CAB line designs to reduce energy costs - Seco-Warwick

LOAD CONFIGURATIONSECO/WARWICK S.A.Degreaser belt speed – 833 mm/minDryer/brazer belt speed – 1083 mm/min

POWER CONSUMPTION SPLIT FOREACH UNIT OF THE LINESECO/WARWICK S.A.DegreaserDry-off ovenPreheatchamberBrazechamberTotalkW (gas)245147172101665%37222615100

DEGREASER & AFTERBURNERD E G R E A S E RA F T E R B U R N E RSECO/WARWICK S.A.10%3%6%11%5%60% 5%HEATTO CORESHEATTO FIXTURESHEAT THROUGHHEATCASINGTO BELTHEAT TODILLUTION AIRHEAT TODEGREASEREXHAUST AIRHEAT THROUGHCASING

DEGREASERPOSSIBLE SOLUTIONSSECO/WARWICK S.A.DEFINITIONSDIRECTBurners or Electric Heaters in the oven bodyINDIRECTNO Burners or Electric Heaters in the oven body

DIRECTDIRECT FIRED with burners or electrical heaters in the oven bodyEXHAUST FANSECO/WARWICK S.A.MANUAL DAMPERSBURNERS

DIRECT FIRED with burners or electrical heaters in the oven bodyDIRECT FIRED WITH AFTERBURNERSECO/WARWICK S.A.AFTERBURNERMANUAL DAMPERSEXHAUST FANBURNERS

SECO/WARWICK S.A.DIRECT FIRED DEGREASER WITH AFTERBURNER

DIRECT FIRED with burners or electrical heaters in the oven bodyDIRECT FIRED WITH HEAT RECOVERY HEAT EXCHANGERAFTERBURNERHEATEXCHANGERSECO/WARWICK S.A.EXHAUST FANMANUAL DAMPERSBURNERS

SECO/WARWICK S.A.DIRECT FIRED SYSTEM WITH HEAT RECOVERY HEATEXCHANGER

INDIRECT FIRED without burners or electrical heaters in the oven bodyINDIRECT FIRED WITHOUT HEAT RECOVERY HEAT EXCHANGERAUTOMATICDAMPERSECO/WARWICK S.A.AFTERBURNEREXHAUST FANMANUAL DAMPERSPRESSURESENSORAUTOMATIC DAMPERS

SECO/WARWICK S.A.INDIRECT SYSTEM

INDIRECT FIREDSECO/WARWICK S.A.INDIRECT FIRED WITH HEAT RECOVERY HEAT EXCHANGERHEATEXCHANDERAFTERBURNEREXHAUST FANMANUAL DAMPERSAUTOMATIC DAMPERS

INDIRECT FIREDHEAT AXCHANGER MOUNTED IN DEGREASERAUTOMATICDAMPERAFTERBURNERSECO/WARWICK S.A.EXHAUST FANMANUAL DAMPERSPRESSURESENSORHEATEXCHANGERAUTOMATIC DAMPERS

DIRECT FIREDDIRECT FIRED WITH CATALITIC OXIDISERSECO/WARWICK S.A.CATALITIC OXIDISEREXHAUST FANMANUAL DAMPERSBURNERS

SECO/WARWICK S.A.CATALITIC OXIDISER

DIRECT FIREDWITHOUT HEATEXCHANGERDIRECT FIRED WITHHEAT EXCHANGERINDIRECT FIREDWITHOUT HEATEXCHANGERINDIRECT FIRED WITHHEAT EXCHANGERDIRECT FIRED WITHCATALITIC OXIDIZERINDIRECT FIRED WITHHEAT EXCHANGERMOUNTED IN THEDEGREASERINVESTMENTCOSTENERGYCONSUMPTIONSECO/WARWICK S.A.NOTESVERY LOW HIGH THE SIMPLEST SYSTEMMEDIUM/LOWLOWHIGHVERY HIGHHIGH/MEDIUMMEDIUM/LOWHIGHLOWVERY LOWLOWCOMPROMISE BETWEENINVESTMENT ANDRUNNING COSTSIMPLE SYSTEM WITH ONEHEATING SOURCENO CONTACT OFPRODUCTS OFCOMBUSTION WITH THELOAD - VERY HIGH HEATUP/SHUT DOWN TIMEADDITIONAL COST OFFREQUENT CATALISEREXCHANGES(EACH 2 YEARS)NO CONTACT OFPRODUCTS OFCOMBUSTION WITH THELOAD

APPROXIMATE POWER CONSUMPTIONFOR DIFFERENT SOLUTIONSOF DEGREASER/AFTERBURNER HEAT RECOVERYSECO/WARWICK S.A.DIRECT FIRED WITHOUT HEATEXCHANGERDIRECT FIRED WITHHEAT EXCHANGERINDIRECT FIRED WITHOUT HEATEXCHANGERINDIRECT FIRED WITHHEAT EXCHANGERDIRECT FIRED WITH CATALITICOXIDIZERINDIRECT FIRED WITHHEAT EXCHANGER MOUNTED INDEGREASERPOWER CONSUMPTION(kW gas)245204205177171185

OTHER DESIGNING SOLUTIONSTO REDUCE ENERGY CONSUMPTIONSECO/WARWICK S.A.- Heat recovery from furnace to dryer- hood between dry-off oven and braze chamber- common belt through dry-off oven and braze chamber- increased insulation thickness- enlarging of system size- heat recovery from air blast cooling chamber.

