of the mirror
can be adjusted permanently
to a constant value. For this
purpose the required mirror
temperature is dened as a
tion of the charging frames
to the usually fully automatic
production process.
Conveyor chains strips can
be supplied for areas of high
and low temperature as ready
components for continuous
annealing furnaces. The
single chain links are costed
in accordance with the process
engineering and the
heat treatment products with
breakouts, overlaps, webs,
carriers or chambers according
to customer specication.
Friedr. Lohmann GmbH
www.lohmann-stahl.de
Hall 9 / Booth E02
Vacuum furnaces in vertical and horizontal type
Dewchecker 1.1 is the same
as in the old device. The furnace
gas is passed through a
measuring chamber on the
surface of a mirror. The mirror
is cooled with a thermoelectric
Peltier element until
dew shows on the mirror
surface. By use of a temperature
sensor the temperature
of the mirror surface can be
detected. As soon as condensation
starts the temperature
of the mirror is read out
directly.
xed set point. The electronics
then controls the Peltier
element so that the predetermined
set point temperature
of the mirror is kept. This
allows an accurate approximation
to the dew point and
thus a very accurate measurement
of dew point independent
of the operator.
MESA Electronic GmbH
www.mesa-gmbh.com
Hall 9 / Booth D02
Schmetz is the leading partner
for most modern vacuum
furnaces in vertical and horizontal
type with graphite
insulated hot zone or molybdenum
insulated all-metal hot
zone.
The modular system *FUTUR*
(dual heating system for a
convection supported heating
and tempering) and the
system *2R* / *2x2R* (vertical
and/or horizontal direction
reversal of the cooling gas
stream at the overpressure
achieves less current consumption
by means of less
empty losses. At the same
time shorter heat-up times
are realized. Weight optimized
gas guiding devices
with inlet nozzles can thus
also achieve higher quenching
speeds of the load.
Besides modern furnace
technology Schmetz offers
intensive support in the fur-
Heat-resistant castings play a special role in the
form of charging frames
With the help of CAD moulding
and simulations, Friedr.
Lohmann develops and manufactures
heat-resistant and
abrasion-wear components
to meet the individual needs,
including aspects related to
economics and customer orientation.
Heat-resistant castings play
a special role in the form of
charging frames as a link
between the work piece to
be treated and the furnace
installation up to the straightening
machine. Grates and
charging supports of modular
design principle are
delivered according to standard
measurements or individual
customer requirements.
Through an intensive
dialogue between operators
and the foundry, the most
cast-effective ideal solution
for the company can be
developed by optimal adap-
gas quenching) have become
established for quite some
time. The separate quenching
chamber of the system
*2PLUS* offers a doubling of
the cooling speed. Vacuum
furnaces of the type *RD*
lead the gas stream through
radially installed nozzles. The
system *COOL PLUS* realizes
a complete automatic heat
treatment process with integrated
„sub zero“ phase.
The Schmetz vacuum furnace
with innovative hot zone
design Schmetz system *eSS*
nace’s surroundings. Support
regarding the integration of
the furnaces into the production
or the adaptation to
the corresponding local surroundings
are of course part
of our advice service. The
complete design and delivery
of the furnace periphery like
for example loading devices,
re-cooling systems and so on
can be offered upon request.
SCHMETZ GmbH Vacuum
Furnaces
www.schmetz.de
Hall 9 / Booth C 50
140
HEAT PROCESSING · (9) · ISSUE 2 · 2011

PRODUCT PREVIEW
Thermprocess 2011
Electric furnaces for thermo-chemical treatment
Nakal is a leading company
in Russia, producing furnaces
for all types of heat treatment
processes. For European
extruders Nakal represents
electric furnaces for thermochemical
treatment, especially
developed for nitriding of
extrusion dies and die steels
to improve quality, reduce
costs and increase heat treating
speed of these parts.
and stabilized operating abilities
of treated parts as well as
lower manufacturing costs.
Nitriding process control is
provided automatically by
NPCS* which doesn’t require
humans to be involved in the
process. The usage of CGN
technology in nitriding furnaces
allows to:
the products can be rened
via high-temperature cleaning,
coating and inltration
with pyrolytic carbon or silicon
carbide according to your
needs. The special processes
also ensure long life of the
operating components and a
high degree of effectiveness
of the nal products.
In addition to the C/C solutions
for high temperature
applications, Schunk
also provides standard hard
and soft felts for insulation
applications. The refined
Oxatherm ® insulation materials
are characterized by excellent
resistance against chemical
attacks and achieve long
operating lives even in critical
atmospheres.
Schunk Kohlenstofftechnik
GmbH
www.schunk-group.com
Hall 9 / Booth F49
The main advantage of nitriding
furnaces is a new technology
of Catalytic Gas Nitriding
(CGN) which has a patent in
Russia as well as in Germany,
Canada and USA. CGN technology
is a multipurpose,
simple and proven in practice
method of low temperature
thermo-chemical treatment
for machine and tools components,
providing improved
Schunk Kohlenstofftechnik
GmbH in Heuchelheim produces
the world‘s largest
plates made of carbon ber
reinforced carbon (C/C) with
sizes up to 3 x 2 m. However,
not only C/C plates, but also
proles, fasteners, graphite
foils as well as cooling fans
and heating elements for special
high temperature applications
are supplied to the heat
treatment industry, among
• minimum twice reduce the
process time
• improve new quality of the
nitrided case
• greatly increase treated
parts service life.
JSC Nakal – Industrial
Furnaces
www.nakal.ru
Hall 9 / Booth E03
Largest plates made of carbon fiber reinforced
carbon
others. The special property
of the products is its high
degree of dimensional stability
and durability at extreme
temperatures.
Schunk provides the complete
process chain from planning,
development and production
of components all the way
to quality assurance and testing,
including for C/C plates
up to 3 x 2 m – a globally
unique product. In addition,
New process imaging solution
RAYTEK ® presents the new
ThermoView Pi20 Process
Imager. Designed for automated
monitoring and control
of continuous or stationary
targets, the ThermoView
Pi20 xed-mounted process
imager provides a process
view of thermal images,
allowing plant operators to
shorten process startup times
and lower production line
changeover costs.
The rugged ThermoView Pi20
camera is offered in two tem-
perature ranges: -40 to 500
°C and 200 to 2,000 °C. For
each temperature range, two
lens options are available:
21.7° x 16° or 30° x 22°. The
ThermoView Pi20 provides
easy networking over long
distances using a standard
Ethernet interface, which
transmits up to 30 frames/s of
imaging data from the camera.
The ThermoView Pi20
camera is easily interfaced to
the intuitive DataTemp ® Pi
(DTPi) software for real-time
viewing, archiving and play-
HEAT PROCESSING · (9) · ISSUE 2 · 2011 141

Thermprocess 2011
PRODUCT PREVIEW
back of both on-line and offline
thermal images. The DTPi
supports up to 16 Pi20 cameras
simultaneously in a single
software package where each
camera can have up to 192
process alarms to be assigned
as relay outputs. Additionally,
DTPi software interfaces
The latest addition to the
SPECTRO XEPOS Series is
optimized for the analysis
of medium and heavy elements.
It achieves detection
limits that are a factor
of 5 to 10 times better than
conventional ED-XRF instruments.
The SPECTRO XEPOS
HE (“HE” stands for “Heavy
Elements”) was developed
specially for laboratories
conducting environmental,
geological and waste disposal
analysis.
to remote I/O modules can
be employed as triggering
inputs, allowing for le saving
or other application events to
occur.
Raytek GmbH
www.raytek.com
Hall 9 / Booth C01
XRF instruments sets a new standard for heavy
element quantification
XRF instruments typically are
setup for rapid screening
analyses and for the quanti
cation of multiple elements.
They often are used to determine
the concentrations
of heavy elements only in
screening quality. However,
especially heavy elements,
such as cadmium or antimony,
are of great interest for
many applications. XEPOS HE
is an instrument that offers
all the advantages of modern
XRF, but with an innovative
Gradient cooling with nominal variables
design that is able to reliably
quantify even heavy elements
in ppm ranges.
Among the unique features of
the SPECTRO XEPOS HE is its
flexible excitation source. The
instrument uses an extremely
stable end-window tube with
a power of only 50 W. The
instrument also offers a target
changer with up to eight
polarization and secondary
targets that allows users to
achieve excellent sensitivity
and accuracy for an ED-XRF
instrument during the analysis
of medium and heavy elements.
For these demanding
environments, the XEPOS HE
is equipped with a large area
SDD detector. With the large
surface area, the instrument
provides much higher sensitivities
and gives laboratories
the ability to decide whether
to measure a great deal faster
or achieve lower detection
limits.
SPECTRO Analytical
Instruments GmbH
www.spectro.com
Hall 12 / Booth C24
Vacuum- and conveyer-belt
furnaces – this cooling is possible.
The heat treated materigradient.
Heating and cooling
with nominal variables allow
heat treatment programs,
als are best handled for certain
applications. Even bainite
is possible. Cooling gas mass
flows from almost 0 up to the
required maximum amounts
per kg of heat treated material
can be adjusted by the
which were not possible
in gas atmospheres up to
now.
WMU GmbH
www.wmu-gmbh.de
Hall 10 / Booth B29
THERMPROCESS 2011
DÜSSELDORF
28. Juni - 2. Juli 2011
Visit HEAT PROCESSING
in Hall 9, booth 9B52

HEAT TREATMENT
Reports
Aluminium Recycling – Latest plant
technology for energy efficiency and
environmental protection
Dominik Schröder, Hermann J. Meyer
For the construction of a high-performance Twin-Chamber Melting Furnace
TCF, CFD calculations were carried out to optimize scrap melting
performance. The results of the calculations have been confirmed by
measurements. For a well-founded analysis of the plant, thermographic
analyses are also used.
Recycling is becoming increasingly
important in aluminium melting.
Recycling includes the melting of
returned scrap, cuttings, cans, sheets
and old scrap, both loose and packed,
with or without adhering contamination.
In addition to good metal yields
and low energy consumption, the purpose
of the process technology used
is to allow the processing of different
types of scrap at the same time.
To meet these requirements, LOI has
developed the Twin-Chamber Melting
Furnace TCF and continuously improved
the furnace design to reach the level
needed for efcient and economical
melting by recycling companies.
Twin-Chamber Melting Furnace
TCF
The Twin-Chamber Melting Furnace TCF
consists of two chambers installed in a
furnace casing. In the heating chamber,
the metal is heated via the bath surface.
Scrap is charged into the scrap chamber
using a charging machine or a wheel
loader. Cuttings and thin-wall scrap are
charged directly to a Charge-Well. In the
Charge-Well, the molten metal is circulated
by the metal pump, ensuring that
the scrap is rapidly drawn under the surface
of the molten metal. Fig. 1 shows
the Twin-Chamber Melting Furnace TCF
with the heating chamber door on the
right-hand side, the cuttings charging
system on the left and the Charge-Well
with metal pump and tapping system in
the centre.
Charge material and charging
The scrap mix used can be varied with
virtually no limits:
• 100 % cuttings or thin-wall scrap
such as UBCs can be charged into
the Charge-Well via the cuttings conveyor
• 100 % scrap with up to 10 % contamination
can be charged via the
scrap chamber
• 50 % scrap and 50 % cuttings or
thin-wall scrap can be charged via
the scrap chamber and the Charge-
Well
• 0 to 100 % bloom material may be
charged via the heating chamber
• Any combination of scrap cuttings or
thin-wall scrap and blooms may be
charged.
Fig. 2 shows a dosing and charging
system for cuttings and thin-wall scrap.
The metal to be melted is loaded into
the funnel and then fed to the conveyor
belt in a controlled way via a vibrating
chute. From the conveyor belt, the
charge material is fed to the Charge-
Well through a chute.
Bulky scrap is charged into the scrap
chamber using a charging machine of
the type shown in Fig. 3. The use of
a charging machine is recommended.
While contaminations of the previous
charge are pyrolized in the scrap
chamber, the charging machine can be
carefully loaded with scrap. Scrap from
the store can be selected to produce
the alloy required without using bloom
material or additional alloying elements.
In addition, contaminated and less contaminated
scrap can be batched in such
a way as to allow easier pyrolisis of contamination
in the furnace.
Fig. 1: Twin-Chamber Melting Furnace TCF for recycling contaminated
HEAT PROCESSING · (9) · ISSUE 2 · 2011 143

Reports
HEAT TREATMENT
Fig. 2: Dosing and charging system for cuttings and thin-wall scrap
Fig. 3: Scrap charging machine
Process and aluminium yield
When contaminated scrap is melted, the
pyrolisis and melting stages of the process
must be separated. Pyrolisis takes
place on the scrap chamber bridge.
Recirculation fans support the process
and prevent overheating of the scrap
close to the big size burners system. It is
important to ensure that scrap batches
are made up in such a way that the
burn-off process is completed before a
new charge is loaded into the furnace.
When the new charge is loaded, the
previous charge is pushed onto and into
the bath. Any contamination not already
removed by partial combustion is combusted
immediately when the scrap
makes contact with the molten metal.
The smoke which develops is removed
safely and reliably via the scrap chamber
hood. Contact between contaminated
materials and the liquid metal should be
avoided as it results in higher burn-off
losses.
The Twin-Chamber Melting Process is
primarily designed for high metal yields
Fig. 4: Central regenerator system CCR
with a view to ensuring efciency and
the conservation of resources. Pyrolisis
times and charge weights are carefully
adapted to each other taking the
charge material into account in such a
way that the holding time on the bridge
is not too short and not too long. If the
holding time is too short, contamination
will not be eliminated sufficiently.
If the holding time is too long, there
are two effects. Firstly, there is a risk
that the scrap will adhere to the bridge
and need to be scraped off by a skimming
machine. Secondly, thin-wall scrap
may already oxidize on exposure to the
atmosphere before it is melted, resulting
in metal loss.
In the case of scrap with poor pyrolising
behaviour, the holding time on
the bridge must be extended or the
charge weight must be reduced. The
result is a reduction in melting performance,
which can be compensated for
by charging cuttings or other thin-wall
material via the charge well at the same
time. The charging rate via the charge
well should be sufficiently high to keep
the melting bath temperature constant
between 730 and 745 °C.
Energy consumption and
emissions
A central recuperator system was optimized
to ensure a further reduction in
energy consumption. Even in full-load
operation, the flue gas temperature
downstream from the regenerator does
not exceed 200 °C. Fig. 4 shows the
central regenerator system. The regenerators
are fitted with honeycomb systems
designed to ensure that particles
entrained by the flue gas does not block
the ducts. Two regenerators, operated
alternately, reach combustion air preheating
temperatures up to in excess of
850 °C.
The pyrolysis gas produced by the partial
combustion of contaminants is combusted
in the heating chamber where
the energy released can be used for
heating the molten metal and does not
„burn“ the thin-wall scrap in the scrap
chamber. The oxygen concentration in
the heating chamber is maintained constant
at a low level. This system ensures
extremely low energy consumption, in
some cases even lower than 500 kWh/t.
In addition, a low oxygen concentration
also minimizes dross formation in
the heating chamber, because dross on
the surface of the molten metal forms
an insulating layer, preventing effective
heat transfer to the metal. The mode of
operation maximizes the scrap melting
performance of the plant. The atmosphere
in the scrap chamber is kept
free from oxygen. This is a necessity for
low metal loss and a high metal yield.
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Reports
Fig. 5: Pyrolysis gas line between recirculation
fan and heating chamber
Fig. 6: Flow distribution with asymmetric metal pump angles
The latest generation of regenerators is
also designed to ensure that pollutants
in the waste gas are cooled as rapidly
as possible. This is necessary in order to
prevent the recombination of dioxins
and furans, for example, during cooling
after thermal cracking in the furnace
chamber. The special feature of
the LOI system is that the entire waste
gas is passing via the regenerators. All
the waste gas leaves the furnace via a
waste gas duct and passes through the
regenerator. This prevents hot and cold
waste gases from being mixed, which
may lead to recombination.
As regards NO x emissions, the firing system
and low-NO x burners used reflect
the stage of the art of aluminium melting.
Oxygen concentration control is
used to reduce carbon monoxide and
hydrocarbon emissions to the lowest
possible level. This plant technology
ensures that emissions are kept
far below the limits laid down in the
applicable standards. The use of fossil
fuels naturally means that CO 2 can not
be prevented. Carbon dioxide emissions
are reduced by minimizing energy consumption.
Pyrolysis gas is fed from the scrap chamber
to the heating chamber using part
of the flow from one of the recirculation
fans. The arrow in Fig. 5 indicates the
direction of flow from the scrap chamber
to the heating chamber.
Metal recirculation
The trend in aluminium recycling is
for scrap and cuttings to account for
100 % of the charge material. This has
the advantage that very little dross,
which prevents heat transfer to the
metal, is formed on the surface of the
metal bath in the heating chamber of
the Twin-Chamber Melting Furnace
TCF. On the scrap side of the furnace,
an efficient recirculation system can be
used to improve scrap melting performance.
Following the pyrolisis of con-
tamination on the bridge, the scrap is
pushed into the bath by the following
charge. At this point, the scrap has
only absorbed about 2 /3 of the energy
required for melting. It is therefore clear
that optimized recirculation of the molten
metal is required to prevent a critical
temperature drop as the scrap is pushed
into the chamber. Experience with many
Twin-Chamber Melting Furnaces has
shown that the scrap melting performance
is largely determined by the flow
direction of the molten metal in the
bath. In order to solve this problem, LOI
Thermprocess carried out a CFD study to
optimize metal flow with respect to flow
rate and vector. The study showed that
the vectors of the two metal pump outlets
should not simply be set up in a mirror
image configuration but with a view
to ensuring a secondary flow within the
batch. Fig. 6 illustrates this point.
As expected, the comparison of flow
conditions in configurations with one
and two metal pumps in Fig. 7 very
Fig. 7: Comparison of flow distribution at the bottom of the scrap chamber using one (A) and two (B) metal pumps
HEAT PROCESSING · (9) · ISSUE 2 · 2011 145

