Furnaces International June 2021

PRODUCTS & PROJECTS

FURNACE FOR THE FUTURE

INDUSTRY 4.0

REFRACTORIES

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JUNE 2021

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Contents

PRODUCTS & PROJECTS

FURNACE FOR THE FUTURE

INDUSTRY 4.0

REFRACTORIES

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JUNE 2021

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

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Furnaces International June 2021

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Comment

Welcome to the June issue of Furnaces International!

I’m not quite sure how we are already in June, but I fear that time is only going to speed up as we all hopefully start to have the luxury of making plans and socialising more again for work and pleasure.

While it is starting to look more positive that industry events will be able to open up again towards the end of the year, with travel still uncertain for many and others (understandably) wary about attending large-scale events, we would like to invite all readers 2

Projects and products

BIFCA Column 10 BIFCA Seminar to highlight standards

of Furnaces International to join us online for a new virtual event on 14th - 15th September 2021.

The event is called the Future of Furnaces, which is not to be

Furnaces for the future 14 The ‘Furnace for the Future’ project gathers momentum

confused with the FEVE project ‘Furnace for the Future’!

Manufacturing industries are already seeing the results of

Industry 4.0 18 Using artificial intelligence with near infra-red furnace imaging

the ‘Furnace of the Future’ in reducing CO2 emissions and producing cleaner, more sustainable materials. But how can

Industry 4.0 22 Use of in-furnace thermal imaging for industry 4.0 and decarbonisation in steel, non-ferrous and glass Industry 4.0 26 How Al makes furnaces energy efficient through data analysis Industry 4.0 30 Digitalizing the EAF process

energy-intensive manufacturers work towards making this future a reality? Are we already seeing the benefits of adopting smarter and more sustainable technologies within furnaces?

Or, could we be doing more?

This online event will unite the glass, aluminium and steel sectors to discuss overcoming heat treatment challenges and

Snart furnaces 36 Furnaces works in the supply of the key equipment of the new casthouse to Almexa in Veracruz (Mexico) Heat treatment 42 A new dimension in gas nitriding

present a collaborative approach to bring the Furnace of the Future to life.

Find out more about how you can be involved in the article on page 10 or visit:

Refractories 44 Safer refractory installation

www.aluminiumtoday.com/furnaces/future-of-furnaces

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

1 Furnaces International June 2021

Projects/Products

FORGLASS COMPLETES PROJECT FOR UK FURNACE MODIFICATION Polish glass melting technology supplier Forglass has completed a project on a UK furnace.

Having completed a similar project for the same client recently, Forglass was once again chosen to raise the working end, waist and canal monorails of the furnace.

For this project, the total weight of the construction to be raised was well over 1000 tonnes.

The project included: • Preparing complete technical documentation for the scope of the project • Fabrication and installation of support structure • Selection and installation of a synchronous hydraulic system • Modification and existing structure

reinforcement

of

• Synchronised raising of the Working End

2 Furnaces International June 2021

Forglass developed technical documentation, a model of the existing structures, drawings of supporting structures, calculations and necessary descriptions.

The hydraulic system used by Forglass is said to guarantee a smooth and safe lifting of the structure.

The pre-determined height of the raised structure will be confirmed at each of the control points.

As Forglass has its own fabrication facilities, it allows for great flexibility and agility in responding to clients’ needs.

Projects/Products

HORN STARTS HEAT-UP PROCESS OF FRIGOGLASS´ 300 TPD FURNACE Horn has started the furnace heat-up process at container glass supplier Frigoglass' 300 tonnes per day end-fired furnace GF2 in Nigeria.

The heat-up started on Friday, 21 May, with the first glass expected early June.

Once heated, the new container glass furnace will manufacture glass in green and amber.

Horn technicians will support the entire start-up process, with the project due to be finished by the middle of June 2021.

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Furnaces International June 2021

Projects/Products

HEINZ-GLAS IN €15 MILLION KLEINTETTAU FURNACE INVESTMENT Heinz-Glas has commissioned a €15 million electric furnace at its Kleintettau glass manufacturing facility.

The electric furnace can produce high-quality perfumery glass, clear glass with a high PCR cullet content as well as opal glass and also means the glass manufacturer can react flexibly to market and customer requirements.

For more than 15 years, the opal glass within the group was produced exclusively at the Dzialdowo, Poland site but the fact that this is now also possible again at one of the German locations opens up further flexible possibilities for the group to serve its customers.

“Technical progress in particular helps to overcome crises and create entrepreneurial perspectives. A certain amount of courage to try something new and then the necessary bit of luck are of course also part of it,” said owner and CEO Carletta Heinz.

In 1971, Heinz-Glas was the first company in the glass industry to put an electrically heated melting tank into operation at its Kleintettau location.

The investment secures more than 120 jobs and about the same number of jobs at suppliers in the region. The furnace was commissioned in March this year.

JSW’S FIRST HOT SLA VISY TO INVEST $70 MILLION IN SOUTH AUSTRALIAN FURNACE REBUILD Visy will invest over $70 million over the next 12 months on a furnace rebuild in South Australia.

The investment will form part of Visy Executive Chairman Anthony Pratt’s recent $2 billion investment pledge in Australian manufacturing.

The $70 million investment will completely rebuild Visy's West Croydon based glass furnace, ensuring it is able to manufacture glass bottles in South Australia for years to come.

Visy will also invest in three new glass forming machines used to shape glass bottles for our customers.

4 Furnaces International June 2021

Visy’s glass facility in West Croydon employs approximately 160 people, and the investment will reportedly secure these jobs for the long term.

Visy has also committed to increasing the average recycled content glass content used by its glass manufacturing plants from 30 to 70 per cent.

Visy hopes that by doing this it will keep more glass in the circular economy, reducing landfills and creating environmentally sustainable remanufacturing jobs.

Fives, a global industrial engineering group, and JSW Dolvi Works, part of India’s leading steel producer JSW Steel, successfully discharged the first hot slab from the reheating furnace on March 31, 2021.

Projects/Products

AB FROM NEW FURNACES JSW Steel contracted Fives to design and supply two reheating furnaces Stein Digit@l Furnace® - for their new hot strip mill at Dolvi works in the state of Maharashtra. The furnaces have the highest capacity installed in India to date

- each 450 tonnes per hour - and feature high environmental performance and low fuel consumption.

"It required a lot of dedication and continuous efforts from our team to work on site during the challenging

period, but we were very determined.”

Chandrajit Sinha, project manager, Fives Stein India Projects The first furnace was ignited in January 2021.

“It required a lot of dedication and continuous efforts from our team to work on site during the challenging period, but we were very determined,” says Chandrajit Sinha, project manager at Fives Stein India Projects, a Fives’ subsidiary in India.

“Our strength was our local manufacturing capabilities and the dedication of our team to work through these difficult times. We achieved more than 85% localization and discharged the first slab in very good conditions without skewness or skid marks.”

Asis Das, head of project management at Fives Stein India Projects.

“We appreciate Fives’ team determination to commission the first furnace in the extreme conditions due to the national lockdown. It’s an important milestone in our cooperation by definition,” says Ashutosh Sharma, project head - hot strip mill at JSW Steel.

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Projects/Products

THIRD SECO/WARWICK FURNACE FOR A EUROPEAN ALUMINIUM ROLLING MILL

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Projects/Products

Eurometal S.A., member of the EkoŠwiat Group and manufacturer of highly processed aluminium products, has purchased a third SECO/WARWICK furnace.

This solution will be used by the only rolling mill currently in operation in Poland, with Polish-owned equity.

The new equipment will consist of

a Vortex® furnace for aluminium coil annealing equipped with an external cooling system. The furnace is adapted for operation under a nitrogen protective atmosphere.