DRYERSECO/WARWICK S.A.28%9% 17% 14%32% HEATTO CORESHEATTO FIXTURESHEATTO BELTHEAT TOEVAPORATEWATERHEATTHROUGHCASING

DRYER – HEAT RECOVERY SYSTEMHOT FLUES FROM BRAZER DELIVERED TO DRYERSECO/WARWICK S.A.One common combustion systemexhaust for dryer, preheat andbrazerDRYERPREHEATBRAZER- Savings for reference example: consumption of 147 by basic dryerreduced to 102 kW (45 kW (gas) savings).

DRYER – HEAT RECOVERY SYSTEMHOT FLUES FROM BRAZER DELIVERED TO DRYERSECO/WARWICK S.A.

PREHEATSECO/WARWICK S.A.38%11% 23% 6% 22%HEATTO CORESHEATTO FIXTURESHEATTO BELTATMOSPHEREHEATTHROUGHCASING

BRAZERSECO/WARWICK S.A.21%7% 13%19%40%HEATTO CORESHEATTO FIXTURESHEATTO BELTATMOSPHEREHEATTHROUGHCASING

HOOD BETWEEN DRYER AND BRAZERSECO/WARWICK S.A.- energy saving for the reference example lineis 20 kW (gas)- additional advantage – increased brazingproductivity

Common belt for dryer and brazerSECO/WARWICK S.A.- Energy saving for the referenceexample line is 27 kW (gas)- additional advantage – increasedbrazing productivity

Increased insulation thickness - ovensSECO/WARWICK S.A.- for currently used mineral wool insulatingmaterials (thickness 150 mm) heat losses are0,08 kW/m 2 (15 kW for the reference example)- further increasing of insulation can give onlyminor effect of energy saving.

Increased insulation thickness – preheat and brazerSECO/WARWICK S.A.- for currently used insulating materials andthickness of 250 mm heat losses are 0,22kW/m 2- by increasing the insulation thickness to 300mm heat losses will be reduced to 0,18 kW/m2- the energy saving for the reference exampleline is 12 kW (gas).

Savings achieved by increasing system sizeSECO/WARWICK S.A.2 x 665 kW = 1330 kWDoubled length: 1 x 1150 kW = 1150 kWRedesigned configuration (2 loads on belt width):1 x 1120 kW = 1120 kW

Heat recovery from cooling chamberSECO/WARWICK S.A.In the air blast cooling chamber load, fixtures,belt is cooled down from about 250ºC toambient temperature.For the reference example line the energytransferred to cooling air is appoximatelly 50kW.This energy can be recovered by using the airfor i.e. plant heating.

Comparision of energy cost in aspect of natural gasand electrical energy pricesLands//continentsNatural gasprice[EUR/Nm3]Elec.energyprice[EUR/kWh]SECO/WARWICK S.A.Hourly natural gasconsumption costfor reference system[EUR]Hourly electrical energyconsumption costfor reference system[EUR]Europe0,30,062027USA0,280,0451920

CONCLUSIONSDesigning solutionsSaving of energyfor referenceexample line[kW gas]Yearly cost saving basedon 8000 working hoursand natural gas price: 0,3EUR/scm [EUR]Savings on 1 piece ofheat exchanger for thereference example line[EUR]Heat recovery ondegreaser40 - 709.600 – 16.8000,012 – 0,021Heat recovery onbrazer-dryer4510.8000,013Hood204.8000,006Common belt27SECO/WARWICK S.A.6.5000,008Thermal wall losses122.9000,004Heat recovery from airblast cooling chamber5012.0000,015Increased system size10525.2000,031

CONCLUSIONSTOTAL SAVING AVAILABLE FOR REFERENCEEXAMPLE BRAZING LINESECO/WARWICK S.A.* 300 kW (gas) of savings possible to achieve on the lineof ~700 kW original consumption.* 72.000, - EUR savings per year.* 0,09 - EUR savings per core.

CAB line for precoated materials or paint fluxtechnology reduces energy consumptionSECO/WARWICK S.A.Power saving for reference example ofCAB line is 130 kW (gas) in this case.

Forced air cooling instead ofwater jacketed in the atmosphere cooling sectionSECO/WARWICK S.A.The air cooling chamber eliminates water from the linestructure but increases energy consumption(a level of 10 kW for the reference example).

SECO/WARWICK S.A.Thank you for attentionSECO/WARWICK LtdUl. Sobieskiego 866-200 ŚwiebodzinPOLANDTelephone: +48 68 38 21 713Facsimile: +48 68 38 21 757Web Site: www.secowarwick.com.pl