Reports
HEAT TREATMENT
a conventional plug, can be opened
without any hazards with the pump on
low power. During reverse operation,
the tap hole is above the level of the
molten metal in the bath. Fig. 9 shows
the release of molten metal from the
Charge-Well. The mass flow may be set
by controlling the pump.
Fig. 8: Temperature distribution with two metal pumps
Fig. 9: Metal tapped from the charge well
clearly shows considerably more intensive
flow to the bath area where scrap
is to be melted if two metal pumps are
used. With two pumps, the metal flow
reaches the entire area of the bath on
the scrap side, ensuring improved melting
performance. A homogeneous bath
temperature not only improves melting
performance but also ensures a higher
metal yield, as the dwell time in the
furnace and the enrichment of heavy
metal alloying elements at the solid-liquid
transition temperature are reduced.
With two pumps, melting performance
is improved by almost 40 %, „cold“
areas in the bath are avoided and a
homogeneous distribution of alloying
elements is ensured.
Fig. 8 shows a comparison of scrap
chamber inlet and outlet temperatures
and the more even temperature distribution
in the scrap chamber. There
are no longer any „cold“ areas. On the
basis of the theoretical comparison of
the single-pump and twin-pump solutions,
a 33 % increase in melting performance
was expected. Measurements
on a Twin-Chamber Melting furnace
confirmed that these expectations were
met, and even exceeded, with a performance
improvement of almost 40 %.
Metal tapping
One of the metal pumps is also used
for tapping the molten metal from the
Charge-Well. The tap hole, closed by
Plant analysis
Normally, tests to determine melting
performance and energy consumption
are required under the contract for the
plant. For continuous improvement, it is
also necessary to adopt a holistic view of
the plant. Temperatures are measured
at all points in the plant. To identify any
weaknesses on the surfaces of plant
components, it is also recommended to
take thermograms of the plant. Fig. 10
shows a thermogram of a Twin-Chamber
Melting Furnace together with a
photograph of the same plant section
to give a clearer view.
Photos and thermograms of this type are
taken of all furnace details. Apart from
optimization analyses, thermograms of
this type can be used to identify operating
phenomena such as fatigue, shrinkage,
erosion or vibration.
Conclusion
The latest LOI Twin-Chamber Melting
Furnaces have set new standards in
terms of melting performance, flexibility,
energy consumption and emissions
reduction. The flexible possibilities of
melting different types of scrap with
very low energy consumption lay a firm
foundation for economically viable melting
furnace operation.
Dr. Dominik Schröder
LOI Thermprocess GmbH
Essen (Germany)
Tel.: +49 (0) 201 / 1891-865
dominik.schroeder@
loi-italimpianti.de
Hermann J. Meyer
LOI Thermprocess GmbH
Essen (Germany)
Fig. 10: Thermogram of Twin-Chamber Melting Furnace
Tel.: +49 (0) 201 / 1891-855
hermann.meyer@
loi-italimpianti.de
146
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INDUCTION TECHNOLOGY
Reports
Use of induction systems
for the production of extruded,
high-alloyed steel tubes
Stefan Beer
The production of extruded seamless high-alloy steel pipes demands tight
heating tolerances. This article examines a modern system which offers
significant benefits in terms of flexibility and energy efficiency. Demand
for high-alloy seamless pipes has increased noticeably in recent years due
to the need for enhanced service performance. The percentage of special
alloys ordered, accompanied at the same time by ever smaller batch sizes,
is continuing to rise simultaneously, necessitating an improvement, as
well as greater flexibility, in process control.
The key technical developments for
extrusion of large scale, seamless
steel tubes took place largely in the late
1950s and the 1960s. Several plants
were built for press sizes of up to 40
MN, and, for the most part, these plants
in modernised forms are still in use
today. Since 2005, the world has started
to again install new production lines due
to changes in the market.
Due to current competition with other
manufacturing processes, such as continuous
rolling, the extrusion process is
used primarily for high-alloy austenitic,
duplex and superduplex steel, as well as
for nickel-based alloys, titanium and zirconium
alloys [1].
Depending on the press size, typical
billet dimensions are in the range of
180 to 450 mm diameter, and up to
1500 mm in length. Cycle times of approx.
60 s at a billet diameter of 200 mm and up
to 3 min with a 350 mm diameter billets
are typical in actual plants. The performance
of such modern heating systems
is up to 15,000 kg/h, depending on the
application and material properties.
For complex stainless steel alloys, a very
narrow range of press exit temperature
is acceptable. As a result, the induction
furnace is, in spite of higher energy
costs, the preferred form of equipment.
The lower energy costs for gas heating
are considered mostly for rare alloy
changes. In current projects, a practical
combination of both concepts has been
used, where modern induction furnaces
offer signicant efficiency improvements.
Applications of seamless, corrosion
resistant, high heat resistant and high
pressure-resistant seamless tubes are
found in the following:
Fig. 1: Production process for extrusion of stainless steel billets
• Onshore and offshore oil and gas
industries
• Chemical and petrochemical
• Power plant technology
• Machinery and equipment
• Water Treatment
• Nuclear industries
• Food industries
• Coal gasification
• Fertilizer production
• Environment protection
• Aviation and aerospace
• Marine technology
• Biotechnology and Medical technology
A major aim of the pipe extrusion is
continuous and reliable production with
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Reports
INDUCTION TECHNOLOGY
The following system concepts are used
for heating amongst various users:
• horizontal induction basic heating
system with vertical final induction
heating (Fig. 2)
• gas-fired rotary hearth furnaces with
reducing atmosphere and vertical
final stage induction heating
Fig. 2:
Horizontal induction
billet heating plant,
installed electrical
power 2 x 3,600 kW
• for small billet diameters up to
180 mm, in operation without a
piercing press, horizontal induction
pre-heating plants are used for high
throughput (Fig. 3)
• gas pre-heating up to 700 °C, in combination
with intermediate induction
heaters and final stage single billet
heaters (Fig. 4: plant overview before
piercing press and downstream final
heating).
Piercing press and vertical
reheating
After completing the basic heating of
the billets to a temperature of approx.
1,100 to 1,200 °C, the billets are
brought to a vertical piercing press.
Here, the billets are pierced to a defined
diameter according to the required inner
diameter of the tube.
Fig. 3: Horizontal induction billet heating plant, installed electrical power 3,300 kW
During the piercing process and the subsequent
movement, the billet partially
cools down and prior to entry into the
final heating, the billet has a highly nonuniform
temperature profile.
tight dimensional tolerance requirements
[2].
The primary causes for increased eccentricity
in seamless tubes are:
• undefined temperature profiles
• poor temperature distribution
• non-constant process conditions
• inadequate lubrication
Process requirements include:
• high number of orders with less billets
of the same geometry
• greater variation of the billet diameters
and shorter changeover times
• new requirements for complex materials
Considering the above issues and the
requirement to reduce production costs,
it is necessary that a high performance
heating system is required in order to
achieve this complex range of requirements
(Fig. 1).
Fig. 4:
Intermediate hot
piercing press and
final stage vertical
induction heating
A billet with such a typical temperature
profile, shown in Fig. 5 is characterised
by significant temperature loss of about
300 °C at the surface, front & end faces.
Another aspect is a higher temperature
around the inner diameter.
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INDUCTION TECHNOLOGY
Reports
In order to correct this non-uniform
temperature profile, and to increase the
process temperature back to 1,230 to
1,300 °C, the induction final heating
plays a crucial function within the overall
process.
Fig. 5:
Heated billet Ø
280 mm x 1100
after piercing
press, view of the
temperature profile
Fig. 6: Principle schematic plan of power supply: IGBT converter with multiple outputs
In general, one of the most important
developments is the sectional heating
of the billets in the vertical final heating.
Since 2002, the IAS systems are
equipped with this feature. This feature,
known as multi-zone heating (Fig. 6
and Fig. 7), as improved by IAS’ technology,
guarantees small temperature
tolerances, low temperature gradient
during heating and good homogeneity
of the temperature distribution in the
billet.
By splitting the coils into multiple
axially-arranged sections, separately
switched, the process requirement for
individual zone heating of the billet can
be achieved, importantly, without overheating
the material. This technology
has been recognised within the aluminium
extrusion industry for many years
as the most state of the art technology
and is proven to achieve isothermal
extrusion by use of an axial temperature
gradient [3].
In order to the minimize thermal losses
and to avoid completely the negative
influence of the protection rails on the
billet’s temperature distribution that
would occur in a horizontal heating system,
the steel billets are moved from
horizontal position by a 90° rotation to
a vertical position. These billets can have
different lengths so, in order to ensure
that defined positioning of the billet in
the coil is achieved, the coil is located
above a brace. By use of this brace, the
billet is turned and shifted carefully into
the multi-zone coil, until the defined top
position is reached.
By using three to four parallel arranged
TEM-Pro-Heaters ®1 (max. single output
of 850 to 900 kW) for the final heating
of billets Ø200 x 900 mm, a cycle time
of approximately 0.8 to 1 billets/min and
an average temperature difference of
350 °C is guaranteed (Fig. 8).
1 TEM-Pro-Heater: Registered Trademark of
I.A.S. GmbH + Co. KG
Fig. 7: Converter ITN-3 with 4 outputs
Fig. 8: Final heating system with 3 single heating coils each with
4 control zones
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Fig. 10:
Thermal image
evaluation of the
billet after final
heating (stainless
steel billet
Ø280 x L970mm)
Fig. 9: Heated billet after final heating in a
four zone billet heater
This application consists of four electrically-isolated
and individually adjustable
single coil sections with a maximum
output of 230 kW to 250 kW each
(Fig. 9). The maximum usable length of
the entire coil is determined by the billet
length and is typically up to 1500 mm.
For heating of shorter billets in a reliable
way, an un-cooled field extender
has been developed. Due to the high
specific resistance of the material long
coil overhangs are required in order to
heat the billet homogeneously, even at
the heads and tail ends.
Use of low-loss, multiplayer coils ensures
high efficiency is achieved. Combined
with wear-free switchgear designed as
multi-zone IGBT converters, low operating
costs and improved temperature
control are key additional benefits
(Fig. 10). Depending on the configuration,
an electrical efficiency of up to
81 % can be achieved. For titanium alloys
even up to 83 % is possible, through
the use of the multi-layer coil which
reduces the nominal current rating. The
design of the coil’s profile shape has a
significant influence on the efficiency
of the system. This design enables the
adjustment of the frequency within a
defined range in order to reduce internal
overheating at the final heating stage.
Conclusion
By use of a multi-zone induction heating
system for final heating, in combination
with adjustable frequency and variable
power control with IGBT converters, the
temperature profile can be influenced in
order to substantially improve processing.
The use of modern multiple verti-
cal single billet heaters, in conjunction
with basic pre-heating, which can also
be realised with a gas furnace, achieves
an economical, flexible and repeatable
process control solution.
Literature
[1] Bauser, Sauer, Siegert: Strangpressen
(2001). Aluminium Verlag Düsseldorf,
S. 416 - 420. ISBN-3-87017-249-5
[2] U. Muschalik: Vortrag bei S+C Edelstahlakademie
9-2010, Moderne Strangpresstechnik
für die Produktion von
hochlegierten, nahtlosen Stahlrohren
[3] Beer: ALUMINIUM 80 (2004) 5, Optimale
Bolzenerwärmung im Strangpressbetrieb
Dipl.-Ing. Stefan Beer
I.A.S. Induktions-Anlagen +
Service GmbH
Iserlohn (Germany)
Tel.: +49 (0) 2371 / 4346 30
s.beer@ias-gmbh.de
Hotline
Managing Editor: Dipl.-Ing. Stephan Schalm
Editorial Office: Annamaria Frömgen
Editor:
Silvija Subasic
Advertising Sales: Bettina Schwarzer-Hahn
Subscription: Martina Grimm
+49(0)201/82002-12 s.schalm@vulkan-verlag.de
+49(0)201/82002-91 a.froemgen@vulkan-verlag.de
+49(0)201/82002-15 s.subasic@vulkan-verlag.de
+49(0)201/82002-24 b.schwarzer-hahn@vulkan-verlag.de
+49(0)931/41704-73 mgrimm@datam-services.de
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Reports
Extending the process limits
of warm forging by intermediate
induction heating
Martin Mach, Egbert Baake, Dietmar Köhler, Thomas Walther
Warm forging at temperatures between 600 °C and 900 °C is an economical
alternative to conventional hot forging technology (usually at
1,250 °C) providing reduced energy input, minimal scale, reduced decarburization
and surface roughness and closer tolerances. On the other
hand, more forging operations are necessary as the tool material can only
withstand limited loads. For this reason, preforming by additional rolling
operation is a suitable way for obtaining the required mass distribution.
Nevertheless, every preforming operation causes additional reduction of
the work piece temperature that directly affects the following forging
sequence. That is why an intermediate heating able to compensate temperature
losses due to warm rolling within a short cycle time is needed
for optimal warm forging conditions. In frame of the European research
project DeVaPro „Development of a Variable Warm Forging Process“ both
warm rolling and induction reheating are developed, with the aim to
broaden the spectrum of producible geometries, increase the production
output, and improve the final work piece properties making the warm
forging technology more variable. In this paper a new induction reheating
system is introduced and the first results of its industrial implementation
are presented. In particular, main principles of this technology, development
of the induction heating unit by means of numerical simulation as
well as the results of temperature measurements and practical tests in the
forging line are shown.
Against the background of rising
market opportunities for high quality
warm forged products, in the project
DeVaPro „Development of a Variable
warm forging Process“ a warm forging
process is developed, enabling the
forges to produce more complex long
flat geometries and thus making the
warm forging technology more variable
[1]. To reach those goals, new technologies,
namely a warm rolling operation
and an induction reheating process are
developed and embedded within a warm
forging process chain. In the frame of
this project, the Institute of Electrotechnology
(ETP) is responsible for development
of the induction reheating system,
its practical verication and the installation
and testing of the equipment in the
warm forging line.
The investigated warm forming process
chain is shown in Fig. 1. After cutting
(sawing) the work pieces (performed
centrally) a primary induction heating
up to the warm forming temperature
of 900 °C starts. It is followed by
a preforming operation by means of
the cross wedge rolling or forge rolling
process. As during the rolling the work
piece is intensively cooled down by the
heat transfer to the tools, an intermediate
heating located after the preforming
operation should equalize the work
piece temperature back to the forging
temperature of 900 °C. The nal step
is the forging sequence in the press followed
by the punching and controlled
cooling of work pieces to the ambient
temperature. Compared to common
heating installations operating with a
nearly constant cross section of the billets
and with mainly uniform temperature
before heating, the new system
allows reheating of preformed parts
from non-uniform temperature back
to the determined temperature needed
for the forging sequence. Taking into
account the background of forging
companies in the project consortium,
the reheating operation including the
transportation must be done quickly
and fulll the requirements given by the
total cycle time and the particular disposition
of the forging line.
The temperature of the work piece at
the beginning of the reheating operation
is given by the preforming (cross
wedge rolling) taking place immediately
before. This temperature prole is
strongly non-homogeneous and must
Fig. 1: Warm forging process chain with implemented rolling and reheating operation
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INDUCTION TECHNOLOGY
temperature was measured. While the
surface temperature has been measured
by the infrared thermo-camera, the
measurement of the core temperature
was realized by thermocouples. Representative
results of the temperature
measurement for rolling speed of 9 rpm
are shown in Fig. 4.
Fig. 2: Forging sequence of steering link and corresponding dimensioning of cross wedge
rolled billet
be determined by combination of temperature
measurement and FEM simulations
of the rolling operation.
The reheating process is supposed to
be performed in the batch mode with
manual inductor charging by an operator.
It means that the work piece is
placed in the induction furnace as long
as it has achieved the required temperature.
Having reached the required temperature
the work piece is moved from
the furnace and delivered to the metal
forming station.
Within the project DeVaPro two long
flat parts (steering link and connecting
rod) were chosen as sample parts [2].
The steering link is currently hot forged
and is transferred into the new warm
forging process chain in this project.
This part represents a typical long flat
geometry. The forging sequence as well
as the main dimensions of the cross
wedge rolled billet (being reheated) is
shown in Fig. 2.
Initial conditions and requirements
for intermediate heating
During the cross wedge rolling process
a cylindrical billet is plastically deformed
into an axis symmetrical part by action
of wedge shape die moving tangentially
relative to the work piece. As the temperature
distribution in the work pieces
coming from the cross wedge roller
into the reheating unit is unknown, a
measurement of temperatures occurring
after this operation has been performed.
At the beginning of the test,
the work piece was heated up to the
selected rolling temperature (900 °C)
and after controlling the output temperature
transported into the cross wedge
rolling machine. Position of the work
piece during the forming operation as
well as the influence of tools on the surface
temperature is shown in the Fig. 3.
After the rolling operation, the work
piece was manually removed and the
Looking at the temperature distribution
immediately after rolling operation, it
can be seen that a strongly non-homogeneous
temperature profile occurs due
to rolling. During the rolling process
the middle section of the work piece is
cooled down due to thermal conduction
into the rolling tools. At the same time,
the temperature in the inner part of this
section increases due to deformation
energy. Left and right from the deformation
zone the temperature increases
up to the maximum value that can be
found at the end of the deformation
zone. Going to the front face of the
work piece a decrease of temperature
can be observed. This effect is caused
by enhanced influence of the thermal
losses by convection and radiation in
front face area. The following conclusions
can be drawn from the performed
test:
• max. temperature difference is
approx. 120 °C,
• min. temperature appears in the
deformed zone and at the work piece
end,
• the measurements results are repeatable
for various process parameters.
It should be pointed out, that the thermal
losses and herewith also the resulting
temperature prole in the billet
depend also on the rolling speed. The
Fig. 3: Cross wedge rolling operation
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Reports
Fig. 4: Temperature distribution along the work piece axis measured for different times after the rolling operation
Fig. 5: Implementation of measured temperature data into simulation model
faster the rolling the lower is the overall
temperature decrease. The resulting
temperature prole should also always
be related to the particular process conditions.
Process simulation
In order to design and optimize the
reheating procedure, FEM electromagnetic
thermal coupled model has been
developed at ETP using the commercial
software package ANSYS. The simulation
model allows performing the simulation
of the electromagnetic eld that
induces power (Joule losses) in the work
piece and the consequent transient thermal
analysis during the whole reheating
process. As results the model provides
the knowledge on temperature distribution
within the work piece as well as the
information on all electrical parameters
of the process.
Electromagnetic and thermal material
properties used in the model are temperature
dependent and ensure the correct
behavior of the model in the whole
investigated temperature range. They
are evaluated for each time step of the
transient thermal analysis at each position
in the work piece. As the arrangement
of the work piece and the induction
coil can be assumed as rotational
symmetric, 2-dimensional modeling has
been used for the description of the process.
Construction parts of the induction
heating unit which are not relevant for
the heating process are not included in
the model.
Based on the measured temperature
data a routine for implementation of
the initial work piece temperature into
the simulation model has been created.
An example of the implemented
temperature distribution can be seen in
Fig. 5. The influence of the forming
energy on the increase of the temperature
in the middle work piece section is
not taken into account at the moment.
Nevertheless, an increase of the inner
temperature that is expected in this area
makes the initial condition for induction
reheating more comfortable. The higher
the inner temperature in the deformed
zone, the less energy must be generated
by the induction system.
Fig. 6: Induction coil concept
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Fig. 7: Calculated temperature distribution in the work piece before forging (left), time-evolution of temperature during the heating and
transportation time
Induction reheating concept
Having considered the process requirements
as well as the initial temperature
distribution, a flexible concept of induction
coil consisting of three adjusted
sections has been developed, see
Fig. 6. The purpose of this solution is the
adaptation of geometrical coil parameters
according to the variable work
piece geometry and to the non-uniform
temperature prole at the beginning of
the reheating process. An optimal heating
effect in all three sections can be
reached by adaptation of the section
length (l A , l B , l C ), number of coil turns
(N A , N B , N C ) and by the coil section
diameter (d A , d B , d C ). Electrically are all
three coil sections series-connected. It
means that the current is the same in
all turns.
Global parameters of the reheating system
as well as parameters of the par-
ticular sections have been determined
by means of numerical simulation. As
an example of the model capability and
obtained results, temperature distribution
in an optimized coil, particularly
the temperature prole at time of 5 s
after nishing the reheating process is
described in Fig. 7. Compared to the
initial temperature prole shown in
Fig. 5 it can be seen that the surface
regions with decreased temperature
have been reheated up to temperatures
between 890 °C and 900 °C. At
the same time, the increase of the temperature
in the work piece core can be
observed. Due to the thermal conduction,
the heat is transported towards the
core and causes the overall unication
of the work piece temperature.
Corresponding time evaluation of the
minimum and maximum temperature
in the work piece is shown in the
Fig. 7 (right). Starting from the tem-
perature distribution after the rolling,
unication of the temperature can be
observed resulting in very low deviation
before forging. An appropriate control
of the induction power supply is shown
as well, being calculated by means of
an optimization procedure and providing
the starting information for experimental
tests.
The numerical investigations have provided
all input data needed for layout
of the reheating unit. Having dened
the design of the induction coil, optimal
working frequency, required output
power of the power supply and the optimal
heating regime, a function prototype
has been built at the ETP workshop
and the functionality of the suggested
heating system as well as the suitability
of its parameters was veried [3]. Consequently,
the prototype installation for
experimental verication of the intermediate
induction reheating has been
Fig. 8: Optimized induction coil, heating station and power supply
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INDUCTION TECHNOLOGY
Reports
launched and constructed in cooperation
with the company EMA-TEC GmbH.
The installation includes an optimized
inductor for reheating of rolled work
pieces of variable length integrated into
a heating unit and a power supply. An
overview of main components is shown
in the Fig. 8.
Experimental tests in the
forging line
In order to test and optimize the developed
warm cross wedge roll process and
variable induction reheating system, the
complete manufacturing line has been
installed in the forge VIVA in the Czech
Republic. It contains the transportation
system for the raw material, the primary
heating, CWR-machine, reheating unit,
forging press as well as control and
measurement equipment (Fig. 9).
In the following, selected results related
to the induction reheating are shown.
In the Fig. 10 (left), the temperature
distribution along the longitudinal work
piece axis before and after reheating is
shown. It can be concluded, that the
strongly non-linear temperature prole
after rolling is equalized back to the
initial temperature. The time used for
reheating was set to 10 s and the average
power taken from the grid by the
reheating unit was 25 kW. In the Fig.
10 (right) an example of the energy consumption
monitoring shows the input
and output power during the reheating
of the particular parts.
Fig. 9: Experimental verification within the forging line
basically related to the specic energy
of the steel being heated and to the
electrical and thermal efficiency of
the particular heater. For hot forging,
energy consumption of 450 kWh/ton
can be considered as a typical value
for common industrial heating applications.
In the new warm forging process,
primary heating up to 900 °C is used.
Compared to the hot forging technology,
this reduction of the forging temperature
leads to a signicant reduction
Table 1: Energy analysis of warm forging and hot forging process
of energy consumption based on lower
specic energy input and lower thermal
losses.
While the required specic energy input
decreases proportionally to the temperature
difference of approx. 350 °C,
the reduction of thermal losses is more
signicant due to its proportionality to
the fourth power of the surface temperature.
Having considered these factors,
an ideal consumption of 0.30 kWh/
The results of energy evaluation are
summarized in Table 1. The energy
consumption of induction heating is
Fig. 10: Examples of experimental data: work piece temperature before/after reheating (left), monitoring of energy consumption of the
reheating system
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Reports
INDUCTION TECHNOLOGY
kg for the heating process up to 900 °C
can be estimated.
Energy consumption of the reheating
process has been evaluated experimentally
during the forging and heating
tests. According to the process parameters
used during the tests, a nominal
energy consumption of 0.045 kWh/kg
was estimated for the reheating process.
The total energy consumption, given by
the sum of the both values for primary
heating and reheating process, is herewith
23 % lower than the efciency of
the hot forging method.
Conclusion
An intermediate induction heating has
been developed and integrated into a
warm forging line to compensate the
thermal losses occurring during the
preforming operation by means of
cross wedge rolling. The experimental
verication by means of heating tests
has conrmed the system performance
to reheat the rolled billets within the
required time and temperature tolerance.
In this way, optimal forging conditions
can be achieved within the current
cycle time.
The energy consumption of the warm
forging method is 23 % lower than hot
forging method providing (beside the
forging related improvements) signicant
reduction of the heating costs.
The developed method can be also benecial
in other forging processes requiring
reheating of partially completed
forgings. The main advantage of this
approach is the possibility of a very fast
and selective heating providing homogenously
heated parts for further forging
operations. Additionally, this approach
offers a new freedom in design of new
forming sequences which consider temperature
sensitive materials (Titan alloys)
or complicated geometrical shapes
(crankshafts).
Acknowledgments
We acknowledge the funding of the
project DeVaPro (GA no. 221967) by
the European Union 7th Framework
Programme (Research for the Benets
of SMEs).
Literature
[1] Behrens, B.-A.; Suchmann, P.; Schott, A.:
Production Engineering, 261-268 (2008), 3.
[2] Kache, H.; Nickel, R.; Behrens, B.-A.: Proceedings
of the 13th International Conference
on Metal Forming, Sept., 19 - 22
2010, Toyohashi (Japan), p. 346-349.
[3] Mach, M.; Baake, E.; Neumeyer, J.; Walther,
T.; Köhler, D.: Proceedings of the
International Symposium on Heating by
Electromagnetic Sources, May, 18-21
2010, Padua (Italy), p. 531-539.
Prof. Dr.-Ing.
Egbert Baake
Dipl.-Ing. Dietmar Köhler
EMA-TEC GmbH
Sondershausen (Germany)
Tel.: +49 (0) 3632 6651-70
induction@ema-tec.de
Thomas Walther, M.Sc.
EMA-TEC GmbH
Sondershausen (Germany)
Tel.: +49 (0) 36 32 6651-77
induction@ema-tec.de
Dipl.-Ing. Martin Mach
Institute of Electrotechnology
Leibniz Universität Hannover
(Germany)
Tel.: +49 (0) 511 762-2366
mach@etp.uni-hannover.de
Institute of Electrotechnology
Leibniz Universität Hannover
(Germany)
Tel.: +49 (0) 511 762-3248
baake@etp.uni-hannover.de
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17.02.2011 17:11:36 Uhr