Thanks to the proprietary jet flow technology, the SECO/WARWICK Vortex aluminium coil annealing furnace combined with an optional by-pass

cooler for cooling under a nitrogen atmosphere and SeCoil® – the control and simulation software – enables aluminium coil manufacturers to significantly shorten the production cycle. As a result, this design produces energy savings, increases productivity and improves the surface quality of the processed coils. The key feature of the system is the increased heattransfer coefficient achieved thanks to directing the atmosphere at high speed simultaneously on both sides of the coil.

Vortex increases the capacity by as much as 30% When it comes to annealing aluminium coils, the challenge is to optimise the process by shortening the cycle duration as much as possible while maintaining the desired properties of the final product. Vortex is a heat treatment technology than can improve process efficiency by up to 30% in comparison with conventional annealing systems. At the same time, the furnace ensures very high process quality characterised by the uniformity of material properties, minimising local cracks and eliminating burnt rolling oil residues.

“Our product for aluminium coil annealing guarantees lower operating costs for the rolling mill, and thus an increase of economic efficiency.

Eurometal has been our partner for many years. Our current third furnace will be operated in a line with the two existing systems that we delivered previously. From the very beginning, our cooperation has been based on trust. We always focus on approaching each order individually. We create a flexible system design, custom-made for the needs of a particular rolling mill — said Sławomir Wozniak, CEO of SECO/WARWICK Group.

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Furnaces International June 2021

Projects/Products

THYSSENKRUPP STEEL EUROPE AWARDS ORDER FOR THE

GALVANIZING LINE TO TEN

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Projects/Products

REVAMPING OF BURNER TECHNOLOGY IN A CONTINUOUS

NOVA LOI THERMPROCESS Tenova LOI Thermprocess, a leading global company in the field of heat treatment plants, has received another order from thyssenkrupp Steel Europe AG (tkSE) for the revamping of burner technology at the continuous galvanizing line located in Bochum, Germany.

This modernization measure is an important cornerstone in enabling thyssenkrupp Steel to produce highstrength steels (AHSS) in Bochum in the highest quality and with increased production capacity for further use in the automotive industry. In order to meet market requirements and reduce both emissions and energy consumption, the furnace will be equipped with new burners that meet even highest requirements by targeting the lowest possible NOxemission levels (lower than 140 mg/Nm³ (@3%O2 reference)) during production.

In addition, the heating system will be upgraded in order to increase the target strip temperatures to > 900°C. For Tenova LOI Thermprocess, this is the third consecutive modernization order received for the continuous galvanizing line in Bochum, proving the company’s successful R&D development strategy.

With an annual production capacity of 540,000t of high quality galvanized steel it is one of the core production lines of thyssenkrupp Steel Europe for the production of car body parts and AHSSsteels.

The line was commissioned in 1992, and since 2014 major parts have been upgraded with the latest state-of-the-art technologies. In the first phase, the preheating and over-aging sections were modified to improve the annealing cycle in over-aging regarding larger heating capacity and improved temperature homogeneity. The energy recovery in the pre-heating section has nearly doubled and therefore the carbon footprint of the line was significantly reduced.

In 2017, a major step towards production of AHSS was realized through a substantial revamp of the fast cooling section. A new set of nozzle boxes, fans and heat exchangers were added to the existing equipment. The system

is designed for highest heat transfer coefficients and lowest strip vibrations, even with enlarged strip length without roller support.

"The modernization step that is now pending is important in order to meet our customers' upcoming requirements for hot-dip galvanised materials. We are also relying on Tenova LOI's experience and expertise in the field of burner technology for this project. The upgrade of our FBA7 is part of the modernization

strategy at the Bochum site," explained Dr. Carsten Groß, team leader of FBA7 at thyssenkrupp Steel.

“Together with tkSE, we developed a well-defined modernization strategy with intense R&D effort in different steps”, said Sascha Bothen, Head of Sales LOI Group. “This project proves that innovative revamping solutions can give an economic and technological benefit even for plants that have been in operation for a long time.”

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Furnaces International June 2021

BIFCA Column

BIFCA Seminar to highlight standards BIFCA is pleased to announce that it is supporting the new Furnace Industry technology showcase event called Future of Furnaces.

This brand new online event will take place on 14-15 September 2021 and will attract an international audience of senior delegates from the furnace industry including manufacturers, end users and ancillary product and service providers.

The event will unite the glass, aluminium and steel sectors and is being promoted via this journal Furnaces International, and other key media including Aluminium International Today, Glass International and Steel Times International, whose collective reach is 50,000.

Alongside the two-day congress, participants will be able to join live discussions and will have the opportunity to network with new industry contacts, arrange video meetings and exchange resource information.

Subject areas will include: Adoption of Industry 4.0; Furnace Maintenance; Heat Treatment; Energy Efficiency; Testing and Measurement; Operations and Productivity; Emerging Technologies and Retrofitting.

Organisers, Quartz Business Media, have said “One way we have worked to keep our sectors connected is through virtual events, conferences and webinars”, in response to the continuation of business throughout the Covid-19 pandemic. “It gives people a platform to meet and discuss new projects and plan for the future.”

Additionally, BIFCA will be hosting its Standards and Regulations Seminar as part of the overall Future of Furnaces event on day two, 15th September (see separate panel).

“One way we have worked to keep our sectors connected is through virtual events, conferences and webinars” Organisers, Quartz Business Media, in response to the continuation of business throughout the Covid-19 pandemic.

BIFCA’s Annual Standards and Regulations Seminar will be held on 15 September 2021 alongside, and in support of, the Future of Furnaces two-day showcase.

This year’s seminar will be held on-line and once again we aim to update and inform the industry on the various safety standards and regulations affecting all aspects of our sector.

Central to the theme is the continuation of the evolving standards work within the suite of EN746 standards which will be presented by Lars Boehmer of CECOF. Even though Brexit has now happened, many UK industries are entrenched in safety standards developed in conjunction with our European partners over many years and it is likely that the work mandated within these reference texts will continue as European documents within a national framework.

The expert speakers have vast experience and will highlight key changes and updates occurring within the last twelve months in relation to safety, design and use of various types of furnace equipment. Legislation comes in the form of both standards and regulation effected by directives such as the machinery directive.

If you are interested in submitting a presentation for the BIFCA seminar please contact the Association: enquiry@bifca.org.uk.

We particularly welcome papers from end users on the impact of furnace standards in all types of applications.

10 Furnaces International June 2021

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Incorporating the BIFCA Standards Seminar

ONLINE EVENT 14-15 SEPTEMBER REGISTER TODAY

The future is now when it comes to furnace technology

Manufacturing industries are already seeing the results of the ‘Furnace of the Future’ in reducing CO2 emissions and producing cleaner, more sustainable materials.

But how can energy-intensive manufacturers work towards making this future a reality?

Are we already seeing the benefits of adopting smarter and more sustainable technologies within furnaces? Could we be doing more?

This online event will unite the glass, aluminium and steel sectors to discuss overcoming heat treatment challenges and present a collaborative approach to bring the Furnace of the Future to life.

REGISTER NOW

FROM THE PRODUCERS OF

Topics will focus on: r Industry 4.0 (the Furnace of the Future) r Furnace Maintenance r Heat Treatment r Energy Efficiency r Testing & Measurement r Retrofitting r Emerging Technologies r Operations & Productivity Alongside the two-day virtual conference, participants will also be invited to join live discussions and will have the opportunity to network with new industry contacts, arrange video meetings and exchange resources and information.

IN ASSOCIATION WITH

ASSOCIATION PARTNER

ORGANISED BY

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If successful, Ardagh Group will build the first furnace in Germany in 2022 with the first bottles produced in 2023.

14 Furnaces International June 2021

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Furnace for the Future

project gathers momentum FEVE’s ‘Furnace for the Future’ project has recently been elected to Stage 2 of EU funding. Adeline Farrelly* explains what that means, what happens next and what it means for the future of the container glass industry.

On 24th March 2021, the EU Commission published their short list of projects invited to enter the second-round application process for funding from the EU’s new ETS Innovation Fund. The container glass industry’s Furnace for the Future (F4F) was one of the selected projects.