MEASUREMENT & PROCESS CONTROL
Reports
Soft optimization –
How to increase the overall energy
efficiency by optimizing processes and
material flows
Karl-Michael Winter
Steadily increasing energy costs driven by the scarcity of raw materials
and a growing political awareness of the environment have lead to a
rethinking of the production of economic goods. The main priority now is
energy efficiency. In heat treatment especially, one of the industries with
the highest energy consumption, this will cause drastic and therefore
comparably expensive measures.
How can we then cut down on energy? It is obvious that more intelligent
burner systems, insulation, and approaches for energy recovery can
reduce the gross energy consumption dramatically; however, all of these
“hard” measures require huge investments.
This article will present a number of
installed case studies where so-tosay
„soft“ measures increased the productivity
and reduced the amount of
resources such as process gas, energy,
but also labor, with the help of simple
and inexpensive means. Soft optimization
aims at the consistent use of existing
equipment and thus the net energy
demand.
Soft optimizing versus hard
optimizing
When talking about optimizing overall
energy efficiency in heat treating there
are three major subjects to address:
energy generation, energy usage and
energy recycling. In order to analyze
what could be done to reduce the
overall energy footprint and energy
costs, one would first have to take into
account whether the heating source is
electrical or natural gas.
In the fifirst case, a consumer is not able
to influence the efficiency of the energy
generation and the energy costs are
based mostly on the peak consumption
the provider has to supply. For that reason,
the best way to save money is avoiding
high peaks. In the case of gas fired
heaters, it is possible to install new and
more efficient burners [1], or an oxygen
control system [2] in the case of open
burners. Wall losses can be reduced by
applying better isolation material [3],
and there are certainly other measures
that could be applied to reduce energy
consumption. For recycling energy there
are several attempts already on the
market or still in testing. Nevertheless,
the major problem with recycling is the
huge amount of energy needed to heat
up loads of several tons. When quenching
or cooling, this energy cannot be
recovered and stored in an appropriate
manner. It has to be used more or less
immediately; i.e. for preheating process
gas and loads, heating tap water and
washers or heating the shop floor in
winter time. The excess heat still has to
be wasted in heat exchangers and will
be released into the environment.
All of these “hard” measures require
relatively high investments, but thinking
of the fact that heat treating companies
spend about 25 % of their overall costs
on energy [4], such investments will pay
off. Still, a reduction of energy costs of
let’s say 20 % will only result in an overall
cost reduction of 5 to 6 %.
This percentage improves immediately if
we are able to increase the overall efficiency
or usage of a heat treating installation,
in which case the total cost per
part will equally be reduced – in the best
case with very moderate investment.
The following article will present several
examples where such “soft” measures
have been successfully implemented.
Using a model to control gaseous
carburizing
Using a mathematical model to calculate
the carbon transfer into and the carbon
diffusion within the steel enables a loopback
control of surface carbon and carburizing
depth incorporated into a recipe
driven temperature and atmosphere
controller. The built-in auto-boost and
surface carbon control functions will
give huge advantages over a traditionally
performed two or three stage temperature/carbon-potential/time
process
setup. Table 1 compares the process
times of a set of processes aiming for
different case depths. The gain is mostly
Table 1: Potential savings on process time
in carburizing when applying auto-boost
compared to traditional two stage time
based recipes for various case depths
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MEASUREMENT & PROCESS CONTROL
Fig. 1: Carbon potential control. Left, traditional two stage recipe with fixed carbon potentials; right, auto-boost control to gain maximum
carburizing speed
given by a sophisticated carbon potential
control, keeping the potential as
high as possible while at the same time
avoiding soot and carbide formation
(Fig. 1).
If this is combined with a carrier gas
composition control, which adjusts the
carbon monoxide percentage in such a
way that the furnace atmosphere provides
a carbon transfer coefficient just
high enough not to slow down the diffusion,
while trying to reduce the consumption
of expensive hydrocarbons,
it is possible to further improve the
overall efficiency of the process [5].
Table 2 displays the possible savings
based on several processes for different
case depths.
Applying such a system in a typical heat
treating shop where the average case
depth is about 0.8 mm will result in an
overall cost reduction of 15 % and an
Table 2: Potential savings on methanol in
carburizing when applying auto-boost and
beta-control compared to traditional two
stage time based recipes with fixed ratios
for nitrogen and methanol for various case
depths
increase of about 24 % in profit before
taxation.
Controlling potentials in
nitriding / nitrocarburizing
Switching from fixed gas flows to
potential controlled nitriding and nitrocarburizing
processes as well provides
several advantages. In a typical nitriding
process, the target would be to create
a comparably deep case depth while
avoiding a thick white layer. A nitrocarburizing
process, on the other hand,
aims for a shallow case with a rather
thick white layer. Unfortunately in many
cases these requirements are contradictory.
In order to produce a uniform diffusion
layer, the nitriding atmosphere has to
maintain sufficient nitrogen availability
and a minimum nitriding potential, in
other words, a certain ratio of residual
ammonia versus hydrogen. Using a one
stage recipe with fixed flows of ammonia
and additional gases will lead either
to a too low potential, and therefore
to non uniform layers, or to a too high
potential, and therefore to an uncontrolled
growth of the white layer. For this
reason, recipes aiming for a deep case
will mostly use two stages, one with a
high flow of ammonia to create a small
white layer that will act as a nitrogen
reservoir during the second stage with
a significantly lower ammonia flow to
reach the desired case depth. Nevertheless,
changes in materials composition,
load surface and deviations in flow or
temperature cannot be taken care of. In
order not to risk a non uniform diffusion
this process policy requires high potentials.
The unnecessarily created white
layer will often have to be grinded off
the surface after the nitriding process.
Adding an atmosphere measurement
and controlling the nitriding potential
to the exact needs during the process
eliminates post-nitriding grinding while
still maintaining uniformity. Any deviations
will be taken care of by the atmosphere
control loop.
If a white layer is the target of the
process, then this layer, in most cases,
should be composed of epsilon-(carbo-)
nitrides, and very often only a limited
percentage of porosity is allowed.
Again, operating with fixed flows does
not guarantee the asked for results. In
a nitrocarburizing process where both
potentials – nitriding and carburizing –
are controlled, it is possible to produce
the required white layer thickness and
composition including a desired porosity
[6] (Fig. 2).
These modifications do not reduce
the energy consumption of the nitriding
process itself, but elimination of
grinding operations will give better
energy efficiency and cost savings for
the finished part. Moreover, the ability
to design white layers with certain
properties like epsilon or gamma prime
phase, percentage of carbon and nitrogen
and the amount of porosity leads
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Fig. 2: KN and KC controlled compound layers with differing nitrogen and carbon contents
by mass. Process parameters: Steel 1010, pre-oxidized at 360 °C, 2 h soak time (4 h for
sample 1) at 580 °C with subsequent high speed cooling under nitrogen
to improved working properties of the
parts, once in use. Similarly enhanced
corrosion resistance, temperature stability,
ductility, etc. will increase the parts
lifetime and again save on energy in the
long run.
Controlling the material flow on
pit type carburizers
Moshe Eliyahu Goldratt, the inventor of
the Optimized Production Technology, a
production planning method stated [7]:
• An hour lost on a bottleneck is an
hour lost of the total system
• An hour saved on a non-bottleneck is
just a mirage
Consequently, optimizing the production
flow by eliminating bottlenecks will
give the best overall usage in a complex
production chain.
In an installation using pit-type carburizers
for treating big gears, the bottleneck
is typically the oil quench. There
are two reasons for this: quenching
capacity and labor resources. To begin
with, there are not as many quenches as
there are carburizers, and quenching is
performed manually to avoid accidental
fires.
As operators are not readily available
at all hours to move loads to quench,
these loads have to be scheduled in
sequence to ensure that load after load
is ready for quenching while operators
are at work [8]. As a treated load cannot
wait for too long in a furnace for
risk of falling out of specification, using
a sophisticated planning system with
a direct connection to the carburizer’s
controllers can help create a real-time
scenario and automatically start recipes
in such a way that they will be ready for
quenching, one after the other at working
hours. Fig. 3 shows the appropriate
planning tool.
Automatically starting loads on
conveyor belt furnaces
When starting a new load on belt furnaces
(Fig. 4) the operator has to wait
with feeding new parts until there is a
gap, long enough to ensure that there
will be no mixing of parts at the end
of the furnace, once the new parts will
come out of the furnace line. Simply
put, he has to be able to change the
containers once the last part of the old
load leaves the furnace and before the
first parts of the new load will fall off
the belt.
As long as the old load and the new
load require identical process parameters,
this is a comparably simple task to
perform. This changes, if the new load
Fig. 3: Actual load planning situation displayed in a GANTT chart. Outages will
be taken into account
HEAT PROCESSING · (9) · ISSUE 2 · 2011 159

Reports
MEASUREMENT & PROCESS CONTROL
Fig. 4: SCADA representation of a conveyor belt furnace for case hardening with 7 temperature
(including oil quench) and 3 atmosphere zones
If furnaces in a heat treating shop are
electrically heated, restarting the furrequires
new temperature or atmosphere
set points. In this case the gap
has to be big enough to guarantee that
the furnace will operate with the new
recipe.
Using a small software application connected
to the furnace controllers and a
counting device on the belt drive makes
it possible to automatically send the
new set points and to track the back
end of the old load and the front end of
the new load. The new set points will be
sent to the controllers the moment the
old load has left the appropriate temperature
or atmosphere zone. The software
will give a green light to the operator
when it is certain that all parameters
will be within the tolerances of the new
set points, once the new load will reach
the according position.
Assuming that a furnace is operating
with a belt speed providing 60 min on
temperature and further assuming a
typical work schedule of eight different
loads each 24 h, this idea can save
up to two hours production time a day,
resulting in a performance increase of
approximately eight percent.
Automated heating control of
furnaces
Fig. 5: SPC control chart, load chart recorder and Pareto analysis provided by modern a
SCADA system
naces after a weekend of after holidays
is always a crucial task. As the prize for
electrical power is set mainly by the
peak consumption, the furnaces will
have to be restarted one by one, taking
care that the total power demanded is
as low as possible.
Ready-to-go systems limiting the peak
power consumption [9] unfortunately
do not have an understanding of furnaces.
These type of systems will simply
switch off or limit the power available
to connected machines by some
kind of a priority, in the best case.
Using the knowledge of a SCADA system
managing the heat treating facility
enables to automatically switch off
the furnace heaters prior to a weekend.
At the beginning of the week a scheduler
will invoke a sequenced restart of
all furnaces, ramping up instead of just
switching on the power.
This will ensure that furnaces will be
ready for operation on a Monday
morning just before the first operator
arrives. The furnaces will have the recipes
loaded in order to start the planned
load immediately. This saves the operator’s
time and peak consumption and
also reduces possible deformations of
furnace muffles due to the non uniform
heating coefficients of the different furnace
zones.
In addition, such a system can decide, if
a furnace should be set on standby or
staying on temperature, analyzing the
actual load situation.
Comparing quality data with
process data
Preventive maintenance is agreed upon
to be the state-of-the-art policy to keep
your production facility in operation.
Taking a closer look at the equipment
regularly and exchanging parts when
they come close to their projected lifetime
will prevent longer downtimes due
to machinery failures. Applying statistical
methods on alarm messages, like Pareto
analysis or others can help to detect the
sources of an outage more easily, again
minimizing equipment downtime.
If, on top of these widely used policies,
the maintenance department is given
access to the control charts from the
QA laboratory and the charts of the process
parameters, it is possible to react to
upcoming failures before they actually
occur [10]. Evaluating how the process
gas or energy consumption changes
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MEASUREMENT & PROCESS CONTROL
Reports
over time while maintaining the quality
level or observing how the case depth
reached is getting more and more shallow
while running time based recipes,
can raise alarms, indicating for example
that a retort has to be burned out, sand
blasted or exchanged (Fig. 5).
This requires tracking gas flows and heating
power besides the typical process
parameters like temperature and atmosphere
potentials, and an additional feature
in the SCADA system, able to store
QA data. The power/target or gas/target
ratios need to have alarm limits assigned
and can be treated in the identical way
as used in control charts. If the system
sees a violation of the tolerance limits or
a trend, it will automatically notify the
maintenance department.
Conclusion
No doubt, trying to reduce energy consumption
as much as possible is a necessity
in order to stay competitive. Nevertheless,
this will not reduce the overall
costs in the long run. As with a lower
total consumption and with the actual
trend to switch to green energy solu-
tions, the energy will get more expensive
and the additional cost will eat up
the savings. Therefore these measures
will only maintain the “status quo” – in
the best case.
Increasing the overall productivity on
the other hand will save on costs per
produced part by reducing all cost factors
like labor, energy and process gas
and other media. Most of the measures
needed can be performed with a comparably
small investment, just applying
common sense on the equipment
already in use.
Literature
[1] Georgiew, A.; Wünnung, J.; Bonne,
U.: Regenerativbrenner für Doppel-
P-Strahlheizrohre in einer Feuerverzinkungs-linie;
GASWÄRME International,
6/2007, p. 425-428
[2] Boltz, E.S.; Boltz, Y.H.; Clark, J.M.: Rugged,
Verifiable, In-situ Oxygen Analyzers
for Combustion Optimization in Sulphuric
Acid Production; proceedings of the
Sulphur 2009 International Conference &
Exhibition, Vancouver, BC, Canada
[3] Wimmer, H.: Hochtemperaturwolle –
Vernachlässigte Innovation im Feuerfestbau;
GASWÄRME International, 5/2004,
p. 273-278
[4] Energiepreise nehmen Lohnhärtereien in
die Zange; Pressemitteilung, Industrieverband
Härtetechnik, Hagen; 2008
[5] Winter, K.-M.: Beta-Control in carburizing
– ways to cut heat treating costs;
HEAT PROCESSING, 4/2008, p. 307-310
[6] Winter, K.-M.: Nitrocarburizing with independently
controlled nitriding and nitrocarburizing
potentials; HEAT PROCESS-
ING, 3/2006, p. 184-186
[7] The OPT Philosophy, Quelle: Zimmermann,
G.: PPS-Methoden auf dem Prüfstand;
Verlag moderne Industrie, 1987
[8] Winter, K.-M.: Bottleneck oriented load
planning in heat treatment – optimizing
the production flow saves on time and
resources; HEAT PROCESSING, 3/2010,
p. 231-235
[9] Nelles, D.; Tuttas, Ch.: Elektrische Energietechnik;
B.G. Teubner Verlag, Stuttgart,
1998
[10] Winter, K.-M.: Automated heat treatment
lines; HEAT PROCESSING, 3/2005,
p. 156-159
Dipl.-Ing. (FH)
Karl-Michael Winter
PROCESS-ELECTRONIC GmbH
Heiningen (Germany)
Tel.: +49 (0) 71 61 / 94888-0
km.winter@
process-electronic.com
Care of Haus
Sarlin Furnaces
Innovative furnace competence
Sarlin Furnaces develops, manufactures, modernizes and services equipment
for the heat treatment of iron, steel, aluminium and other metals.
• Heat treatment furnaces
• Hot dip galvanizing furnaces
• Furnaces for melting and holding of aluminium
• Gas and burner technology
• Modernization and revamping
• Service and spare parts
Sarlin Furnaces AB, Bastborregatan 5,
SE-721 34 Västerås, Sweden, Tel: +46 21 109 800
www.sarlinfurnaces.se
Sarlin Furnaces, Karhutie 1,
FI-01900 Nurmijärvi, Finland, Tel. +358 10 550 4800,
www.sarlin.com

BURNER & COMBUSTION
Reports
Modern reheating practices focus
on combustion technology
Sacha Scimone, Giovanni Carrara
This technical paper introduces combustion systems and controls as one
of the most important feature in the design of modern reheating furnaces
(Fig. 1), starting with a general overview of the available technologies,
their development in the years and the actual State of the Art. Without
denying that an efficient furnace is always the sum of many technical
choices, the Reader has the chance to focus on the day by day advantages
of proper designed combustion system and controls and to get
different points of view with regard to pulse firing technology.
In the last decade, the main mill operators
urged walking beam furnace
(WBF) designers to give maximum consideration
to the improvement of the
following strategic technical issues:
• Slab heating quality
• Fuel consumption
• Furnace reliability and maintainability
• Environmental friendlier process.
This effort has been rewarded by important
WBF enhancements such as:
• Skid marks

Reports
BURNER & COMBUSTION
Table 1: Influence of excess air on furnace efficiency
Table 2: Potential extra costs for an excessive air/gas ratio
nace malfunctioning among which the
most important are:
• Less energy efficient furnace operation
• Higher (with more combustion air)
or harder (with less combustion air)
scale formation
• Higher NO x formation (with more
combustion air) or CO in the waste
gas leaving the furnace (with less
combustion air).
To avoid the problem of a furnace operation
with an insufficient ratio, many
furnaces are working with a higher than
needed ratio setting and thus decreasing
the furnace efficiency as well as
increasing the NO x and scale formation.
Table 1 below shows the consequences
a hot strip mill operation has to confront
Fig. 2: NO x emission trend
with when the ratio is not kept stable
at the optimum value (for this example
natural gas and 5 % excess are considered).
Considering a hot strip mill with a yearly
production of 5,000,000 t, the use of
natural gas, the cost of natural gas
$ 5.12 per MJ [1] and a cost of $ 947
per ton of finished product [2] loss due
to scale, Table 2 presents the potential
extra costs due to a wrong ratio control:
The above does not consider the burden
of NO x emissions that in some countries
could eventually impair the operation
of the mill. The following figure
(Fig. 2) provides the NO x emissions
of DCC’s standard MAB Burners and
flameless MAB Burners for different
excess air. This figure also shows the
advantages offered by flameless versus
conventional burners with emissions
reduced by approx. 50 %.
The consequences of a wrong ratio setting
and/or ratio control are so expensive
that they draw the attention of all
furnace operators as well as furnace
engineers.
In the following paragraphs the focus
is given to modern combustion system
control philosophies and a proprietary
technology able to provide the best furnace
combustion and control system for
all mill production rates.
Combustion philosophies
Combustion systems of large Reheating
Furnaces for the steel industry can be
designed with at least one of the following
different “philosophies” and/or
more combination of the same.
Conventional cold air firing: This represents
the simplest solution and involves
the minimum capital investment cost.
The big handicap is the running cost,
which is terribly high compared to any
of the other firing technologies.
Conventional preheated air firing: Actually
the most used solution for large
furnaces. Compared to cold firing,
the addition of a centralized recuperator,
has a fast payback because of the
increased fuel efficiency achieved by
preheating combustion air up to 540 °C
(higher temperatures would require the
use of high alloyed steel for both recuperator
and hot air pipelines).
Conventional preheated air and gas
firing: When a low calorific value gas
feeds the furnace, the use of a central
recuperator for gas preheating is also
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recommended primarily for two reasons:
the flame temperature of the low
CV gas might be insufficient to meet
the reheating process requirements and
for furnace efficiency improvement. This
scheme is very similar to the combustion
air preheating system but the gas temperature
is normally lower at approx.
350 to 450 °C.
Oxygen enriched air firing: Mostly used
to increase fuel efficiency of existing
furnaces that previously worked on cold
air only and/or to boost the flame temperature
of fuels with very low calorific
values, has proven to be a good solution
where oxygen is readily available or layout
constraints might impair the installation
of a recuperator. The efficiency of
the system is increased mainly due to
higher radiation exchange factors inside
of the furnace (higher flame temperatures)
and reduced waste gas flow to
the stack (energy wasted is a function
of waste gas temperature and volume)
Regenerative firing, Air only: This system
allows for higher preheating temperatures
of air without the need of costly
materials for recuperator or pipework.
In this case the furnace design is also
affected because the length of the
unfired zone, very critical for conventional
firing, is normally not used for
energy recovery and it is therefore much
shorter.
Regenerative firing, Air & Fuel: If a gas
with LHV

Reports
BURNER & COMBUSTION
Typically sized for the “maximum thermal
power”, all burners create difficulties
if used at lower heat inputs: when
used between 75 and 100 % of their
capacity the flame is close to its design;
below 70 % of nominal capacity the
flame length reduces and the pattern
looses stability. The effect is that on all
combustion zones equipped with side
burners the flame does not reach the
center of the furnace and might overheat
the slab head or tail. In all zones
equipped with longitudinal burners the
flame loses its kinetic energy and thus
“shortens” the zone effective reheating
capacity.
The best solution in order to solve
this fluo-dynamic problem intrinsically
related to the burner is to use on-off
(pulse) firing.
Combustion control philosophy
Provided that the specific project
requirements have been properly investigated
and the burner’s technology
chosen, the design of the combustion
system must be completed by selecting
the applicable control philosophy.
Independently from which firing mode
will be chosen, furnace process engineers
have available several “tools” for
working out the correct control design
strategy of the furnace such as but not
limited to:
Temperature control loop
This closed loop controls the furnace
temperature by comparing the actual
measured T with set T and thus sending
the required heat input variation to the
flow controller.
Flow control loop
This closed loop controls both fuel and
air flow rates by comparing the actual
measured flow with the internally set
flow, calculated as a function of the
heat input variation. Within this control
loop, temperature, pressure and density
compensations are used where necessary
(Table 3).
Pressure control loop
This closed loop is used to control combustion
by means of keeping the pressure
at the collector (air or gas independently)
at the set design figures. Under
the assumption that all pressure drops
of the system remain constant in time,
flowrates are set by means of calibrated
orifices commissioned manually and
once only at start-ups (or eventually during
main re-calibration campaigns).
Table 4: Comparison between different ON-OFF control philosophies
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Flow ratio control loop
The air/gas flow ratio control is done
considering air/fuel stoichiometric value,
automatic tuning at low flow rates and
air excess set by Operators.
Ratio deviations are reduced by using
Double Cross Algorithm (DCL), which
provides dynamic high/low limits to the
variation of fuel flow as a function of
the actual air flow and of air flow as
a function of actual fuel flow. Tuning
parameters are set during commissioning.
ON-OFF control
There are practically two ways to perform
on-off firing control:
• Each burner is controlled independently
thru a traditional ratio control
(Fig. 3). There will be one ratio control
per burner and each burner can
be operated as a single zone. Each
burner is equipped with automatic
fuel and air control and shut off
valves.
• Each burner is fed with constant air
and fuel flow (Fig. 4). The desired
ratio is set in the design and start up
stage by balancing the air and gas
pipeline pressure drops. Each burner
can be operated as a single zone.
Each burner is equipped with automatic
fuel and air shut off valves.
Proportional high-low firing
control (PHL)
ON-OFF firing offers unique process
advantages and therefore is today
widely used. However, ON-OF firing was
not yet supported by an efficient control
system able to guarantee all advantages
of this technology in a reliable and
simple way. DCC therefore developed
a technology called PHL (proportional
high-low firing control) according which
the benefits of the modulated flow and
ratio control are combined with those of
the ON-OFF firing operation.
While the conventional modulated control
of each furnace zone always ensures
correct flow rates, and therefore combustion
ratio, the PHL controls each
individual burner of the zone in ON-OFF
mode and thus guarantees that all burners
are always working very close to the
design parameters (Fig. 5). PHL works
exactly like a conventional modulated
zone with continuously controlled air
Fig. 5: ON-OFF gas distribution with zone ratio control (PHL)
and gas ratio but with on-off burners,
each one equipped with automatic fuel
and air shut off valves.
PHL defines the number of burners lit,
in accordance with the zone heating
requirement, by dividing the actual load
by the single burner nominal capacity. If
the result is not an integer, the PHL will
use a number of burners equal to the
integer plus 1.
The number of cycling burners is computed
and updated continuously and
the firing matrix modified automatically
(i.e.: for a six burners zone with
actual load of 64 %, the burners lit are:
6 x 0.64 = 3.84 equal to 3 + 1 = 4
burners). The position of the burners
off is shifted every cycle according to
a predefined matrix and after 6 cycles
(Fig. 6) all burners have released the
same amount of heat (Fig. 7), the sum
of which is exactly the required 64 %.
By applying PHL firing logic all over the
different combustion zones equipped
with side wall and/or longitudinal burners,
the furnace is able to perform a real
condition of uniform temperature distribution
across the furnace chamber and
therefore below and above the slab sur-
Fig. 6: PHL firing matrix for zone load of 64 %
face, assuring a uniform slab reheating.
finally, in case of a single burner valve
failure, the system automatically opens
all PHL valves and switches the zone to
modulated mode, allowing working with
modulated control logic until the failed
valve has been repaired.
Pros and cons of available combustion
control systems
As reviewed in paragraph 4 and 5, there
are basically three systems able to perform
ON-OFF firing. Each solution allows
achieving the benefit of the pulsing
firing technology but thru different philosophies
and thus with pros and cons.
Table 4 explains in detail the main pros
and cons associated with all three systems.
Since each PHL zone has its own conventional
modulated contral, there is no
concern if the single burner might be
eventually slightly off ratio while working
in low mode because the whole zone
is always working according to the correct
ratio.
Needless to say, PHL control philosophy
is by far more flexible, consistent and
HEAT PROCESSING · (9) · ISSUE 2 · 2011 167

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BURNER & COMBUSTION
• The combustion technology must
always be complemented by an accurate
control system.
With reference to the sole ratio control
we proved that a badly-designed combustion
system as well as applicable
controls can be the source of major
draw backs both in terms of economics
and environmental implications.
Due to the complexity of this matter
we recommend that combustion issues
for large reheating furnaces are
approached only by reliable furnace
engineers with comprehensive process
knowledge and therefore with the ability
to cope with this subject from a
global point of view.
Literature
[1] U.S. Energy Information Administration:
www.eia.doe.gov/dnav/ng/hist/
n3035us3m.htm
[2] Metal Bulletin Research, issue 108, 07 April
2011, HR coil US domestic (EXW)
Fig. 7: PHL iring sequence for zone load of 64 %
reliable than other pulse firing control
system today available but it is more
costly. However, the minor extra cost is
fully justified by the great technological
advantages and the deriving reduced
running costs for decreased fuel consumption
and scale loss.
Conclusion
This paper on furnace combustion and
control technologies, has offered us the
opportunity to stress few fundamental
concepts:
• The pulse firing technology is the
only one able to continuously guarantee
the best burner performances
during all production rates dictated
by the mill operation.
• The right selection of the combustion
system, made by balancing all
boundary constraints imposed by the
plant, is a must.
Dipl-Ing. Sacha Scimone
DANIELI Centro Combustion
SpA
Genova (Italy)
Tel.: +39 (0) 10 / 5341700
s.scimone@danieli.it
Master of Engineering
(Metallurgy)
Giovanni Carrara
Hephaestus Consulting Inc.
Crescent (U.S.A.)
Tel.: +1 (0) 412 / 4434050
gcarrara@hephaestus.us
Hotline
Managing Editor: Dipl.-Ing. Stephan Schalm
Editorial Ofce: Annamaria Frömgen
Editor:
Silvija Subasic
Advertising Sales: Bettina Schwarzer-Hahn
Subscription: Martina Grimm
+49(0)201/82002-12 s.schalm@vulkan-verlag.de
+49(0)201/82002-91 a.froemgen@vulkan-verlag.de
+49(0)201/82002-15 s.subasic@vulkan-verlag.de
+49(0)201/82002-24 b.schwarzer-hahn@vulkan-verlag.de
+49(0)931/41704-73 mgrimm@datam-services.de
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HEAT PROCESSING · (9) · ISSUE 2 · 2011

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www.oerlikon.com/leyboldvacuum