“We are so proud to be on the list and to get to the next stage,” says Fabrice Rivet, FEVE’s Technical Director.

“The evaluators gave us very positive feedback, which is very encouraging, as we now prepare the full application for the 23rd June 2021 deadline”.

The Innovation Fund is one of the world’s largest funding programmes for the demonstration of innovative lowcarbon technologies.

A total of 311 projects were submitted in the first round for grants totalling €21 billion making the ETS fund 21 times oversubscribed.

Furnace for the Future is one of the 70 projects selected to go forward to the final phase.

Industry ambition By 2050 the container glass industry aims to achieve a major revolution, starting now, in the way glass is produced making it fit for a circular and climate-neutral economy.

Companies are gearing up to secure the future of the sector and the jobs that depend on the industry within important value chains (food and beverage, pharma, cosmetics, and perfumery).

The F4F is a collective industry demonstration project, technically and financially supported by 19 container glass companies, which will develop a break-through technology to significantly reduce CO2 emissions from container glass furnaces by replacing

80% of the currently used natural gas by renewable electricity.

It will be the world’s first large-scale 350 tonnes/day hybrid electric furnace to overcome existing technological barriers, capable of melting all glass colours and incorporating high levels of recycled glass.

With this new hybrid technology, container glass will be able to cut 50% of current CO2 emissions from the factories.

Table 1.

Solving the carbon emissions will enable the sector to offer a fully climateneutral packaging solution, in addition to being fully circular.

At present, 80% of container glass CO2 emissions come from the combustion of natural gas to melt glass and Furnace for the Future is addressing this head on. But

there is also the 20% of CO2 emissions from the virgin raw materials used to make glass.

Circular economy – Closing the loop A different strategy is needed to eliminate this remaining 20%. Addressing these emissions involves replacing virgin raw materials with recycled glass (cullet).

Closing the glass recycling loop is therefore a primary objective.

The industry will do this by increasing EU collection of recyclable glass from 76% to 90% and make the Circular Economy for glass work better.

To this end, the container glass sector launched ‘Close the Glass Loop’ in 2020 – a multi-stakeholder platform to unite the

Existing electric furnaces in the container glass industry

Future hybrid furnace (F4F)

Size (tonne glass per day)

80 – 200

350

Technology

Vertical furnace

Horizontal furnace Reduced glass (amber

Type of glass produced

Oxidised glass: flint, emerald

(If successful, all colours will be possible)

) Cullet level (recycled glass)

0 - 30%

70%

% electricity

100%

Able to work from 20% to 80%

Table 1 - Benefits of the F4F project

*Secretary General, FEVE, Brussels, Belgium www.feve.org www.closetheglassloop.eu

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Furnaces International June 2021

Furnace for the Future

glass collection and recycling value chain, and to establish a material stewardship programme that will result in more bottleto-bottle recycling.

This platform brings together all those involved in the collection schemes to achieve 90% collection of recyclable glass by 2030. Close the Glass Loop action plans are being developed at EU level and in several countries.

Company decarbonisation strategies While these flagship sector decarbonisation initiatives are hugely significant, FEVE members are also testing out other strategies at company level.

A revolutionary project undertaken by glass container manufacturer, Encirc (a Vidrala company), and industry research and technology organisation, Glass Futures, is testing whether new bottles are able to be made from 100% recycled glass, using only the energy from burning ultralow-carbon biofuels.

German glass makers are working with BV Glas to investigate hydrogen as a potential fuel source for melting glass and to see what extent it could work off the natural gas infrastructures already in place.

According to BV Glas, hydrogen is one of the most promising candidates in the switch from fossil fuels to

renewable energy sources. It has been assessing the potential of hydrogen for a long time within the framework of its decarbonisation strategy.

“Every climate-neutral production project is an important step towards new approaches in glass manufacturing that will help us achieve the long-term aim of net-zero industrial emissions” says Dr Johann Overath BV Glas Director General.

If all energy-dependent processes were switched over to hydrogen, the glass industry could theoretically reduce its carbon footprint in Germany by approximately 3.3 million tonnes per year.

The European glass industry is investing significantly every year in the

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Furnace for the Future

Allied Glass Containers Ltd Ardagh Group BA Glass I – Serviços de Gestão e Investimentos, S.A. Beatson Clark Ltd FEVE - The European Container Glass Federation Gerresheimer Moulded Glass GmbH Gürok Turizm Ve Madencilik A.Ş. (Gca Gürallar Cam Ambalaj) O-I Europe Sàrl Pochet du Courval SAS Saverglass SGD Pharma Steklarna Hrastnik d.o.o Stoelzle Oberglas GmbH Verallia Packaging Verescence Vetreria Cooperativa Piegarese Soc. Coop.

Vetreria Etrusca Spa Vetropack Holding AG Vidrala SA Wiegand-Glashüttenwerke GmbH Table 2 - The companies involved with the F4F project

The Furnace for the Future project is bringing together 19 container glass companies to significantly reduce CO2 emissions by replacing 80% of natural gas to renewable electricity

decarbonisation of its manufacturing processes (e.g. R&D in hydrogen-firing, energy efficiency measures, use of biomass etc.) and will continue investing to manufacture glass products fit for a resource-efficient, low-carbon European society.

Every year, on average, the industry invests €610 million for plant upgrades, better energy efficiency and reduced CO2 emissions. This is a significant 10% of production costs each year.

What’s next?

In the near term, the container glass industry is potentially one of the energy intensive industries to have a clear

pathway to decarbonisation through direct electrification, but requires breakthrough technology in the Furnace for the Future project.

The Commission intends to evaluate the proposals and award the grants in October/November 2021.

If F4F is successful, the commercial scale demonstration plant will be built by Ardagh Group in Germany in 2022 with the first low carbon commercial bottles being produced in 2023.

A Special Project Vehicle will be incorporated for this project where industry shareholders will co-finance this demonstration project in addition to the EU grant.

Against this industry investment, all the learnings and know-how of running this furnace will be shared among the SPV partners so that this technology can be rolled out and scalable throughout the sector.

There are risks with any new technology and it is not certain that it will succeed. If it does, then this will be one of the most significant breakthrough technologies for glass and represents an iconic moment in the long history and tradition of glass making in Europe.

The 19 independent companies and FEVE operating in partnership to create, fund and demonstrate a technology to prove the concept are: See table 2. �

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Furnaces International June 2021

Industry 4.0

Using artificial intelligence with near Erik Muijsenberg* and Robert Bodi** discuss the rise of artificial intelligence and how modern technologies can improve the glass manufacturing process Furnace modeling Most leading engineering firms and glass producers around the world are already using furnace modeling, also known as Computation Fluid Dynamics (CFD), such as the GS Glass Furnace Model (GS GFM) software package. While in 1990 it was a discussion about the accuracy of modeling, today it is considered reliable and useful. It is now state-of-the-art and is used for almost every furnace design or rebuild.

The GS Expert System III (ESIII) is a model-based predictive furnace and forehearth control system, that has evolved beyond CFD. People were

initially sceptical to believe it was possible to control a furnace with Model Based Predictive Control (MPC) but today there are more than 300 furnaces globally with MPC installed, with many of these glass furnaces in operation also on forehearths.

Since 2010, there has been tremendous interest in Industry 4.0, as the glass industry has become aware that industrial producers (including glassmakers) are instigating new standards like furnace cameras and batch convection movement monitoring within the furnace. The question has become: What is happening now? What will come after this evolution of MPC?

Industry 4.0 captures many aspects of the automation of the manufacturing process, including robots, the Internet of Things, simulations of the process, cyber security, system integration, cloud computing, 3D, big data and augmented reality.

When looking at a modern glass production line today, viewing a typical end-fired furnace, a regenerator, melter and a forehearth deliver the glass to the forming machines, many of the processes are already automated within different areas.