Reports
BURNER & COMBUSTION
Energy-efficient furnace heating –
Regenerative heat recovery with flat
flame burners
Sabine von Gersum, Wolfgang Adler, Wolfgang Bender
The use of thermal regenerators in industrial furnaces produces major
savings in fuel costs and allows high value fuels such as natural gas to
be substituted by process and bio gas. Furthermore, flat flame burners
are often used to achieve a required heating quality. A new type of
heating system consisting of tubular regenerators and flat flame burners
has therefore been developed for this purpose. The system was initially
studied on an experimental basis using numerical simulation and
then tested in operating conditions with great success. With both natural
gas and with process gases from steelworks, fuel savings of 20 to
30 % were documented compared to systems which are commonly in
use today. In addition, the entire system features low flow resistance
while the pressure loss at high-fire rate is only approx. 20 mbar.
The high exit temperature of flue
gases in high temperature process
systems means that a major part of
the energy used in the process is simply
wasted. One idea to minimize these
losses is to use an efcient heat recovery
system which is installed in the stream of
flue gases and uses the heat contained
in the flue gases to preheat the combustion
media. In a ring system which uses
natural gas, the combustion air constitutes
around 90 % of the gas mass
flow. It makes a good deal of sense to
preheat this combustion air. The lower
the air requirement of the combustion
gas, the less heat can be recovered from
the flue gases and returned to the process.
If LCV gases, such as blast-furnace
gas, are used, it also makes sense to
preheat the combustion gas using the
heat from the flue gases.
The central recuperators which are commonly
used today are primarily made of
steel. The flue gas from these high temperature
process systems is emitted from
the furnace at a process temperature
of over 1,000 °C. Since the maximum
material temperature in the recuperator
is well below this level, the hot flue gas
is mixed with cooling air before being
fed into the recuperator. This means
that the large potential of flue gas heat
is not being used efciently. The majority
of the heat energy contained in the
flue gas stream is simply lost from the
process.
Fig. 1 shows an example of the potential
savings for a furnace powered by
natural gas with a flue gas temperature
of 1,200 °C using various heat recovery
techniques. To obtain a heat flow of
Fig. 1:
Savings potential
by heat recovery by
means of combustion
air preheating
1 MW in the process, around 3 MW of
energy must be provided by the combustion
gas in a furnace without a heat
recovery system, while in a system with
a recuperative heat recovery system, the
gure falls to around 2.2 MW. When
using a regenerative heat recovery system,
it falls to around 1.5 MW. Converting
an existing furnace from recuperative
to regenerative heat recovery therefore
allows additional savings of up to
30 % to be achieved.
In heating furnaces in forging and rolling
mills, for example, goods are heated to
a temperature of approx. 1,200 °C. The
annual production of a medium-sized
forging mill is around 30,000 t. With
a typical specic energy requirement
of the forging furnaces of between
2.0 and 4.0 GJ/t, this means that the
energy consumption rate is around
100,000 GJ/a (Table 1), with the appropriate
fuel costs. In large rolling mill
furnaces, this means that the fuel costs
alone reach a level of several million
Euros per annum. Massive potential savings
can be made on these systems.
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Table 1: Typical operational characteristics of existing plants
so as to reduce its pressure loss to just
a few mbar. This new ROREBS system
has been tested on test rigs, improved
by means of numerical simulation (CFD)
and tested in operating conditions on
furnaces in forging mills which use natural
gas, coke oven gas and converter gas
(BOF-gas) as fuels.
Table 2: Caloric value and air requirement of tested fuel gases
Heat recovery using thermal regenerators
has been used in many sectors of
industry for a considerable time. It is certainly
not a new technology. However, to
date there has been little enthusiasm for
converting to this technology in sectors
such as forging and rolling mills since it
is assumed that the amortization time is
simply too long. Until a few years ago,
there were no suitable burners available
for this purpose since the extremely high
temperatures which occur in the preheating
of combustion media resulted
in increased NO x emissions and the service
life of the equipment available at
that time was uncertain. More recently,
the large increases in energy prices have
considerably improved the economy of
regenerator systems. Operational tests
have shown that the NO x problem can
be solved using existing technology and
a satisfactory service life can be achieved
with the components used.
Development of a new heating
system for heating furnaces
flat flame burners are often demanded
by furnace operators to ensure the high
quality heating of the product. The flat
flame burners currently available on
the market include components which
create a torsional effect in the air. This
results in a high pressure loss. In a standard
combustion air preheating system
using a central recuperator, the pressure
loss via the burner alone amounts
to over 40 mbar. An efcient regenerative
combustion air preheating system
would almost double this value. The
investment and running costs for the
combustion air fan increase accordingly.
In addition, the components which create
the torsional effect are not generally
very durable when exposed to the high
temperatures which occur in a regenerative
system. This is why there have
been no flat flame burners available to
date for use with thermal regenerators.
A new flat flame burner has now been
developed, produced and tested in
operational conditions which does not
contain components to create the torsional
effect. Together with a compact
regenerator a new regenerator-burner
system (ROREBS) has been created
which combines the benets of regenerative
combustion air preheating with
the technology of a flat flame burner.
The interior of the flat flame burner is
made of heat-resistant ceramic materials.
This means that there is no need for
cooling and purging air. The pressure
loss in the burner if the air is preheated
to 1,000 °C is around 15 mbar. With
this in mind, the burner has been combined
with a compact tubular regenerator
which features a honeycomb design
Fig. 2: Schema of an implementation at a reheating furnace
Operational testing of the
system on furnaces in forging
mills
A batch furnace and bogie hearth furnaces
were tted with ceramic flat
flame burners and tubular regenerators.
One of these furnaces can be operated
with either coke oven gas or converter
gas. The others are powered by natural
gas. These combustion gases have
very different caloric values and air
requirements (Table 2). A forging furnace
tted with 8 systems is shown in
schematic form in Fig. 2. Each burner
has its own regenerator. The flue gas is
extracted from the furnace through the
burners and regenerators. The systems
operate intermittently. While some of
the regenerators preheat the combustion
air, the flue gas is extracted through
other regenerators. The regenerators
are charged and discharged alternately.
The heating system consisting of the
regenerator and flat flame burner is
shown in detail in Fig. 3. Hot flue gas is
fed out of the furnace chamber through
the burners to the heat accumulator.
This is where the flue gas relases the
majority of its heat energy and then
exits through the bottom end of the
regenerator at a temperature of approx.
HEAT PROCESSING · (9) · ISSUE 2 · 2011 171

Reports
BURNER & COMBUSTION
air is then fed straight into the burner.
Ceramic honeycombs are used as the
heat accumulator.
The burner is designed so that the type
of air flow creates a torsional effect
which is strong enough to form a flat
flame on the burner quarl, no components
are required to guide the combustion
air flow. This means that this burner
features low pressure loss and does not
tend to suffer wear caused by the flow
conditions.
Fig. 3: New heating technology with regenerator and flat flame burner
The flue gas temperature is measured at
the foot of the regenerator. If it exceeds
a limit value, the extraction of flue gas
is stopped to prevent the system suffering
damage and prevent a thermal overload
in the downstream system components.
As an option, it is also possible to
record the combustion air temperature
upstream of the burner using a thermocouple
installed between the regenerator
and the burner.
300 °C. The flue gas extraction system is
then shut down and cold combustion air
is pushed in at the foot of the regenera-
Fig. 4:
flat flame burner
in a bogie hearth
furnace
tor. This is fed through the heat accumulator
and heated to a temperature of
approx. 1,000 °C. The hot combustion
Fig. 4 shows an example of a bogie
hearth forging furnace powered by
natural gas with ten systems with a gas
capacity of 300 kW where ve have
been installed on each side of the furnace.
The new heating equipment on
this furnace has been operating for
around four years. With the furnace
operating at a temperature of 700 °C,
the combustion air for this system is
preheated to between 500 and 550 °C.
With a furnace temperature of 1,260 °C,
the combustion air temperature reaches
values of between 1,000 °C and 1,100 °C.
The furnace is operated at maximum
capacity within this temperature range.
In the subsequent settling phase, the
furnace capacity falls to around 20 to
30 % of the connection capacity. Conventional
heating systems suffer considerable
falls in efciency at this point. The
new heating system, on the other hand,
allows the combustion air temperature
to be kept at an almost constant level
of around 900 °C.
Fig. 5: Attained fuel savings at a reheating furnace
The fuel gas savings achieved by operating
a forging batch furnace with four
burner- regenerator systems on each
side of the furnace have been measured
in detail. This furnace has been running
for over ve years. A comparison to the
recuperator operating mode of an otherwise
identical neighbouring furnace
showed that over the entire furnace
cycle, the system made energy savings
of up to 30 % (Fig. 5).
172
HEAT PROCESSING · (9) · ISSUE 2 · 2011

BURNER & COMBUSTION
Reports
All regenerator systems also featured
low maintenance requirements during
the testing phase together with no
down times for cleaning the regenerator.
Conclusion
ROREBS is a new heating system for
high temperature process systems which
has been developed, built and tested
in operating conditions and combines
efcient waste heat recovery with the
benets of the flat flame burner design.
Savings in fuel requirements (energy
costs and CO 2 emissions) of 20 to 30 %
compared to conventional systems were
made during operational trials. The considerably
lower pressure loss of the new
system also combined the benet of a
lower electrical fan rating with a considerably
increased combustion air temperature.
The suitability of the system for
both natural gas and process gas was
also demonstrated.
The new components of the ROREBS,
the tubular regenerator and flat flame
burners, will be improved both for use
on other industrial ring systems such
as rolling mill furnaces and also for use
with alternative fuels.
Acknowledgement
The authors would like to take this
opportunity to express their gratitude
the following:
• The industry partners G. Grimm Edelstahlwerk
GmbH & Co. KG, Kind &
Co. Edelstahlwerk GmbH & Co. KG
and Saarstahl AG (furnace operators)
• Andritz Maerz (furnace construction)
and R. Buchwald (regenerator production)
• nancial support has been provided
for several research projects by the
German Federal Ministry of Industry
and Technology as well as Projektträger
Jülich, the project patron.
Dr.-Ing.
Sabine von Gersum
Elster GmbH
Lotte (Germany)
Dr.-Ing. Wolfgang Adler
Tel.: +49 (0) 211 / 6707 309
wolfgang.adler@b.de
Tel.: +49 (0) 541 / 1214 374
sabine.gersum@elster.com
VDEh-Betriebsforschungsinstitut GmbH
Düsseldorf (Germany)
Dipl.-Ing.
Wolfgang Bender
VDEh-Betriebsforschungsinstitut
GmbH
Düsseldorf (Germany)
Tel.: +49 (0) 211 / 6707 317
wolfgang.bender@b.de
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BURNER & COMBUSTION
Reports
Furnace burner delivers low NO x with
high combustion air temperatures
Val Smirnov, Ad de Pijper
Eclipse, Inc. has developed and introduced the Furnnox furnace burner
which is designed with Deep Air Staging and additional air split technology.
The burner produces low NO x emissions at high preheated combustion
air operation and low excess air levels. The majority of the combustion
reaction takes place in the volume of the furnace with a permanent
‘rich’ flame jet that is stabilized inside the refractory block combustor.
Industrial burner designs employ a
variety of well known techniques to
reduce NO x formation in high temperature
applications. The most common
and well developed technique is
to use air-to-fuel or fuel-to-air staging
or a combination of both. The patented
ThermJet high velocity burner technology
is built on Deep Air Staging. In this
burner, the combustion air is divided
into multiple streams by the application
of a specially designed nozzle. The
air streams are sequentially mixed with
the fuel gas flow, changing the stoichiometry
inside the nozzle from deep
‘rich’ to slightly ‘rich’. The remaining
air stream is directed around the nozzle
where it co-flows with the air-fuel mixture
downstream of the nozzle allowing
slow, gradual mixing with ‘rich’ air-fuel
mixture coming out of the nozzle. As a
result, a high momentum flame jet is
established, forming two distinguished
zones: a ‘rich’ inner zone and a ‘lean’
surrounding zone. In addition, the high
momentum flame intensies the internal
flue gas recirculation in the furnace
allowing the flame jet to be saturated by
‘cooler’ combustion products. This leads
to the reduction of NO x formation in the
high temperature furnace atmosphere.
spreading the chemical reaction evenly
through the volume of the furnace. As
a result, the temperature spikes inherent
to jet flames are eliminated, and thus
thermal NO x formation is reduced.
Typically, burners that are designed to
operate in flameless oxidation mode
employ double gas or double air valves
(or switch-over valves). These valves
are used to switch the air or gas flows
from a standard flame mode during the
furnace warm up period to a flameless
mode at a furnace temperature
above auto-ignition, which is typically
1,600 °F/ 870 °C. This requires
an additional temperature control
system that must reliably monitor the
temperature in the furnace. This additional
equipment requirement adds to
the capital and maintenance costs for
the users of flameless technology.
Furnnox design and principles
of operation
In the pursuit of a cost effective and
low emission solution, the Furnnox
burner was developed based on the
Deep Air Staging (DAS) nozzle concept
and a combustor design with Air Split
(AS) elements. Laboratory and eld testing
have shown the Deep Air Staging
with Air Split (DAS-AS) design allows the
Furnnox burner to operate at high air
pre-heat and emit less NO x than other
furnace burners.
The burner consists of a main housing
mounted to a refractory combustor
(Fig. 1 and 2). The housing is internally
insulated to reduce the temperature of
the outer shell surface when using preheated
air. The rear cover provides ports
to connect an air-cooled UV sensor,
direct spark igniter and peepsight. The
gas inlet includes an orice to measure
the fuel flow. The burner nozzle is positioned
inside the combustor, which is
formed inside the refractory block. The
refractory block also includes a cavity to
distribute the combustion air between
the combustor and air split lances.
The nozzle design and its unique positioning
inside the burner allow the com-
Recent developments
In recent years, the innovative technology
of flameless oxidation was introduced to
metal, glass and other industries. New
burner designs were developed by WS
and Techint (flOX), Hauck (Invisiflame),
WS/Hotwork (GlassflOX),
and Praxair (DOC dilute oxygen concept).
Operating in flameless oxidation
mode reduces the flame temperature by
Fig. 1: Components and flow patterns of the Furnnox burner
HEAT PROCESSING · (9) · ISSUE 2 · 2011 175

Reports
BURNER & COMBUSTION
Fig. 2: Complete Furnnox burner assembly
bustion air to gradually flow inside the
nozzle in ve stages. Not all combustion
air goes to the nozzle. As a result of this
staging, a ‘rich’ flame is formed and stabilized
inside the combustor. As a result
of the converging conical shape of the
combustor outlet, a high momentum
flame jet is created. The high momentum
of the combustion products exiting
the combustor causes a strong recirculation
of the hot furnace gases and mixing
with the flame jet.
A signicant portion of the total combustion
air stream is injected into the
furnace space through the air split
lances. These secondary air jets from the
air split lances are directed slightly away
from the flame jet causing a mixing of
the remaining combustion with the hot
furnace gases, without affecting the
mixing of the hot gases with the flame
jet. The dilution of the flame jet and the
secondary air jets by the hot furnace
gases produces a thermally uniform
heat release with signicantly lowered
peak flame temperatures. The reduction
of the peak flame temperature is a key
element to inhibiting the formation of
Fig. 4: Furnnox
burner installation
on test furnace
thermal NO x , while also producing an
even temperature distribution throughout
the furnace chamber.
A front view of the refractory block is
shown in Fig. 3. The Furnnox burner
may be oriented either with the air
split lances positioned above the flame
jet (position ‘A’) or below the flame
jet (position ‘B’) when installed in the
furnace. This minimizes the impact of
the secondary air on the load in the furnace.
Position ‘A’ is more suitable for top level
horizontal installations, when the load is
moving through the furnace below the
flame jets. Position ‘B’ is more suitable
for bottom level horizontal installations,
when the load is moving above the
flame jets. The air split lances are oriented
with a diverging compound angle
in respect to the combustor centerline in
order to optimize delayed mixing, and at
the same time prevent the emission of
unburned fuel from the furnace stack.
Burner development
Tests of the prototype and pre-production
burners were conducted in a
full scale lab furnace of 8 feet (2.4 m)
wide, 6 feet (1.8 m) tall and 18 feet
(5.5 m) long (Fig. 4). The burner was
tested with both ‘A’ and ‘B’ positions
of the block. The air was preheated in
an indirect-red air heater. The stack
damper was adjusted to keep a slightly
positive to neutral pressure in the furnace.
Multiple burner sizes were tested,
with maximum ring rates ranging from
250 KBtu/h (67 kW-net) to 2000 KBtu/h
(530 kW-net). The performance of each
burner was tested for a turndown range
of 10:1.
The tests demonstrated that the Furnnox
burner can be ignited at any input
within the 10:1 turndown range in a
cold furnace and it can run up to the
high temperature in the furnace without
need of the additional control
equipment that is required by flameless
oxidation technology. In the DAS-
AS design, an increase in air preheat
temperature allows for more air flow
through the air split lances, and accordingly,
less through the combustor. This
“automatic” redistribution of the air
flow helps to depress NO x formation at
higher air preheat temperatures.
Fig. 3: Front view of Furnnox burner refractory block
Influence of excess air on
Furnnox NO x emission
The impact of a change of the oxygen
level in the furnace on the NO x emission
from the Furnnox burner is similar
to typical furnace burners. Fig. 5 demonstrates
that at reduced excess air
levels the NO x emission is reduced. At
176
HEAT PROCESSING · (9) · ISSUE 2 · 2011

BURNER & COMBUSTION
Reports
lower excess air levels, the amount of
combustion air going through the nozzle
is reduced and the air/fuel mixture
inside the combustor is more fuel rich.
As a result, less combustion takes place
in the flame jet and more takes place
in the volume of the furnace. The temperature
of the flame jet is reduced, and
as a result, the NO x emission output is
reduced. However, the Furnnox burner
generates signicantly less NO x than the
standard ThermJet burner (top curve in
Fig. 5).
The NO x emission generated by the
Furnnox burner is higher than burners
operating in flameless oxidation mode.
But considering the advantage of operating
without the need for the sophisticated
control equipment required with
flameless oxidation mode burners, the
Furnnox burner is a good alternative for
low NO x , high air preheat temperature
applications.
Influence of combustion air
preheat temperature on Furnnox
NO x emission
Combustion air preheating is a powerful
method to decrease the fuel consumption
required for a heating process.
Unfortunately, ‘hot’ air-fuel combustion
increases the flame temperature, resulting
in an increase of NO x formation.
Fig. 6 shows this tendency for combustion
air preheat temperatures changed
from ambient up to 1,000 °F (537 °C).
At an average furnace temperature of
2,200 °F (1,200 °C), the NO x emission
more than doubled for each excess air
level tested. For reference, the ThermJet
emission at 15 % excess air operation
and a similar furnace temperature are
included on the graph. The higher the
combustion air preheat temperature,
the higher the NO x emission formation
for both the Furnnox and ThermJet
burner. However, the NO x generation of
the Furnnox burner is less sensitive to an
increase of the combustion air preheat
level.
Fig. 5: Excess air influence on NO x emission
50 % with a furnace temperature
increase from 1800 °F (982 °C) to
2,300 °F (1,260 °C). For the same temperature
increase, the NO x emission
from the standard ThermJet increases
more than 100 %. As expected, thermal
NO x formation is more sensitive to
furnace temperature changes at higher
excess air levels. This conrms that high
levels of free oxygen in the furnace
atmosphere promote higher level of
thermal NO x formation.
Operational turndown and
NO x emission
The Furnnox burner was developed to
provide a 10:1 operational range. The
NO x emission data within that range
for the 1500 KBtu/h (400 kW) burner
model is presented in Fig. 7. The NO x
emission from the Furnnox burner is
lowest at high ring rates. At high-re,
the high momentum of the flame and
air split jets coming out of the burner in
addition to the combustion products are
mixed with the highest amount of hot
gases in the furnace volume, so flame
peak temperatures and NO x emissions
are minimized.
Reducing the input from maximum to
minimum leads to a reduction of the jet
momentum and it lowers the recirculation
intensity of the hot furnace gases.
The resulting higher flame temperatures
cause the NO x emission to increase. The
Furnace temperature and
NO x emission
In general, the thermal NO x emission
increases as the furnace temperatures
go up. This trend is inherent to the
combustion reaction in general, but
it was found that the burner design
influences the intensity of that process.
For example, the NO x emission from
the Furnnox burner increases by 37 to
Fig. 6: Influence of combustion air preheat temperature on NO x formation
HEAT PROCESSING · (9) · ISSUE 2 · 2011 177

Reports
BURNER & COMBUSTION
and the NO x emissions go up accordingly.
Fig. 7: NO x emission of FN0150 burner within 1 to 10 operational range
graph shows the highest level of NO x
emission at inputs 20 to 25 % of high
re. At lower inputs, the flame turns
to a yellow, lazy and luminous jet. This
increases the amount of radiation from
the flame, resulting in a cooler flame
and slightly lower NO x emission. Fig. 8
shows the flame of a natural gas red
Furnnox burner operating at a furnace
temperature of 1,800 °F (982 °C) in
the test furnace. View A is a side view
and view B is a front view of the same
burner. The furnace temperature here
was set lower than maximum to intentionally
make the flame visible against
the furnace wall for the camera. At furnace
temperatures approaching 2,200 °F
(1,200 °C) and higher, the actual flame
is nearly transparent.
NO x emission with propane
and butane
The burner was tested not only on natural
gas, but also on propane and butane
fuels. As expected, the NO x emission is
higher on propane and butane than on
natural gas operation. At a low excess
air level of 5 %, the emission with propane
is about 20 % higher than for
natural gas. At a higher excess air level
of 25 %, that difference increases to
40 %. This can be explained by the
higher flame temperature of propane
combustion. At higher excess air levels,
more of the chemical reaction of
combustion is shifted from the furnace
volume back into the combustor. As a
result, the flame temperature increases
Conclusion
The Furnnox burner provides exceptionally
low NO x emissions with 5 to
10 % excess combustion air and combustion
air temperatures up to 1,000 °F
(550 °C). Due to its unique design, the
NO x emissions are consistent over a wide
range of combustion air temperatures,
chamber temperatures and turndown.
The high momentum flame characteristics
deliver improved furnace temperature
uniformity. Compared to flameless
oxidation burners, the Furnnox burner
is less costly to install and maintain and
also simpler to operate. This burner is
ideal for high temperature processes in
the metals industry including reheating,
annealing and forging.
Literature
[1] Val Smirnov, Scott Stroup and David Collier,
“High Velocity Burner Development
for Low NOx Formation”, Industrial Heating,
p. 53-57, May, 1998.
[2] Val Smirnov, “High Momentum flame
Technology for Low-NOx Formation in
SER Radiant Tube Burners”, Heat Processing,
(3), Issue 3, p. 142-144, 2005.
[3] Joachim G. Wunning “New Recuperative
and Regenerative Burners for Minimizing
Exhaust Gas Losses and Emissions”, Heat
Processing, (7), Issue 4, p. 333-336, 2009.
[4] James Feese, Felix Lisin, Gerrit
Wohlschlager, Sandra Runde, “Pusher
Reheat Furnace Combines Increased Production
with a Reduction in Emissions”,
Heat Processing, (7), Issue 4, p. 343-346,
2009.
[5] Anne Giese, Reiner Mackh, Carl Zirkelbach,
“GlassflOX Burner – 3 Years in
Operation”, Heat Processing (7), Issue 2,
p.137-141, 2009.
[6] Larry Cates and Rick Browning,
”Advanced Oxy-Fuel Burners and Controls
Improve Fuel Savings and Uniform
Heating”, Forge, 8-11, January, 2011.
Dr. Val Smirnov
Eclipse, Inc.
Rockford (U.S.A.)
Tel. : +1 (0) 815 637-7356
vsmirnov@eclipsenet.com
Ad de Pijper
Eclipse, Inc.
Rockford (U.S.A.)
Fig. 8: View of the front of Furnnox burner in operation in the test furnace
Tel.: +1 (0) 815 637-7307
adepijper@eclipsenet.com
178
HEAT PROCESSING · (9) · ISSUE 2 · 2011

BURNER & COMBUSTION
Reports
Regenerative burners for reduction of
energy consumption and emissions
Jörg Teufert, Stefan Baur
Regenerative heating systems are coming increasingly into use in steel
industry reheating furnaces. The basic principle of this technology has
been known for a long time. The concept was intensively further developed
during the 1990s, in the context of a Japanese research program for
the introduction of high-temperature combustion in reheating furnaces.
Regenerative burner technology presents an attractive alternative for cost
reductions for furnace operators, in view of continuously rising fuel prices
and the future emission trading systems. This article examines the use of
regenerative burners in existing furnaces.
By now regenerative burner systems
have also been established in the
steel industry and are denitely stateof-the-art.
Numerous applications at different
furnaces account this for a fully
developed, energy saving technology.
Construction
A regenerative burner system always
consists of at least two burners, each
burner with a regenerator lled with
ceramic material and equipped with
two changeover dampers. Regenerator
and burner are refractory insulated
due to the high working temperature.
The burner has an air-cooled fuel lance
(Fig. 1). Balls, honeycombs or sponge
material made of ceramics are used as
regenerative media.
The burner pairs can be connected
directly with pipelines. Today a piping
via collecting pipes and allocation of
the pairs by an electronic compound is
state-of-the-art. This offers – depending
on the application – better control possibilities
and lower assembly costs.
Mode of operation
The active principle of the regenerative
burners is shown in Fig. 2. While burner
1 is ring 90 % of the exhaust is sucked
off by the regenerator bed of burner 2.
At this the exhaust renders the bigger
part of its heat quantity to the ceramic
storage medium.
For optimization of the changeover
cycles as well as for simplication of the
chamber pressure control the remaining
exhaust quantity of 10 % should
leak from the furnace conventionally.
The exhaust leaves the regenerator with
a temperature of about 200 °C and is
conducted into the waste gas flue via
the waste gas removal fan. There, both
flue gas streams are mixed and diverted
into the stack with a mixing temperature
of about 300 °C.
The changeover of the burners happens
after 50 to 60 s (according to burner type
and regenerator size). Now burner 2
res whilst cold air is conducted through
the hot regenerator and heats strongly.
The air preheat reaches on average
v150 °C less than the exhaust temperature
of the respective furnace zone.
Meanwhile the hot exhaust flows
through the now sucking burner 1 and
recharges the regenerator. The schematic
view of such a construction with
the arrangement of the dampers and
valves is shown on Fig. 3. The changeover
cycle runs automatically according
to a xed time which enables the
regenerator to work in an optimum
range with best possible efciency. If
the exhaust temperature behind the
regenerator exceeds 200 °C changeover
takes place earlier.
Fig. 1: Construction of a regenerative burner
Fig. 2: The regenerative burner principle
HEAT PROCESSING · (9) · ISSUE 2 · 2011 179