On the melting side, PID DCS control has had limited success previously,

Fig 1. Furnace images by a near infrared camera and temperature trend lines

*Vice President, **General Manager, Glass Service, Vsetin, Czech Republic email: info@gsl.cz, www.gsl.cz

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Industry 4.0

r infra-red furnace imaging

Fig 2. Automation, artificial intelligence, machine learning and deep learning

because of slow furnace reactions.

Therefore, GS began by applying modelbased predictive control strategies, because PID control by an operator for 24 hours non-stop was limiting, along with slow temperature reaction times of the furnace and a very large dead time for the responses.

With MPC and its dynamic matrix algorithms, it is possible to capture process behaviours with such models and equations and improve furnace operation.

For MPC models and the dynamic base of its algorithms, the process can be driven for optimum quality with the lowest emissions, lowest operational costs and with minimal assistance, even sometimes without the operator. That is why GS has integrated the furnace camera into the ESIII concept.

Furnace camera uses The main motivation for GS A.SENS furnace camera was to start monitoring the batch blanket to relieve the operator from this difficult task. But apart from monitoring the batch blanket, the operator also typically takes some optical temperature readings to make sure the thermocouple readings are reliable and refractory is not overheated. This led to the idea to develop a furnace camera that can also capture the furnace temperatures, which resulted in the near infra-red (NIR) camera solution. But the NIR cameras available from the market had low pixel resolution. The lower pixel resolution may have been sufficient for temperature readings but it is insufficient to detect the

Fig 3. Neural networks

smaller batch islands that float on the glass surface.

The next step is how to decide if the camera actually sees batch, foam or glass surface and how to avoid a dust particle on the camera lens not being identified as batch. For this requirement, GS in cooperation with A.SENS had to develop an artificial intelligence algorithm that uses deep neural networks to learn from many glass furnace images what is what. The AI solution with the GS NIR camera detects flames but also decides what is flame, refractory and other objects that are commonly seen in glass melting furnaces.

The AI software also makes temperature readings that can be used by the MPC control more reliable. When the temperature is influenced by other parameters, the AI software can use this to correct the virtual TC reading given to the MPC or DCS. Such NIR cameras can give valuable visual information, as well as data that can be used in the control algorithm (Fig 1)

AI and neural network definitions So what are artificial intelligence (AI) and neural networks, how do they work and how can they help in the glass industry?

Automation is the basis of this consideration. Most people are used to DCS control and MPC control.

Automation is the creation of technology and its application, in order to control and monitor the production process.

It performs tasks that were previously performed by humans. AI is a field where regular control techniques cannot resolve

irregular issues that are inefficient. AI then enables the computer to mimic human intelligence using neural network decision trees and machine learning to solve a problem. Machine learning is simply a subset of the AI, using sufficient data subsets to train the neural network.

Deep learning may be referred to as something magic but it is simply a multilayered deep neural network that handles vast amounts of information. Actually, it is used daily when searching something on Google. Google suggests an answer what is actually being searched for, or Netflix suggests movies, because they are learning from a person’s previous behaviour. This is already AI. Referring to fig 2, the relationships between the various entities can be seen. Automation (A) is the creation of technologies and its application, to control and monitor a production process. It performs tasks that were previously performed by humans.

Artificial intelligence (AI) is the field where regular control techniques fail or are inefficient. AI enables computers to mimic human intelligence using neural network decision trees. Machine learning (ML) is a subset of AI using sufficient data to train a neural network.

Deep learning (DL) trains multi-layered deep neural networks with vast amounts of data.

What is a neural network? It was probably given this name because some parts function similarly to neurons in the human body. A set of data needs first to be analysed, and after it is analysed,

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Industry 4.0

Fig 4. Furnace image from a camera with neural network analysis results

the result is the outer layer which is its meaning.

First, this data has been created in the inner layer of the analysis, formalised and then put it into the neural network.

This neural network is taught to fill certain highs and constants inside different neurons, to learn (with lots of data on the entrance side) to predict what comes out as the output and to recognise it automatically. The key factor is these neurons are not fully understood, although it is not necessary to understand them. They are simply filled out by giving sufficient data and sufficient output for the neurons that are going to be filled with the mechanism that they recognise best.

Fig 3 shows the input of data, the analyses of the data and the output of the process.

Machine learning is nothing more than training a neural network with many inputs and outputs, until all these

neurons (at least one hidden layer) has learned enough to predict what is happening. Deep learning means there is a neural network with more than one hidden layer. This is quite common, especially for more complex tasks that need more than one layer.

To illustrate these concepts, an imaging technique is presented that is used with the GS NIR furnace camera. By ‘training’ the camera software as to what kind of images it is seeing, after some time the camera is able to detect what is the batch, the flame, the glass surface, the refractory and the camera build-up.

Where, for example, there is camera buildup covering a thermocouple, it can no longer be used reliably.

Furthermore, input data of this thermocouple should not be applied to deep learning. Deep learning is also able to detect the flame independently from the batch and determine if the flame is up or down, as well as providing

information or an alarm that the furnace needs attention. With neural network technology, it is possible to obtain much more information from these images and process them into control and decision making, as opposed to what it is possible to learn with furnace temperatures only.

Fig 4 shows a template for a furnace operation, including identification of batch islands, the flame, glass surface, refractory and even build up around the camera.

During the next step and after the batch is identified, it can be seen that the camera is typically looking at an angle into the furnace. After the batch coverage is calculated, the image is then transferred into a horizontal picture looking from a bird’s eye view (Fig 5).

The image is digitally analysed as the yellow area on the section there and this would then enable the user to calculate the square meters of the batch in the various positions.

For some furnaces, stability is very important and for others, it is less of an issue. The batch monitoring system allows the user to monitor the batch location, coverage and movement, enabling any corrective actions to be made and to automatically alarm if necessary.

In summary, the NIR AI furnace camera developed by GS in co-operation with A.SENS is a perfect combination with the ESIII expert system solution. Benefits include more stable automatic furnace control and glass production, increased glass quality and energy saving, plus CO2 and NOx emissions reduction.

About the company Glass Service is headquartered in the Czech Republic and develops technology to optimise glass melting, performing defect analyses, 3D furnace simulations, MPC and bench marking of large furnaces. Furthermore, GS supplies the necessary hardware.

Subsidiary GS companies are FlammaTec for burners, FIC (UK) Ltd for electric melting and super boosting in hybrid melters and A.SENS for AI software with near infra-red (NIR) furnace imaging. The combination of AI NIR cameras connected to MPC is bringing Industry 4.0 and Big Data connected to the Internet of Things. �

Fig 5. Batch coverage as converted into a bird’s eye view

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Industry 4.0

Use of in-furnace thermal imaging for industry 4.0 and decarbonisation in steel, non-ferrous and glass

By Philippe Kerbois* and Neil Simpson**

*Glass Sector Lead at AMETEK Land **Consultant of Simpson Combustion & Energy

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Industry 4.0

Left: Accurately and continuously profile the temperature of the entire furnace, including glass, refractory walls and port arches, and the crown/roof

Near Infrared Borescope (NIR-B-2K-Glass) thermal imaging solution for glass furnace applications

Ensuring consistent temperatures within furnaces is essential to maintaining highquality production of metal or glass, and for extending the campaign life of the furnace.

There are a variety of furnace locations where the temperature must be closely monitored to achieve these objectives.

For best results, the ability to trend temperature measurements throughout the whole furnace is essential.

For more than a century, optical pyrometers were the temperature measurement instrument of choice for high-temperature combustion processes.

Temperatures were taken within the process at least once per shift, and

Auto-Retract System to protect the thermal imager from damage by overheating in the event of loss of water flow, air pressure, electricity supply or high borescope tip temperature alarm.

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IMAGEPro advanced

sometimes every 20 minutes.

A portable pyrometer – such as the AMETEK Land Cyclops L or equivalent – is often used to check temperatures at critical points in the furnace whenever there is a process problem.

Ten years ago, AMETEK Land developed remote, infrared imaging technology, allowing hundreds of thousands of temperature measurement points to be recorded every second.