Reports
BURNER & COMBUSTION
Fig. 4: Comparative assessment of efciency
System characteristics
The planning of applications with regenerative
burner systems needs a careful
analysis of the furnace system and the
heating process. Besides the mentioned
advantages there are further charac-
Fig. 3:
Schematic structure
of a regenerative
burner system
teristics of the regenerative burners
benecial for the heating processes in
the metal industry such as:
• The number of torch heads is usually
hardly bigger than those of conventional
systems. The capacity of the
single burners is on average 50 to
80 % higher than at hot air or cold
air burners, depending on the application.
Therefore the burners supply
a much higher impulse (mass x
speed) and longer flames. This leads
to the improvement of the intermixture
of the furnace atmosphere and
the „coverage“ of the charge by the
flames.
• The flame temperatures of the regenerative
burners are higher due to the
high air preheat and this leads to
an intensication of the direct heat
transfer to the charge.
• At continuously operating furnaces
like pusher furnaces or walking beam
furnaces a better zone separation is
reached (only 10 % of the exhaust
merge into the following zone).
• For new furnaces the waste gas
flues and stacks can be dimensioned
signicantly smaller.
• At furnace rebuilds a furnace capacity
increase of 10 to 15 % can be
reached without change of waste
gas flues and without increase of the
specic heat consumption.
However, in general, the main reason
for use of regenerative burner systems
in the furnaces of the metal industry is
the high energy saving.
Possible savings of energy
In comparison to a hot air system with
an air temperature of about 450 °C the
high air preheat permits energy savings
of theoretically up to 30 % (Fig. 4). This
value has to be checked according to
the application. Especially rebuilds of
Fig. 5: A new furnace with complete regenerative heating
Fig. 6: Regenerative heated rotary hearth furnace
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Fig. 7: Booster zone for two pusher furnaces (upper zone)
Fig. 8: Partial reconstruction of a roller hearth furnace
existing systems have to be calculated
with regard to the expected energy saving.
At batch type furnaces for example the
saving potential is determined in dividing
up the heating cycle into several sections
and then calculating the average
savings of each section. The sum of all
single values is the total saving.
At continuously working heating furnaces,
walking beam furnaces and
pusher furnaces (Fig. 5) or rotary hearth
furnaces (Fig. 6) the energy balance of
each zone and the reciprocal effect of
these zones has to be considered. At
rebuild of a furnace zone to a regenerative
burner only 10 % of the hot exhaust
of these zones flow towards the stack.
It is very important to check the new
working conditions of the recuperator
at partial rebuilds or booster regenerative
zones.
Furthermore, with an installation of a
booster regenerative zone (Fig. 7) an
increase of the furnace capacity can be
reached – without rebuild of the existing
waste gas flues and without an increase
of the specic energy consumption.
A complete rebuild of the existing
pusher or walking beam furnaces with
central recuperator (air preheat of
450 °C) can effect an energy saving of
15 to 20 %, depending on the furnace.
At partial rebuilds of heating systems to
regenerative burner systems the savings
are accordingly lower.
The modication of a combustion system
at roller hearth furnaces for steel
plates which work with a low furnace
temperature of 600 to 1,050 °C can be
purposeful, too. Fig. 8 shows a roller
hearth furnace for heavy plates with top
and bottom ring which is completely
operated with a regenerative burner for
mixed gas. The use of a regenerative
burner led to energy savings and a better
control mode of the furnace (better
separation of the temperature zones).
For years regenerative burners are successfully
used in melting furnaces of the
aluminium industry. The main reasons
for this development are energy savings
of 20 to 25 % – compared to a hot air
system – and a signicant reduction of
NO x discharges. Another convincing
argument for use of these burners is the
relative short durability of recuperators
in such furnaces due to abrasive parts
within the exhaust. A pair of regenerative
burners with a capacity of 3.5 MW
is shown on Fig. 9.
A forge furnace yields very different savings
according to the operation method.
During the oftentimes long furnace
holding time at high furnace temperature
the efciency factor of the regen-
Fig. 9: Regenerative burner in an aluminium melting furnace
Fig. 10: A forging furnace modied with regenerative burners
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BURNER & COMBUSTION
Fig. 11: Potentials for energy savings
erative system is very high, but therefore
the fuel consumption is very low
(Fig. 10). In practice energy savings of
20 to 25 % compared to a recuperative
system have been reached.
Fig. 11 shows the saving potential of different
furnaces whereas only the energy
savings resulting from the use of regenerative
burners have been considered. In
practice the rebuild of furnace systems
with antiquated heating systems and old
furnace controls can lead to a signicant
higher energy saving potential.
Reduction of exhaust emissions
An energy saving reached by use of
regenerative burners reduces the generated
exhaust quantity. Commensurate
to low exhaust quantities the absolute
discharge of carbon dioxide and nitrogen
oxide decreases. Oftentimes the
specic NO x exhaust of the regenerative
burners lies below the values of the
existing burners (150 to 350 mg/Nm 3 ).
In such cases the absolute NO x discharge
can be reduced disproportionately high.
Furthermore the rebuild of a cold air
or recuperator system to a regenerative
technique can give the chance to
reduce the connected load of the system
so much that the system does no
longer apply to the emission trading (20
MW limit).
System maintenance
Experiences of the successful operation
of many furnaces with regenerative
burner systems show that the maintenance
costs stay in line with a well
dened budget and are comparable
with conventional systems:
• Gas solenoid valves do not cause any
problems.
• The air and exhaust changeover
dampers with pneumatic drives are
checked periodically once a year, the
abrasion is very low.
• Fans for combustion air and suction
require standard maintenance.
• Measuring and control systems for
regenerative burners with SPS and
visual display systems do not cause
many problems. They supply the
operator with important information
about the status of the system
which facilitates the maintenance of
the total regenerative heating system
signicantly.
• The cleaning frequency of regenerators
depends very much from the used
raw material. Clean charge material
only needs a cleaning at intervals of
8 to 12 months. At extreme cases, e.
g. at melting of contaminated scrap
metal in aluminium melting furnaces
or at high quantities of casting powder
on the material within the furnaces
of the steel industry, this period
can be reduced to 6 to 12 weeks.
• The maintenance of regenerators can
be signicantly facilitated by use of
regenerators with a quick disconnecting
feature. Regenerators and burners
are featured with a special gasket
system that allows quick separation
and connection of regenerator and
burner.
Conclusion
Rebuild and new construction of furnace
systems with regenerative burner
systems lead to procedural advantages
and a signicant saving potential
at energy and emission costs to be
expected (energy tax).
For the future, the payback period of
the systems will reduce dramatically due
to savings of up to 25 % compared to
systems with one central recuperator,
and up to 45 % compared to cold air
systems and the hereby also reduced
quantity of CO 2 emissions.
The regenerative burner technology
is fully developed. The experiences of
long-time operation at different furnace
types show that reservations by reason
of a possibly higher maintenance effort
are without any reason.
Today, regenerative burner systems are
state-of-the-art and a proven instrument
for reducing energy costs and the
emission taxes to be expected.
Jörg Teufert
BLOOM ENGINEERING
(EUROPA) GMBH
Düsseldorf (Germany)
Tel.: +49 (0) 211 / 50091-31
j.teufert@bloomeng.de
Stefan Baur
BLOOM ENGINEERING
(EUROPA) GMBH
Düsseldorf (Germany)
Tel.: +49 (0) 211 / 50091-55
s.baur@bloomeng.de
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New ceramic heat exchangers with
enhanced heat transfer properties for
recuperative gas burners
Dimosthenis Trimis, Volker Uhlig, Robert Eder, Alberto Ortona, Simone Pusterla,
Elisa Paola Ambrosio, Paolo fino, Pascal Rumeau, Claire Chazelas, Sandro Gianella,
Joachim G. Wünning, Herwig Altena, Franz Beneke, Michel Debier, Tobias Grämer
Heat recovery from waste gas is a major key process for increasing
efficiency of thermal processes. The aim of the present work is to increase
heat transfer coefficients of ceramic heat exchangers of recuperative
burners using highly structured surface elements created from a textile
precursor. The paper describes the chosen geometries and their thermal
behavior, the ceramization process and the preliminary design of the new
recuperative burners.
Heat recovery at a high temperature
level is essential in industrial thermal
processing. Ceramic components in heat
recovery equipment offer the possibility
to achieve higher temperature levels
and subsequently, higher thermal recovery
efciencies. The aim of CEREXPRO,
a research and development project
nancially supported by the European
Commission within the 7 th framework
program, is to develop a new generation
of ceramic heat exchangers for high
temperature heat recovery with the target
of signicantly reducing the size and
weight of the exchanger components
while reducing the price of such components
through simplifying the manufacturing
process and allowing higher
flexibility in heat exchanger geometry.
The use of precursor/template materials
taken from the textile industries and a
subsequent ceramic conversion is the
main technological path proposed to
reach these objectives. Although the
principal idea is not new, there are no
known efforts into the development
of such technology for the utilization
of such an approach for industrial
high temperature heat exchangers. The
approach leads to a high flexibility in the
heat exchanger geometry and design,
while the costs for shaping are reduced.
The development/renement of the
conversion process for textile derived
materials into a thermal-shock resistant
gas-tight ceramic (e.g. silicon inltrated
silicon carbide - SiSiC) and the optimization
in terms of size, geometry, material,
and production costs is the major
challenge of the ongoing research
work. A technical concept facilitating
this development is based on the
combination of existing robust ceramic
components already applied in industrial
furnaces, like SiSiC tubes, with compatible
ceramic heat exchanger enhancing
elements built through the textile technology
based manufacturing process.
This approach leads to a high application
safety and proven robustness. At
the same time, a signicant size reduction
or, alternatively, an increase of the
heat recovery level can be achieved due
to the higher heat transfer rate of the
geometrically flexible heat exchange
enhancing elements.
The present paper gives an overview
of the current status of the ongoing
research efforts in the framework of
the CEREXPRO project. The numerical
studies conducted at the design phase
provided promising results regarding
energy savings for industrial burners.
The rst prototype ceramic plates
have been manufactured with various
geometries, and the experimental
results show a good agreement with
the numerical simulations. The validated
basic geometries are used for the design
of the integrated recuperative burner
construction.
Concept
In industrial branches with high energy
consumption, most of the processes are
operated at a high temperature level.
Fig. 1: Combustion efciency with respect to the flue gas temperature before heat recovery;
Practical performance for different types of heat recovery (source: Handbuch der Brennertechnik
für Industrieöfen, Wünning J. G., Milani A. (Eds.), Vulkan, Essen, 2007)
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BURNER & COMBUSTION
Fig. 2: Typical burners of NOXMAT GmbH
with ceramic heat exchanging parts
Heat recovery at this high temperature
level is essential in terms of efciency,
especially if the thermal process is heated
by burner systems. The most common
way for heat recovery is preheating of
the combustion air by using the sensible
heat of the hot waste gas flows. Recuperative
or regenerative heat exchanger
systems, which may be integrated in the
burner assemblies, are commonly used
for this purpose and show typical performances
as indicated in Fig. 1.
Fig. 3: Different basic designs/arrangements of heat enhancing elements
Fig. 4: Path from ceramic structure to one repeating single cell
The use of burners equipped with recuperators
shows high efciencies. It can
be presumed that a 100 K decrease
of the flue gas temperature after heat
recovery results in an estimated reduction
of total fuel consumption of about
5 %. However, the heat recovery of
recuperators is limited by the overall
volume and burner length restrictions,
the required heat exchanger surface
and the material limitations. The heat
exchangers used nowadays are mostly
built out of high temperature steel with
corresponding temperature limitations.
The use of ceramic materials (for example
SiSiC) allows operation and heat
recovery at higher temperatures and
subsequently higher process efciency.
Ceramics also show a very good corrosion
resistance. However, application
restrictions due to dust transported with
the gas flow may occur in practice. Heat
recovery devices should be directly integrated
into the thermoprocessing facility
in order to minimize thermal losses and
to utilize the energy in an immediate
manner. Despite the obvious benets
of ceramic heat exchanger components
for heat recovery at high temperature
applications, the penetration of such
technologies in industrial furnaces is
relatively low. This is due to the com-
paratively high prices and large size of
such components. Only a few, very simple
ceramic heat exchanger geometries
with large dimensions are currently used
because of several manufacturing and
operational obstructions.
Development of highly
structured surfaces for the heat
exchanger
The new recuperative heating element
has been designed to be integrated in
existing burners, while further work is
needed towards its integration inside
of the burner assembly. The elaborated
geometry designs are robust and similar
to existing heat exchangers and also consider
constraints from available textile
and ceramic technologies. A 180° loop
was selected as the basic element for
the structured surface. The aim was to
reach a higher heat transfer coefcient
by increasing the transferring surface
and also by utilizing the increased dispersion
and thermal boundary layer
structures due to the resulting turbulent
flow characteristics. Fig. 3 shows different
possible arrangements (staggered,
not-staggered, inclined or not etc.) of
such loops on a flat plate.
Numerical simulations using commercial
CFD packages
were performed for
such basic geometries
in order to
assess the increase
in heat transfer and
drag coefcient. For
the sake of simplicity
and in order to facilitate
the numerical
investigations, a planar
arrangement was
selected as reference
geometry, instead
of a pipe, which is
the typical application case. In order to
simulate the fluid flow and heat transfer
process a typical repeating module was
dened. This module was used to represent
the entire structure by geometrical
symmetry to further decrease the computational
efforts (Fig. 4).
The governing equations were solved
using nite volume methods assuming
a forced convection situation. The
minimum dimensions of the elements
were considered to guarantee robust
manufacturing and long term stability.
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This example calculation indicates, that
the targeted recuperator design will
result in either signicantly higher heat
recovery levels at the same overall burner
size as the current recuperative burners
and slightly higher pressure losses, or
alternatively to approximately the same
heat recuperation level at signicantly
smaller size and lower pressure losses.
For each side of the cubic cell a boundary
condition is required. For example,
a constant temperature at the bottom
of the cell is assumed, which must
be lower than the inlet temperature
of the air flow in order to generate a
heat flux from the hot air to the cooled
heat exchanger surface. Based on this
numerical experiment with a single cell
the heat transfer coefcient of the reference
heat enhancing element was calculated.
The reference surface for comparison
and normalization purposes is the
smooth cylindrical surface between the
two flows. A smooth tube at typical
recuperator operating conditions shows
a heat transfer coefcient of approximately
α = 51 W/(m 2 K). Assuming the
wavy surface as an increase in surface
area the heat transfer coefcient of the
wavy tube (see Fig. 2) rises to α = 82 W/
(m 2 K) on the basis of the plane tube surface.
This number is used as reference
for evaluation of the new structured
surfaces, while the operating conditions
are kept constant.
Fig. 5 shows the velocity eld of a single
cell for the layout with 3,600 loops/m 2 .
At the bottom and the top the velocity is
less than in the free cross section of the
model because of the “no-slip” boundary
condition.
Pressure drop, Nusselt number and heat
transfer coefcient can be calculated
for different Reynolds numbers. Fig. 6
shows the ratio of the expected performance
in comparison to the reference
conventional recuperator burner at
nominal conditions.
Fig. 5:
Result of a simulation
with 3600
loops/m 2 , here
velocity eld
Currently, a recuperative burner with
160 kW heating power operates with
a pressure drop of 5 mbar at the recuperative
elements and an overall pressure
drop of 50 mbar. For Geometry
01, the pressure drop of the recuperative
elements and overall pressure drop
is 30 mbar and 75 mbar, respectively.
Comparing the two, the pressure drop
of the recuperative elements is six times
higher and the overall pressure drop is
1.5 times higher for Geometry 01 than
for the burner. However, the heat transfer
coefcient of Geometry 01 is 4.8
times higher.
Table 1: Processing techniques of SiC ceramics
Fig. 6: Results of different layouts
Ceramization process
Advanced ceramic materials are extensively
applied for high temperature
applications in oxidative as well as
reductive environments. For this very
special application, some ceramic Silicon
Carbide is the most appropriate material.
It is already employed in many furnaces
parts because it withstands burner
operating conditions for long time. SiC
bulk material was optimized by selecting
a suitable composition and the relevant
processing. The available methods are
shown in Table 1.
In CVD a base material is coated with
a SiC layer obtained from the decomposition
of a ceramic precursor (e.g.
methyltrichlorosilane CH 3 SiCl 3 ) at high
temperatures and low pressures. Since
CVD is a very expensive and long lasting
process it was immediately discarded
for use in the project. Sintering was also
discarded for processing limitations (very
high temperatures). In Polymer Impregnation
and Pyrolysis (PIP) the preform
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BURNER & COMBUSTION
Fig. 7: Rendering of the loop structures
Fig. 8: Voids inside the loops and on the
plate due by the supporting fabric
is dipped into a liquid polymer. Excess
polymer is drained and the remaining
cross-linked. Several slurries were produced
by adding ceramic powders and
deposited onto weaved and/or knitted
polymer bers and laments. PIP indeed
leaves a ceramic body which is always
interrupted by a pattern of cracks which
appear upon polymer shrinking during
pyrolysis. These cracks dramatically
In this fashion flat plates decorated
with loops were rst produced. From
both plates a signicant portion, conreduce
the thermo-mechanical and oxidation
resistance of the bulk material.
In the replica production technique a
polymer template is impregnated with
ceramic slurry, pyrolysed and inltrated
with molten Silicon, at high temperatures
in a vacuum furnace. This process
is widely used to make Si-SiC material for
high temperature applications. Due to
the properties of the material produced
and to the level of industrialization of
the relevant production technique it was
adopted to produce the loop structure.
Processing
Fig. 9:
Burner Model with
loops assembled in a
jacket tube
Ceramization tests on both fugitive and
non-fugitive textiles were performed;
fugitive textiles (e.g. PE) degrade during
ring leaving hollow loops. Non fugitive
textiles (e.g. SiC bers) do not degrade
during heat treatment and remain inside
the loop.
Fugitive textiles base fabrics with loops
were coated with a ceramic slurry
and placed on commercially available
Si-SiC plates (Schunk Ingenieurkeramik
GmbH, Germany). After heating under
inert atmosphere, they were then
inltrated with molten silicon as previously
described.
Non fugitive SiC bundles were rst
loop shaped and then glued on the SiC
plates. Plates were than coated with a
ceramic slurry, pyrolysed and inltrated
with molten silicon.
Fig. 10: Cross section of a “loop recuperator” for a new developed burner
Characterization
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taining one loop and the plated underneath
were cut with a diamond saw.
These blocks were then inspected via
Computed Tomography. CT data were
acquired using a laboratory micro CT
EasyTom 130 (RX Solutions F) with
image resolution of 13 µm/pixel.
CT data were than processed using dedicated
visualization software Avizo re
(Visualization Science Group, Burlinton,
MA, USA).
The loops rendering in Fig. 7 shows the
two approaches employed in this study.
Fugitive templates are cheaper because
the materials are common polymers
employed in textiles. The drawback
of this solution is that it leaves a hollow
channel inside the loop which
lowers the mechanical strength of it.
Another drawback is that if a base fabric
is employed to support the loops
it will leave also a porous layer as per
Fig. 8. The non fugitive solution leaves
full loops but the bers employed are
more expensive and also shaping and
weaving them is more expensive.
New recuperator design and
outlook
Recuperative burners are available from
several burner manufacturers in different
power ranges of 10 to 300 kW
and tting lengths. Most manufacturers
offer a metallic and/or ceramic design.
The new recuperative burner design
has many similarities in size and power
requirements with pre-existing burners.
Thus, the possibility exists to use parts
(the burner housing for example) from
the current burners.
Fig. 9 shows the section view of new
burner with a “loop recuperator” and
the design of the rst burner prototype.
In comparison to the burners with corrugated
recuperator, the flow section is
higher and as a result the flow velocity is
lower. This will cause a reduction of the
predicted pressure losses. Fig. 10 shows
the cross section of a “loop recuperator”
for a new developed burner. Fabri-
cation and tests of the burner prototype
will follow in the near future.
Acknowledgement
The authors would like to thank the
European Commission for the provided
nancial support for this work within
the 7th framework program, project
CEREXPRo, contract no. 227551.
Authors
Prof. Dr.-Ing. Dimostehnis Trimis
TU Bergakademie Freiberg (Germany)
Tel.: +49 (0) 3731/39 3940
trimis@iwtt.tu-freiberg.de
Dr.-Ing. Volker Uhlig
TU Bergakademie Freiberg (Germany)
Tel.: +49 (0) 3731/39 2177
volker.uhlig@iwtt.tu-freiberg.de
Robert Eder
TU Bergakademie Freiberg (Germany)
Tel.: +49 (0) 3731/39 3141
robert.eder@iwtt.tu-freiberg.de
Prof. Alberto Ortona
Scuola Universitaria Professionale
della Svizzera Italiana
Manno (Switzerland)
Tel.: +41 (0) 58/666 6640
alberto.ortona@supsi.ch
Simone Pusterla
Scuola Universitaria Professionale
della Svizzera Italiana
Manno (Switzerland)
Tel.: +41 (0) 58/666 6615
simone.pusterla@supsi.ch
Elisa Paola Ambrosio
Italian Institute of technology
Genoa (Italy)
Tel.: +39 (0) 110/ 903 406
iit@polito.it
Prof. Paolo fino
Politecnico di Torino
Torino (Italy)
Tel.: +39 (0) 11/5644 705
paolo.no@polito.it
Pascal Rumeau
Institut Français du textile et
de l‘habillement
Villeneuve d’Ascq (France)
prumeau@ifth.org
The CEREXPRo project is presented
at the Thermprocess fair in Düsseldorf
(28.06.2011 - 02.07.2011) at
the CECOF booth, Hall 10, C57, or at
the booth of FOGI e.V, TU Bergakademie
Freiberg, Hall 7, A01. Actual information
can be found at www.cerexpro.
org.
Claire Chazelas
Institut Français du textile et
de l‘habillement
Villeneuve d’Ascq (France)
cchazelas@ifth.org
Sandro Gianella
ERBICOL S.A.
Balerna (Switzerland)
Tel.: +41 (0) 91/697 6360
sandro.gianella@erbicol.ch
Dr.-Ing. Joachim G. Wünning
WS Wärmeprozesstechnik GmbH
Renningen (Germany)
Tel.: +49 (0) 7159/16320
j.g.wuenning@flox.com
Dr.-Ing. Herwig Altena
Aichelin Holding GmbH
Mödling (Austria)
Tel.: +43 (0) 2236/23646 211
herwig.altena@aichelin.at
Dr. Franz Beneke
Fachverband Thermoprozesstechnik im
VDMA
Frankfurt a.M. (Germany)
Tel.: +49 (0) 69/6603 1854
franz.beneke@vdma.org
Michel Debier
European Committee of Industrial
Furnace and Heating Equipment
Associations CECOF
Limal (Belgium)
Tel.: +32 (0) 10/4027 10
mdebier@skynet.be
Tobias Grämer
NOXMAT GmbH
Oederan (Germany)
Tel.: +49 (0) 37292/ 6503 45
graemer@noxmat.de
The Superior Concept for Industrial Burners
resolves your NO x
problems
even at highest air preheating
Wärme
prozess
technik
Trademark WS Wärmeprozesstechnik GmbH Dornierstr. 14 71272 Renningen Tel.: +49 (7159) 1632-0 www.flox.com
HEAT PROCESSING · (9) · ISSUE 2 · 2011 187

VACUUM TECHNOLOGY
Reports
Energy efficient vacuum solutions
for industrial furnaces
Uwe Zoellig, Klaus Buhlmann
Fighting against global warming and increasing greenhouse gas concentrations,
the regimentation of CO 2 emission are the justification for
the European Commission to set up the European Directive 2005/32/EC.
This and several amending directives describe a framework of eco-design
requirements for energy using products asking for increased efficiencies.
New norms have been written and others have been updated which now
need to be considered in new product engineering projects. Beside this
energy costs are rising constantly and will continue to rise in the future.
Considering these aspects the design of modern furnaces has changed
recently. New designed vacuum furnaces are operating much more
efficient as older furnaces. In consequence, also the vacuum pumps and
pump systems must be designed accordingly to support these energy saving
attempts. For sure first priority for the vacuum pumps and systems is always to
reliably provide the required vacuum level; trouble-free operation is a
must. The need of energy saving does not allow uptime reduction of the
furnace. High reliability can be reached by using traditional technologies
as e.g. oil-sealed rotary piston or rotary-vane pumps, roots blowers and
diffusion pumps, but next to these also more modern technologies such
as dry screw pumps already have a proven track record to work most
reliable even under harshest conditions. But, are all these pumps also
optimized in view of energy consumption?
The article will demonstrate that modern
vacuum solutions with dry-compressing
screw type vacuum pumps and
new innovative roots blower designs can
help meeting the goals in energy saving.
Further on it describes measures taken
at conventional vacuum components as
for example rotary-vane pumps or even
diffusion pumps support fulllment of
the new energy-saving requirements.
Standard vacuum systems used
on furnaces today
Oil-sealed vacuum pumps, combined
with roots-type booster pumps are
today’s standard equipment for most
industrial vacuum furnaces. These vacuum
pumping systems do have relatively
low investment costs and are still
the norm for a broad eld in heat-treatments.
Mostly depending on regional preferences,
two concepts for oil-sealed forevacuum
pumps compete against each
other; rotary-vane pumps and rotarypiston
pumps. Rotary piston pumps are
for sure more robust as vane pumps, but
they become more and more obsolete.
For applications such as annealing, hardening
and tempering, which cause only
a benign load with negligible impact on
the vacuum system, oil-sealed vacuum
pumps offer cost-effective and very reliable
performance. Compared with piston
pumps, rotary vane pumps offer the
same sufcient process stability, have
a lower capital cost and consume app.
5 to 10 % less energy, simply as the
rotating mass is lighter weighted. But,
is there additional potential for even
higher energy savings?
For more harsh applications as e.g.
brazing, carburizing or sintering more
and more end-users choose dry screw
pumps as backing pumps, simply as
these are more capable and reliable to
withstand the higher process requirements
as any oil-sealed pump. Tendentious,
even in standard applications
many oil-sealed pumps are substituted
by dry screw pumps because of the
signicantly lower cost-of-ownership of
these pumps.
But, today’s dry pumps are typically
more energy consuming as oil-sealed
pumps of the same size. Is this a pig in
a poke? Does the user have to accept
a higher power demand as trade-in for
the higher robustness?
Roots-blowers are used on nearly
each furnace and have a more or less
unchanged design since decades. Their
power consumption is minor compared
to fore-vacuum pumps but can their
power demand even be further reduced
by modern designs or intelligent controls?
Most high-vacuum furnaces use oil-diffusion
pumps to reach pressure ranges
below 10 -3 mbar. These type of pumps
are proven “working-horses” and very
robust, but their power consumption is
high and does not change even if the
furnace is in idle mode. Can this also be
changed by innovative designs or controls?
The following chapters will give answers
to each of the above raised questions.
It will be demonstrated that by using
modern solutions higher efciency-rates
and reduced power consumption can
be achieved. “The most environmental
friendly and cost saving kWh is the one
which is never consumed – it pays off”.
Detail view on rotary-vane
pumps
The principle of an up-to-date rotaryvane
pump is already quite optimal
for low power consumption. Rotating
masses (including oil) are minimized,
internal friction is low and by principle
the pumps do the most efcient adiabatic
compression. The power consumption
of such pumps is clearly less than
the nominal motor power. A SOGEVAC
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VACUUM TECHNOLOGY
SV630B for example (Fig. 1) is equipped
with a 15 kW flange motor. The effective
power consumption of this pump
at a typical operation pressure for a
furnace below 1 mbar is approximately
7.4 kW.
New pump deliveries will include IE2
motors, which meet latest standards.
Motors declared IE2 have a higher
efciency factor, all kind of losses, such
as iron- and copper-losses, are minimized
to achieve a higher efciency.
Realistically additional energy saving can
only be reached by operating the pumps
motor with a matched variable speed
drive (converter). Thus an optimum in
performance can be achieved. Ramp up
function and torque optimization are
two features among other provided by
modern variable speed drives. Next to
this frequency drives offers extended
possibilities for process control, e.g.
a suction speed reduction during the
boost phase of a carburizing process to
reduce HC-gas consumption.
Detail view on screw-type dry
vacuum pumps
Today’s standard dry pumps are screw
pumps with variable pitch rotor design.
Fig. 1: Energy efcient standard pump for
benign applications: SOGEVAC SV300B
Continues compression along the rotor
length minimizes the energy demand.
Older technologies with constant screw
pitch or even dry pumps based on multiple
stages of roots- or claw type rotors,
have a signicantly higher power consumption
due to design and pumping
principle.
But even the plurality of today’s screwpumps
with variable pitch, differ a lot
from each other. Most pumps of the
600 m³/h class demand app. 10 kW
power at typical furnace operation pressures
below 1 mbar, which is a clearly
higher value as those of a comparable
rotary-vane pump.
During the development of DRYVAC
(Fig. 2), reduction of energy consumption
was a mayor focus. Optimizing the
mechanical rotor design, the electrical
motor concept and by selection of a
perfectly matched build-in frequency
converter the achieved result is overwhelming.
The DRYVAC 650S (Fig. 3) does only
consume 6.9 kW at 1 mbar, it is even
more energy efcient than a rotary-vane
pump and by this becomes the new
bench mark for power consumption in
the market.
The build-in frequency converter also
offers potential for additional savings
and more process control. Many process
steps do not require “full-power” suction
speed, especially during operation
at rougher pressures (e.g. during carburizing).
Soft start and ramping functionality
can be realized with the variable
frequency drive. Chamber pressure can
be controlled by varying the rotational
speed. The customer can even realize
a process specic “standby condition”
considering certain valve positions to
save for example the volume of supplied
Nitrogen.
Next to these environmental issues, for
sure the modern design of the DRYVAC
does eliminate sensitive components as
shaft-seals or couplings which clearly
increase robustness and reliability of the
pump.
Detail view on roots-type
vacuum blowers
Most roots pumps used today are standard
designs with flanged motors and
lip-type shaft sealing. For most applications
this design is sufcient, but it
includes some weaknesses:
• Shaft-sealing, couplings and motorbearings
wear down over time
• Shaft-seals do not allow an operation
at signicantly increased rotary
speed.
• The motor is mostly a standard motor
not really matched to the pump for
optimal usage.
The rst two points could be addressed
by usage of the well known “cannedmotor”
pumps, such as the RUVAC
WS2001 – since years available on the
market. However, when looking at
energy-efciency this is a step back-
Fig. 2: Layout of the hermetically sealed DRYVAC screw pumps
featuring 2 rotors with progressive pitch prole and build-in
frequency-converter driven high-efciency motor
Fig. 3: Picture: DRYVAC Enduro 650S, the new
most energy efcient standard for demanding heattreatment
applications
190
HEAT PROCESSING · (9) · ISSUE 2 · 2011