The company’s innovative Near Infrared Borescope (NIR-B) initially measured 324,000 optical temperatures continuously in the furnace, enabling accurate temperature measurement from any point.

This provides much greater accuracy and control of temperatures in the furnace, ensuring optimum product quality, efficiency and asset longevity.

Benefits of thermal imaging Near Infrared thermal imagers generate a visual, thermal image of the furnace – not to be confused with a simple CCTV image. Modern devices display up to 3 million fully radiometric calibrated camera pixels in the temperature range from 600 to 1800 °C (1112 to 3272 °F) – a development of technical significance for energy-intensive heavy industries like steel, non-ferrous, cement and glass production.

Thermal imaging offers many advantages over visual imaging and point temperature measurements. A permanently installed thermal imaging camera that actively records all necessary and useful data allows the video to be stopped at any frame. Accurate measurements can be taken at the exact same point in the process, allowing processes to be tuned more accurately.

Glass furnace monitoring AMETEK Land’s NIR-B thermal imaging cameras have been operating continuously since 2014, with more than 50 reference installations in glass melting furnaces globally. More recently, transportable instruments are being used to perform dedicated in-furnace thermal surveys.

For decades, in-furnace endoscopy and external furnace thermal imaging have been used to monitor and record visual changes in refractory. With the NIR-B there is the potential for an additional “visual endoscopy” with previously unmeasured thermal data. Wherever there is an existing peep-site, there is the potential to obtain a 95° field of view image. While a visual image will look similar, the thermal data can identify a difference of only a few degrees.

An NIR-B survey is often recommended, as it offers all of the benefits of a

permanent and continuous temperature measurement installation, which provides significant benefits over the traditional “snapshot” method.

In all cases, the key benefit of continuous measurement during a furnace reversal is that it gives better visibility of maximum and minimum temperatures. That is important because in glass, if the temperature goes below 1388 °C (2440 °F), there is a risk of sodium hydroxide (NaOH) condensation.

The potential scope of a survey is significant, and the challenge is to decide the priority of what to look at – with now nearly 3 million thermal data points in one image, the analysis and interpretation of the data can take longer than making the actual measurements.

The in-furnace thermal survey is not an alternative to a conventional traditional refractory inspection, but a supplementary service.

It can provide data to show when there is either too much or insufficient cooling at the metal line and, in extreme cases, where there is a hole. By utilising a negative image, the lighter points show where there may be too much cooling, which leads to increased energy and resulting emissions, but also increased wear of the refractory as the batch piles drag along the refractory.

This information allows corrective

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Industry 4.0

action to be taken before it results in a more costly or disruptive outcome.

The furnace thermal profile will define the hot spot and the location of the thermal up-well. If the furnace is flat bottomed, with no “mechanical” influencers, then the hot spot can move.

However, if there is a mechanical device such as weir wall, bubblers, or electrodes, then the hot spot of the thermal profile needs to be at the same location. If it is not, then there is a conflict between the mechanical and thermal systems, with quality/yield being the only loser.

With the fixed system NIR-B, the thermal profile may be continuously viewed, with the survey offering the opportunity to see the profile along the entire length of the furnace.

Using a single CCTV camera – traditionally in the bridge wall or throat end of the furnace – 60-80% of the furnace is typically visible. However, this means the wall where the camera is located is never seen.

When an NIR-B thermal survey is performed on a float glass furnace, it is typical to view from all four corners. This establishes the hot spot and, specifically, if it has moved or is different from one side to the other. In the majority of float furnaces, the view from the dog-house towards the waist highlights areas where the temperature is below 1388 °C (2530 °F). In some cases, it highlights the corrosion which has already occurred to the silica refractories due to NaOH formation.

If one exhaust port is hotter than before, with another colder, it may suggest that the colder port is becoming blocked, and the exhaust flow is being restricted. If time permits and support is available, there is the option to view each port either through the target wall peepsite or through an under-port burner block.

This will help determine if there is an imbalance from the right to the left side target wall temperatures. The view shows which flame is hotter, suggesting which burner needs adjustment – typically, it is then necessary to make another set of measurements to confirm that the issues have been resolved.

Structural damage caused by abnormally high or low operating temperatures can be identified early on and remedied before it develops into something far more serious, avoiding potentially dangerous situations, expensive repair costs and lost production

time.

Thermal imaging technology makes it possible to accurately image the temperature of a large area of a furnace through only a small opening in the wall.

It gives the operator access to data that would have previously been either time consuming or impossible to collect.

The latest infrared temperature measurement systems allow real-time data to be streamed in time-lapse modes, allowing process engineers to visualise the product flow. Alarms can be set in the control equipment to alert operators and ensure production achieves optimum quality.

Precise thermal imaging can extend the lifespan of the melt tank or furnace, providing greater asset protection through more accurate temperature measurement.

Thermal imaging cameras can also be positioned underneath the melt tank to detect hot spots early on, potentially preventing a break-out below the tank.

Conclusion Analysing the massive amounts of infurnace temperature data captured by the NIR-B enables the validation of computational fluid dynamic (CFD) models and supports predictive control.

Using alarms for variance to design, set point, and previous times improves quality and yield, and reduces waste as the first step to decarbonisation.

Advances in measurement technology are helping plants to make significant improvements in the improved quality of output, and in reducing operating costs. Thermal imaging technology that enables operators to maintain an accurate visual of the entire glass-melt tank, as well as take temperature measurements at any point in the process and in any location within the tank, can provide invaluable data for the operation of any modern plant.

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How AI makes furnaces energy efficient through data analysis Sylvain Leroy* discusses how the glass sector is already taking advantage of digital technologies and which can lead to up to 3% savings on furnace energy consumption.

*Founder, JoonX, Mexico City, Mexico www.joonx.org

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Fig 2. Degradation of regenerator’s efficiency over an 18-month period Fig 1. Typical energy management platform interface (copyright Energiency)

As the Fourth Industrial Revolution gains momentum, the glass sector is taking advantage of modern technologies. One of the most promising use cases of digital services today is the energy savings from furnaces.

Industry 4.0 has succeeded by creating new operating systems designed to manage and optimise businesses. Like previous industrial revolutions, this one is transforming the way people work and use technology. Ultimately, this will lead to the modernisation of entire companies.

However, there is still a discrepancy in the pace of adoption between different manufacturers and different industries.

While some are well advanced in digital transformation, many are not aware of the full potential of such technologies.

Some factories argue that they are not ready because they perceive that they have a lack of resources and a limited understanding of the impact on various stakeholders.

However, for all levels of on-site digitisation maturity and progress, there is a solution available to meet the needs.

An important aspect of Industry 4.0 is that it is not about replacing machines and equipment, but about leveraging software and exploiting captured data to make industries more efficient. Delaying the Fourth Industrial Revolution transformation will no longer be a viable option in the glass industry. If you wish to remain competitive, you must embark on this journey.

Energy efficiency starts by leveraging the underlying data inside the plant The new centrepiece is your data. Data is the asset that in many cases is the most unknown and yet most promising one.

Data inside companies can be described as an iceberg floating on water: only a small portion can be seen. And of the seen portion, only a fraction is used. The water around the iceberg is the potential of data

that can be created.

Data strategy is the process of using and producing more relevant and useful data, aggregating them, increasing your assets, and thus opening more opportunities.

A significant amount of data comes from various glass processes, furnaces, IS machines, lehrs, etc. Smart management of such data could make machines and processes more efficient. To successfully implement these new technologies, several obstacles must be overcome: the lack of time, digital strategy, resources, and domain knowledge. Companies like JoonX can help define and implement this strategy. Digital service suppliers should be independent actors who are also experts in data science. The aim of a digital strategy is first to collect, organise, and centralise data and second, to connect and make them available to the appropriate services in order to improve specific metrics of glass processes.

Digital services are aimed to improve production, value, and supply chains to increase business revenues. These services enable the integration of previously disparate systems and processes through interconnected computer systems of organisations. The methods used vary from monitoring to constraint solving to deep learning.

How to reduce energy consumption and footprint thanks to an energy management platform?

Data science and A.I. companies, such as JoonX partner Energiency, have decided to develop specific programmes and knowledge in the field of energy.

Therefore, instead of focusing on a specific sector, they aim to be the leader of energy savings for all industries. It focuses purely on energy allows the creation and operation of optimal energy management platforms that work across all industries.

The objective of such digital platforms is to control and optimise the energy

Fig 3. Left regenerator rider arch temperature

consumption of processes and to exploit the data to identify new energy savings (Fig 1).

Case study: regenerative furnace This example concerns a typical side-port regenerative float glass furnace of 600t/d which used to produce architectural glass with an air-gas combustion system.

This type of furnace requires reversing the combustion approximately every 20 minutes, from right to left and vice versa, to pre-heat the opposite regenerators with the exhaust fumes. This furnace was at the end of its lifetime and its consumption exceeded 400GWh per year. The main objective of this project was to save 1% on the energy bill by digitising the furnace’s energy flows. Note, this plant also had a relatively low level of digitalisation, which proved not to be an obstacle to the project execution.

Taking a closer look at the plant context at the time of the digital project execution, many similarities can be found with most glassmaker operations nowadays.

The plant had a strong focus on energy consumption, as it was the main on-site OpEx. The KPIs were defined by the group or the upper management and were tracked by an Operational Excellence Manager. Additionally, the customer had a manual, monthly reporting process on energy consumption which was time consuming and subject to human errors.

With the furnace being at the end of its lifetime, one of the objectives was to understand and model the degradation of the regenerators. Indeed, one of the model’s goals was to distinguish in realtime two aspects: the natural reduction in efficiency due to ageing of the regenerators and the variation in energy performance due to operational, process and production parameters that could be optimised.

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PHASE 1: COLLECTION AND ANALYSIS OF EXISTING DATA The implementation started with a data science phase based on historical data provided by the customer. This step used 18 months of available data organised in 700 different dataflows with a 30s timestep (over a billion data points in total). All the parameters were taken, and the influencing ones were identified to create the model of the system. Most of influencing parameters were related to temperatures and production. In general, and if necessary, the number of dataflows used by the model for the calculation of KPIs can be adapted.

Data transfer and storage are flexible, either in the cloud or on-premises (i.e.

hosted inside the plant). Different types of connection are available to provide flexibility in adapting to the plant’s IT architecture and to ensure data protection. Data control and security are indeed essential. For this specific project, the data was sent to a cloud via an SFTP server. The customer had an automated exportation of the dataflows in .csv format. The data science allowed a deep analysis of the furnace consumption and of the different flows with their distribution throughout the system. As previously requested by the customer, this phase made it possible to focus on the regenerative system.

The study of the average delta of temperature between the crown (top) and the arch (bottom) of one of the regenerator stacks during the 18-months period was essential in the analysis of the furnace’s regenerators behaviour – see Fig 2. This temperature difference represented the efficiency of the regenerative system, the higher the temperature delta, the more efficient the system (i.e. the combustive air pre-heating temperature). Due to the degradation of the regenerators’ refractories, the pre-heating temperature decreases with the ageing of the furnace.

PHASE 2: IMPLEMENTATION OF THE MODEL IN THE DIGITAL PLATFORM AND OBSERVATION OF ENERGY CONSUMPTION IN REAL-TIME This deterioration of the regenerators was modelled, so that real-time variations in energy performance could be differentiated, and the digital twin of the furnace could be created. This allowed the creation of the baseline of energy consumption considering the deterioration of the regenerators. The baseline is the point of reference on how the energy consumption should be, depending on the context. The model used machine learning technology to give the values of energies and consumptions in real-time.

The exploratory analysis made it

The results The main recommendation allowed a saving of 2 to 3% (or up to 12 GWh) of energy consumption on the whole furnace gas consumption thanks to the optimisation of the firing time between two combustion inversions. The savings were achieved in a three-month period following the data analysis. This sole result made the implementation of the platform economically viable. In addition, thanks to a better knowledge of the energy temperatures, the customer was able to make optimised planning of the regenerators’ maintenance by acting first on the less efficient ones. The customer was also able to better adjust

possible to look closely at the average temperature inside one of the left regenerator rider arch (bottom) being pre-heated and at times of combustion reversal. We could identify that the temperature of the stack pre-heated by the exhaust fumes decreased before the combustion was reversed (Fig 3).

This detected a non-optimisation of the combustion. Indeed, the change of combustion side must occur at the peak of the regenerator temperature.

Otherwise, the pre-heating of opposite stacks will be reduced. This identification was made through the

the combustion to the required thermal profile of the different types of glass produced. The impact of raw materials and gas quality on consumption was understood in real-time thanks to the definition of a new KPI. The platform also gave the value of emissions in real time and could trigger alarms. Finally, automated reports have saved the customer mandays each month and reports became automated, more accurate, and adjusted to different users.

Conclusion You now have a new dimension to consider, the digital transformation of your businesses. This will support

combination of data science and energy knowledge.

Energy management platform are great tools for closely monitoring consumptions and for precisely identifying the impact of improvement measures. With this in mind, suggestions were made in conjunction with the customer, and results exceeding expectations were achieved.

(In general, recommendations of specific explorations and implementations are made according to the furnace and its operational context).

your projects focused on energy savings, process efficiency, predictive maintenance, product quality, pricing, and so on. Digital services are already a reality for glass makers in order to remain competitive. And remember that your teams can implement these solutions with reasonable resources. It is also totally independent of equipment technology, lifetime, and maintenance schedule.

Digital services are the ultimate optimisation. They are safe, with a short ROI, and the best way to improve unoptimised systems and to bring new savings opportunities you might not have identified yet. �

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Incorporating the BIFCA Standards Seminar

The future is now when it comes to furnace technology Manufacturing industries are already seeing the results of the ‘Furnace of the Future’ in reducing CO2 emissions and producing cleaner, more sustainable materials.

But how can energy-intensive manufacturers work towards making this future a reality?

Are we already seeing the benefits of adopting smarter and more sustainable technologies within furnaces? Could we be doing more?

This online event will unite the glass, aluminium and steel sectors to discuss overcoming heat treatment challenges and present a collaborative approach to bring the Furnace of the Future to life.

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Alongside the two-day virtual conference, participants will also be invited to join live discussions and will have the opportunity to network with new industry contacts, arrange video meetings and exchange resources and information.

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Industry 4.0

Digitalizing the EAF process Using a simple definition, we could say that digital transformation is the application of all tools and digital capabilities focused on processes, products and machinery with the aim of improving efficiency and added value to the customer and improving plant operating conditions, safety and transformation costs. These outcomes are realized by a new platform of innovative systems, products and opportunities introduced at the melt shop level. Tenova’s i EAF® technology is at the forefront of the digital revolution and offers 100% compatibility with the connectivity, digitalization and control standards necessary for the steel industry.

By Armando Vazquez* and Doug Zuliani* TENOVA i EAF® technology is a modular programme, which can be implemented in one step or based on particular needs, can be supplied in different stages, modules or phases. Each implementation step is focused on specific objectives within a complete optimization programme, with priority objectives being to provide savings and productivity improvements through the optimization and dynamic control of the EAF process, using the following to achieve this dynamic control: � sensors, � real-time models, � advanced control algorithms

Sensors: innovative instrumentation providing necessary information to complement field data and when combined are used to achieve real-time mass and energy (M&E) balance that is the central base of the i EAF® technology platform.

Real-time models: evaluate the information from the field, Level 1 and Level 2 of existing automation and Tenova’s instrumentation, in order to make the real-time calculation of mass and energy pertinent to the furnace.

Advanced control algorithms: use real-time results of the M&E balance and execute the evaluation and pertinent actions for the control of energy sources in the EAF (control of chemical and electrical packages plus the fume system).