VACUUM TECHNOLOGY
Reports
Fig. 4: Motor concepts of a standard roots-pump (left) and a RUVAC WH roots-type booster
pump (right)
wards, as the canned motors typically
operate by far less efcient than standard
flange motors.
More promising are the most modern
developments, using build-in, potted
motor designs. Here the advantages of
the canned-motor design are combined
with reduced power consumption and
offers improved compactness. In addition,
the potted motors used for RUVAC
WH roots-type booster pumps (Fig. 4)
Fig. 5:
RUVAC WH4400, most
compact and power saving
design on market
are high efciency IE2 motors without
external shaft seal or couplings. Further
on the pumps are hermetically tight, a
benet for many processes.
At typical furnace operation pressures a
RUVAC WH (Fig. 5) can be sped up by
a frequency converter to rotary speeds
up to 120 Hz (varying with pump-size).
Thus a small pump can often substitute
a much bigger pump, which reduces the
installed and consumed motor power.
Detail view on diffusion pumps
Diffusion pumps work in the high-vacuum
eld and require therefore a complete
different pumping principle as the
before described displacement pumps.
Inside a diffusion pump, oil (Fig. 6) is
evaporated, guided through multiple
jet stages to build a steam “umbrella”
which traps gas molecules flying into it.
The oil steam is condensed when reaching
the outer wall of the pump and
recirculated.
Being a very simple, very robust and
proven principle on the one hand side,
a diffusion-pump on the other hand
requires lots of energy. Most energy is
consumed to evaporate the oil and not
to compress the gas. All this evaporation
energy is then removed by the coolant
again as all oil is condensed again. Obviously,
this is not a pump-principle with
low energy demand.
Poorly the industry still need to stick to
this energy wasting solution for most
applications, as alternative high-vacuum
pumps which are much more energy
efcient (e.g. Turbomolecular pumps
or Cryo pumps) are simply not robust
enough to handle most furnace applications
and next to this their initial costs
are much higher.
But there are ways to minimize the
power consumption of a diffusion
pump. A major intuence is given by the
heater design. Most producers use heating-plates
which are positioned below
the oil-reservoir (boiler), see Fig. 7. This
is not very energy efcient as there are
high losses during the heat transfer into
the oil, e.g. caused by the air-gap in
between the heater element itself and
Fig. 6:
Pumping principle
of a diffusion pump
Fig. 7: Heater elements positioned inside
the oil reservoir of a diffusion pump
HEAT PROCESSING · (9) · ISSUE 2 · 2011 191

Reports
VACUUM TECHNOLOGY
Fig. 8: Oil-diffusion pump LEYBOJET 630, improved for
high throughput and lowest power-consumption
the bottom of the diffusion pump. Better
designs use heating elements positioned
directly inside the oil-reservoir, by
this clearly improving the heat transmission,
bringing all heating energy directly
into the oil.
Most energy is used during the heating
phase of the diffusion pump. To shorten
the heating time, it is important to
minimize the mass of the pump which
needs to be heated. Energy only used
to heat the pumps material is generally
a wasted energy. Intelligent designed
diffusion pumps as those from the DIP
or LEYBOJET type (Fig. 8) have a total
mass around 25 % less as that of most
competitors, therefore offering a much
shorter heating-up time and lots of
energy saving.
The full heater power is only necessary
during the pumps heating phase. Compared
with the total operation time of
a typical furnace process, this time is
relatively short. Most time the furnace is
constantly maintained at high-vacuum
or the diffusion pump is idling behind
a closed valve. During all this time, a
diffusion pump does not have such
high power demand. Despite this fact,
most diffusion pumps are continuously
operated with full heating power, wasting
lots of energy. Innovative controlsystems
can identify the actual power
demand and regulate the power supply
of the heaters accordingly. By these
measures a reduction in power consumption
of more than 30 % can be
realized.
Conclusions
There are many possibilities to safe
energy. For sure vacuum pumps
demand only a smaller part of the total
energy consumption in a heat treatment
process, but the responsible user should
take all useful measures to reduce
energy consumption, helping to reach
our all environmental goals.
To use modern dry-compression screw
type vacuum pumps or roots-pump
clearly helps to minimize the environmental
footprint of a vacuum pumps
and pump-systems. Along with this, the
implementation of latest vacuum pump
designs, even for more traditional technologies
as diffusion pumps or rotaryvane
pumps will further reduce the CO 2
footprint. Intelligent controls will play
a more and more important role and
denitely help to meet the environmental
goals.
Users should evaluate all options and
not just stick to conventional solutions.
Modern pump technology is robust
and reliable, but most environmental
friendly, too. It helps to safe operation
costs and to protect our green environment.
Uwe Zoellig
Oerlikon Leybold Vacuum
GmbH
Cologne (Germany)
Tel.: +49 (0) 221 / 347 1375
uwe.zoellig@oerlikon.com
Klaus Buhlmann
Oerlikon Leybold Vacuum
GmbH
Cologne (Germany)
klaus.buhlmann@
oerlikon.com
Hotline
Managing Editor: Dipl.-Ing. Stephan Schalm
Editorial Ofce: Annamaria Frömgen
Editor:
Silvija Subasic
Advertising Sales: Bettina Schwarzer-Hahn
Subscription: Martina Grimm
+49(0)201/82002-12 s.schalm@vulkan-verlag.de
+49(0)201/82002-91 a.froemgen@vulkan-verlag.de
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+49(0)931/41704-73 mgrimm@datam-services.de
192
HEAT PROCESSING · (9) · ISSUE 2 · 2011

COMPANIES PROFILE
Reports Profile
M.E.SCHUPP Industriekeramik GmbH & Co. KG
Company name/ M.E.SCHUPP Industriekeramik
location: GmbH & Co. KG
Aachen (Germany)
Board of
management:
History:
Number of staff: 30
Michael E. Schupp
October 1996: founded by Michael
E. Schupp
April 1998: main supplier for PTCR
January 2003: master distributor for Fiber-
Max ® in Europe
February 2006: distributor contract for
electric high purity heating elements
May 2006: development of MolyCom ®
Ultra electric MoSi 2 heating elements and
establishing a production plant in Aachen.
Production:
Competitive
advantages:
6. PTCR ® : Process Temperature Control
Rings form 660 °C to 1,750 °C
7. FiberPlast: high temperature adhesives up
to 1,800 °C
High temperature adhesives and cements,
MoSi2 heating elements; furnace insulation
sets made from UltraBoard ® .
M.E.SCHUPP is a reliable and very competitive
alternative to the big players in the market,
providing a considerably good service and
premium products. We provide a high and
consistant quality to ensure safety within
your supply chain. Reply to inquiries and
order proceeding is generally handled in a
24 hour service. In addition we provide a
fast and sophisticated logistics in cooperation
with professional partners.
Export quota: 60 %
Product range:
1. MolyCom ® -Ultra MoSi 2 electric heating
elements 1,700 °C and 1,800 °C,
standard grade in various shapes and
dimensions; MolyCom ® -Hyper MoSi 2
high purity grade 1,800 °C.
2. Ultra-Board ® : Insulation Boards Shapes
& Cylinder form polycrystalline Mullite /
Alumina-Wool Al 2 O 3 (PCW) from 1,250 °C
to 1,850 °C.
3. FiberMax ® Premium Polycrystalline
Mullite / Alumina-Wool Al 2 O 3 (PCW),
double needled blankets, modules, and
paper up to 1,650 °C.
4. PTCR ® : Process Temperature Control
Rings form 660 °C to 1,750 °C
5. FiberPlast: high temperature adhesives up
to 1,800 °C
Certification:
Service
potentials:
DIN EN ISO 9001 for HT ceramic adhesives
Flexibility in customer service; MoSi 2 electric
heating elements, standard grade and high
purity grade 1,700 °C and 1,800 °C from
diameter 3/6 to 12/24 in various shapes
and dimensions, due to customers demand.
Customized production and machined parts
form polycrystalline Al 2 O 3 Mullite Alumina
Wool (PCW); Very short delivery time; Spare
part stock for emergency cases on agreement.
Internet address: www.schupp-ceramics.com
Contact:
Michael E. Schupp
Tel.: +49 (0)241 936 77 0
info@schupp-ceramics.com
HEAT PROCESSING · (9) · ISSUE 2 · 2011 193

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Business Directory
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heat treatment processes ............................................................................... 196
II. Components, equipment, production
and auxiliary materials .................................................................................... 205
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HEAT PROCESSING · (9) · ISSUE 2 · 2011
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204 HEAT PROCESSING · (9) · ISSUE 2 · 2011

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HEAT PROCESSING · (9) · ISSUE 2 · 2011
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KNOWLEDGE for the FUTURE
Handbook of Burner
Technology for
Industrial Furnaces
The demands made on the energy-efficiency and pollutant emissions
of industrial furnaces are rising continuously and have high
priority in view of the latest increases in energy prices and of the
discussion of climate change for which CO2 emissions are at least
partly responsible. Great importance is now attached to increasing
energy-efficiency in a large range of industrial sectors, including
the steel industry and companies operating heat-treatment installations.
This work is intended to provide support for those persons responsible
for the clean and efficient heating of industrial furnaces.
The book discusses the present-day state of technological development
in a practically orientated manner. The reader is provided with a detailed
view of all relevant principles, terms and processes in industrial
combustion technology, and thus with important aids for his or her daily
work. This compact-format book, with its plethora of information, is an
indispensable reference source for all persons who are professionally
involved in any way at all with the heating and combustion-systems of
industrial furnaces.
Selected topics:
Combustion theory, Fluid mechanics, Heat transfer, Combustion technology,
Computer simulation, Pollutant reduction, Heat exchangers, Industrial
burners (types and applications), Standards and legal requirements,
Thermodynamic tables and terms, etc.
Editors: Ambrogio Milani, Joachim Wünning
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Vulkan Verlag GmbH
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Fax

Index of Advertisers
Page
AFC-Holcroft Europe, Boncourt, Switzerland ............................................................................................................................ 173
AICHELIN Ges.m.b.H., Mödling, Austria ...................................................................................................................... Back Cover
ALD Vacuum Technologies GmbH, Hanau, Germany ............................................................................................................... 139
aluexpo 2011, Istanbul, Turkey .................................................................................................................................................. 110
ALUMINIUM CHINA 2011, Shanghai, China ............................................................................................................................. 162
ALUMINIUM INDIA 2011, Mumbai, India ................................................................................................................................... 188
ANDRITZ MAERZ GmbH, Düsseldorf, Germany ............................................................................................................... 111, 131
Bloom Engineering (Europa) GmbH, Düsseldorf, Germany ....................................................................................................... 129
EBNER Industrieofenbau GmbH, Leonding, Austria ................................................................................................................... 99
Eclipse Inc., Rockford, USA ....................................................................................................................................................... 107
Elster GmbH, Osnabrück, Germany ............................................................................................................................................ 95
EMO Hannover 2011, Hannover, Germany ............................................................................................................................... 136
Euro PM2011, Barcelona, Spain ................................................................................................................................................ 114
EXPOGAZ 2011, Paris, France .................................................................................................................................................. 174
Hüttinger Elektronik GmbH + Co. KG, Freiburg, Germany ......................................................................................................... 97
JASPER Gesellschaft für Energiewirtschaft und Kybernetik mbH, Geseke, Germany ............................................................. 101
Küttner GmbH & Co. KG, Essen, Germany ............................................................................................................................... 111
Linn High Therm GmbH, Eschenfelden, Germany .................................................................................................................... 123
LOI Thermprocess GmbH, Essen, Germany ................................................................................................................ Front Cover
Oerlikon Leybold Vacuum GmbH, Köln, Germany .................................................................................................................... 169
Process-Electronic GmbH, Heiningen, Germany ...................................................................................................................... 119
Sandvik Wire & Heating Technology, ZN der Sandvik Materials Deutschland GmbH, Mörfelden-Walldorf, Germany ............ 135
Sarlin Furnaces AB, Västeras, Sweden ..................................................................................................................................... 161
Schick Technik GmbH, Vaihingen an der Enz, Germany .......................................................................................................... 115
Schmidt + Clemens GmbH + Co. KG, Lindlar, Germany .......................................................................................................... 109
SECO / Warwick S.A., Swiebodzin, Poland .............................................................................................................................. 113
SMS Elotherm GmbH, Remscheid, Germany ..................................................................................................... Inside Front Cover
STANGE Elektronik GmbH, Gummersbach, Germany .............................................................................................................. 105
THERMPROCESS 2011, Düsseldorf, Germany ......................................................................................................................... 117
UNI-GERÄTE GMBH, Weeze, Germany .................................................................................................................................... 103
Wire / Tube Southeast ASIA 2011, Bangkok, Thailand ............................................................................................................. 104
WS Wärmeprozesstechnik GmbH, Renningen, Germany ......................................................................................................... 187
Business Directory .............................................................................................................................................................. 195-216
Volume 9 · Issue 2 · May 2011
Official Publication
CECOF – European Committee of Industrial Furnace and Heating Equipment Associations
Editors
H. Berger, AICHELIN Ges.m.b.H., Mödling
Prof. Dr.-Ing. A. von Starck, Appointed Professor for Electric Heating at RWTH Aachen,
Dr. H. Stumpp, Chairman of the Association for Thermal Process and Waste Treatment
Technology within VDMA, President of the LOI Group and Chairman of the executive
board LOI Thermprocess GmbH, Essen, Chairman of the Exhibitors Council for MESSE
THERMPROCESS 2011
Advisory Board
Dr. H. Altena, Aichelin Ges.m.b.H., Prof. Dr.-Ing. E. Baake, Institute for Electrothermal
Processes, Leibniz University of Hanover, Dr.-Ing. H.-G. Bittner, LOI Thermprocess GmbH,
Prof. Y. Blinov, St. Petersburg State Electrotechnical University “Leti“, Russia, Mike Debier,
President of CECOF, Dr. G. Habig, CECOF, C. Hangtrakul, CIM Engineering (Thailand) Co.,
Ltd, Anders Jerregard, JERRES AB, Bästeras, Sweden, Dr.-Ing. F. Kühn, LOI Thermprocess
GmbH, Dipl.-Ing. W. Liere-Netheler, Elster GmbH, H. Lochner, EBNER Industrieofenbau
GmbH, Leonding, Austria, Prof. Sergio Lupi, University of Padova, Dept. of Electrical Eng., Italy,
Dipl.-Phys. M. Rink, Ipsen International GmbH, Dr. A. Seitzer, SMS Elotherm GmbH, Dipl.-Ing.
St. Schalm, Vulkan-Verlag GmbH, Essen, Dr.-Ing. J. G. Wünning, WS Wärmeprozesstechnik
GmbH
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