NextGen® system NextGen® hardware is a state-of-the-art gas analyzer that was designed by analyzing the advantages and disadvantages of the in-situ laser versus the extraction system. � In-situ laser systems use a tunable diode laser to transmit a beam in the near IR range through the off-gas for subsequent pick-up by an optical detector.

The transmitted laser’s wavelength is modulated around the particular spectroscopic line of the gaseous species of interest. The amount of absorption in the detected beam is subsequently used to calculate the concentration of that particular species in the off-gas. EAF insitu laser systems use up to three separate lasers, one for CO2 and H2O vapour, one for CO and one for O2. While in-situ laser systems can analyze several gases, lasers cannot analyze many mononuclear diatomic gases including N2 and H2 [1,2]. �

Extractive systems use a water-

cooled probe, heated line and analyzer to continuously extract and analyze a sample of EAF off-gas from the fume duct.

Various analytical methods are employed to provide a continuous complete spectrum of off-gas chemistry in real-time including CO, CO2, O2, H2, H2O vapour and N2. [1,2]. off-gas solution The NextGen® incorporates all the advantages of both technologies, reducing the disadvantages and offering several advantages over the traditional systems, making it a progressive step towards a digital platform.

NextGen® is a hybrid, breakthrough technology offering the following characteristics[1,2]: � off-gas extraction through a probe positioned directly in the cone of the off-gas exiting the EAF at the 4th hole.

Positive extraction remains the very best way to ensure high system reliability and avoid lost analytical signals. � connection to a probe and short heated line, the compact extractive unit is mounted directly on the melt shop floor without the need for an environmentally protective room. The extractive unit first

* Email: Tenova Goodfellow Inc, Canada. Armando.vazquez@tenova.com, doug.zuliani@tenova.com

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Fig 1. NextGen® hybrid off-gas system at 4th hole configuration

cleans the gases of particulate matter and then uses various types of analytical cells and lasers to analyze the off-gas. � the extractive unit is connected to a compact control unit located in the EAF control room. This unit analyzes the signals from the extractive unit and continuously provides full-spectrum offgas chemistry for CO, CO2, O2, H2, H2O vapour and N2. The control unit has multi-point capabilities for connections of up to four independent extractive stations. � the control unit is interfaced with the plant’s Level 1 & 2 network and provides process information in real-time as needed by process control models.

The PLC interface facilitates continuous dynamic process control of the burners, lances, injectors, fume suction and electrical set points plus water leak detection. � The Web-HMI is designed with the objective of being part of a digital transformation regarding its coconnectivity, accessibility and functions.

It facilitates the use of remote access with set-up and diagnostic functions necessary for the proper operation and troubleshooting of the equipment. Fig 1.

As part of the NextGen® package, Tenova

has designed optical sensors for off-gas velocity (OVM) and temperature (OTM) measurement. These sensors enhance the information necessary for the calculation of the mass and energy balance.

The OVM consists of two compact optical sensors mounted to optical view ports in the fume duct. These inline sensors continuously measure off-gas velocity. Fig 2.

The OTM is an optical sensor that uses a wavelength ratio method to measure off-gas temperature. This design requires minimal maintenance and avoids temperature inaccuracy problems associated with excessive dust. [3] Fig 3.

NextGen® instrumentation and optical sensors (OTM & OVM) are connected in a digital platform allowing connectivity through the Ethernet network implemented between the devices, allowing a manual and automatic operation as well as service assistance, setup and troubleshooting.

Likewise, to complement the i EAF® configuration, described later, an i EAF® computer is added to the real-time models and control algorithms, allowing for a complete digital control platform. Fig 4.

i EAF® Technology i EAF® software replaces statistical process models which are prone to excessive drift with a new generation of more

fundamental thermodynamicand kinetic-based process control models that incorporate real-time mass and energy balances. The i EAF® incorporates two distinct performance saving modules: � Module 1: dynamically controls the quantity of chemical energy and furnace draft � Module 2: dynamically controls chemical energy and electrical set-point timing and oxygen injection during refining to finish the heat on C & T specification

In addition to the modules described above, the i EAF® package includes the industry’s most comprehensive water detection software based on both H2 and H2O vapour off-gas analysis.

Module 1 Using NextGen® off-gas analysis to provide optimized control of chemical energy inputs to the EAF, MODULE 1 dynamically increases the quantity of oxygen and decreases the quantity of methane (CH4) injection in cases where the EAF off-gas contains an excess of combustible CO and H2. Conversely, MODULE 1 will automatically increase methane and decrease oxygen injection if the furnace environment contains

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a

b Fig 2. (a and b) OVM Optical off-gas velocity sensor

Fig 3. (left and right) OTM Optical off-gas temperature sensor

excess free O2. By doing so, MODULE 1 dynamically controls and optimizes the amount of oxygen and methane injected into the furnace to maximize chemical energy efficiency. [3] With the implementation of the automatic control and optimization process (Module 1), Table 1 reveals how Tenova technology has brought great benefits in two scenarios shown below.

Fig 5.

balance to calculate, second-by-second, the ‘Actual Net Energy’ received by the charge/bath after allowing for Actual Energy Losses.

2.2.2 Module 2 MODULE 2 uses the real-time M&E

Actual net energy = [actual energy inputs] – [actual energy losses] • IN [electrical energy + burner energy + energy from oxidation] • OUT [energy lost in the fume system, cooling panels and furnace bottom]

MODULE 2 accurately determined the rate of heating and melting of the solid charge in the EAF, and thereby can provide a second-by-second measure of the “%melting progress” throughout the heat. %Melting progress = net energy received/total energy needed to melt charge mix The %melting progress is calculated in real-time for every heat based on that heat’s actual real-time M&E balance,

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Industry 4.0

Fig 4. NextGen, OTM and OVM connectivity

%melting progress and precisely determines for each and every heat: � The quantity of un-melted scrap in the EAF at any time during the heat � The best time to charge scrap buckets The time when there is sufficient molten metal to initiate supersonic oxygen lancing means: � The onset of flat bath conditions and operative refining has begun; � The degree of superheat and the bath temperature. This is valuable information for determining the best time to take steel samples and thermocouple readings and when to tap the heat. [3]

Fig 5. Module 1 plant benefits

The results in Fig 6 confirm that MODULE 2, Net Energy Control, generates significant operating cost savings.

2.3 Digital Platform The Internet of Things (IoT) makes it possible for us to have smart homes, smart factories and smart cities. Artificial intelligence and machine learning enable predictive approaches to decision making and drive business insight.

Digital transformation is also present in the steel making processes, which is why i EAF® technology makes the data obtained and generated flow according to specific needs. Data is the ‘catalyst’ for new technologies and solutions that open up accessibility and connectivity, which is essential for improving current processes.

The connectivity of the NexGen® Ethernet network is at Level 1

Fig 6. Module 1+2 plant benefits

and 2 to the plant automation, allowing external connectivity to Tenova using direct connection to Tenova HQ or Cloud services, both of which are Industry 4.0 compatible.

Tenova solutions offer remote connection for process optimization, support, analysis, machine learning and training with direct connection and/or with cloud services, putting NextGen® hardware and i EAF® solutions at the

forefront of digital transformation for the EAF process. Using the Cloud or a local server, i EAF® offers a continuous improvement service for the process, data analysis and evaluation of ‘machine learning’ events, as well as hardware and software monitoring to ensure adequate performance.

Likewise, process and maintenance services can also be remotely controlled to facilitate continuous monitoring. Fig 7.

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Industry 4.0

Fig 7. Digital connectivity

The digital transformation implemented with i EAF® includes modules which are based on machine learning, such as artificial intelligence (AI) applications that provide systems with the ability to automatically learn and improve from experience without being programmed. The accessible portal for tuning some advance modules is shown in Fig 8. This Machine Learning process enables the user to check the tuning of control modules based on the evaluation of off-line results to tune the application.

These tuning parameters can immediately upload the results to the i EAF®.

Conclusions Tenova has developed i EAF® technology for dynamic process control based on the

calculation of a mass and energy balance in real-time to facilitate a more complete understanding of process variables in order to optimize functionality and performance. The company has optimized more than 100 installations worldwide with continuous development to ensure that all new EAF industrial challenges can be addressed.

NextGen® is the most advanced hardware solution in the market, offering a hybrid laser/extraction system, incorporating the most significant advancements in the field. Likewise, the i EAF® solution takes the advantages offered by the NextGen® system including modules and algorithms that allow dynamic control of the EAF process to realize important and sustainable benefits. Additionally, i EAF®

is the only optimization system available that offers full remote connectivity on an Industry 4.0 platform. �

References 1 Doug Zuliani; “Next Generation Off-Gas Analysis” Steel Times International 41(3):33, April 2017. https:// www.researchgate.net 2 S. Schilt, F.K. Tittel and K.P. Petrov, “Diode Laser Spectroscopic Monitoring of Trace Gases”, Encyclopedia of Analytical Chemistry, pages 1-29, 2011.

3 Armando Vazquez “Advancements in dynamic EAF offgas process control using NextGen® technology”, ABM 2019 Brazil

Fig 8. Machine learning portal – Tenova

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FIC ads 2019_Layout 1 15/11/2019 10:02 Page 3

, Tomorrow s Technology Today

Are you interested in CO2 reduction?

Come to FIC for superboosting and large all-electric furnaces – we have the answers to reduce carbon footprint l All-electric furnaces l Electric boosting

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, The World s Number One in Furnace Technology

FIC (UK) Limited Long Rock Industrial Estate, Penzance, Cornwall TR20 8HX, United Kingdom

GLASS SERVICE

A Division of Glass Service

Smart furnaces

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Smart furnaces

GHI Smart Furnaces works in the supply of the key equipment of the new casthouse to Almexa in Veracruz (Mexico)

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Smart furnaces

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Smart furnaces

Almexa’s new casthouse will be the newest and most efficient in all America, it will be inaugurated in the second semester of 2021. The key process equipment will be supplied by GHI Smart Furnaces, a world leader in the furnaces industry. The plant will have the most advanced equipment for aluminium processing aimed to achieve a circular economy.

With a production capacity of more than 90.000 t/year, the plant will have the America’s largest tilting rotary furnace of 65 tons capacity, one of the for existing in the world and all supplied for GHI. It is specifically designed for aluminium recovery.

Additionally, a salt slag cooling system will be installed to achieve higher levels of metal recovery with low environmental impact. Furthermore, a high efficiency melting and holding furnace of 50 tons capacity with regenerative burners will be installed.

The new casthouse will be a world reference for the production of canstock, it is carefully designed to obtain high quality aluminium with an environmentally friendly process with full automation and smartization.

The key equipment is completely

sensorized, and the gathered data is analyzed with Big data and Artificial intelligence technological solutions leveraged in the Beyond Alea platform to improve the process productivity and control of the Smart Plant.

The tilting rotary furnace will work as the main melting equipment of the plant, the resulting aluminum will be transferred to a new melting and holding furnace where, additional melting capacity is installed and the alloy will be adjusted and then, it will be transferred to the vertical casting machine.

The 50-ton melting/ holding furnace has an open front which allows a fast and efficient loading of the raw material and enables the deslagging process to be carried out efficiently. The combustion equipment with regenerative burners reduces energy consumption and environmental impact, which is one of our customer's main objectives.

The furnace is equipped with porous plugs that increase the temperature uniformity in the aluminium bath in order to achieve the optimal levels of homogeneity in the chemical alloy.

The supplied equipment has a high technological component as it is specifically designed for the recovery of aluminium, obtaining a high metallic yield. All the equipment will provide high energy efficiency and very low CO2 emissions per ton produced.

4.0 Technology In addition, GHI Smart Furnaces will incorporate 4.0 technology into the supplied equipment through the

BeyondAlea 4.0 Platform. This platform includes advanced sensorization services, digitalization, technical assistance, process consulting and preventive maintenance. As a result, the customer will have better control over the production process and a greater reduction in the consumption of the plant and therefore in the production of CO2. . �

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ALUMINIUM 2021 The World's Leading Trade Fair for Aluminium and its Application Industries

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FIC ads 2019_Layout 1 15/11/2019 10:03 Page 4

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GLASS SERVICE

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Heat treatment

A new dimension in gas nitriding A technological breakthrough from SECO/WARWICK A process that has been known for more than a century, gas nitriding, has seen a technology breakthrough that is a real game changer in the field of metal heat treatment. The ZeroFlow® method introduced to global industry

by SECO/WARWICK in cooperation with

scientists from one of the best technical universities in Poland, Poznan University of Technology, reduces process costs with performance that is far more ecologically friendly.

The reason why ZeroFlow® furnaces with nitriding technology are such a great

technological revolution is that so many industries can benefit from this method, says inventor and promoter of modern heat treatment, Maciej Korecki, PhD Eng., Vice President of the Vacuum Furnace Segment at SECO/WARWICK Group.

Q. Gas nitriding of steel is a process that is over 100 years old. What did the process look like in the past and what does it look like today?

A. It’s true. Nitriding is one of the most widely used thermochemical treatment processes for producing surface hardened layers. Today it is used wherever steel parts are manufactured, for example, gears, bushings, shafts, dies, punches or molds, used mainly in the machinery, automotive, aerospace, mining or toolmaking industries.

only ammonia, instead of a continuous flow of a mixture of ammonia and diluent gas. Consequently, the ZeroFlow method uses the minimum amount of ammonia needed to achieve the required nitrogen potential and replenish the nitrogen in the atmosphere, taking into account the situation where no ammonia is supplied to the furnace at all, no flow, hence the suggestive name of the solution, ZeroFlow. Using ammonia alone in the nitriding process, we are dealing with a stoichiometric reaction (as opposed to some traditional methods), that is, one that is uniquely defined and predictable based on the monitoring of a single component of the atmosphere.

Therefore, the ZeroFlow process controls very precisely through the analyzer only one gas, obtaining an improvement in the quality and repeatability of the results compared to various traditional methods.

research and development department (SECO/LAB®), where the method has been implemented and validated on dozens of industrial-scale processes. The project lasted several years and involved dozens of our engineers and researchers from the Poznan University of Technology.

Historically, it began with nitriding in pure ammonia, but difficulties were encountered in controlling and reproducing process results. Various gases were then added to the ammonia for over 100 years until the present to control the process, which improved the results.

Today, gas nitriding uses a compositioncontrolled mixture of ammonia and diluent gases, primarily in the form of dissociated ammonia or nitrogen to control the nitrogen potential, which is the primary driver of the nitriding process.

A characteristic feature is the need for a continuous flow of atmosphere through the furnace, that is, inflow and outflow.

The latest technological development in this process is ZeroFlow® gas nitriding.

It is a method that significantly reduces process costs while protecting the environment.

Q. What is ZeroFlow® gas nitriding?

A. ZeroFlow nitriding is ammoniabased gas nitriding. It is distinguished by the fact that the nitrogen potential is controlled by introducing the right portion of ammonia at the right time and

Q. Where did the idea for ZeroFlow come from and how long has SECO/ WARWICK been working on this technology?

A. ZeroFlow can be said to go back to the source, to the basics of the nitriding process, by using ammonia alone without any additional gases. The inventor of the method is prof. Leszek Maldzinski of the Poznan University of Technology, who developed the theoretical basis and confirmed it with research. Then, more than 10 years ago, a partnership between SECO/WARWICK and the Poznan University of Technology initiated a project to develop and build the first industrial furnace designed to perform the ZeroFlow nitriding processes. The furnace was launched at SECO/WARWICK’s

Q Does ZeroFlow® nitriding produce the same results as other gas nitriding methods?

A. Definitely yes. The ZeroFlow method is a complete and versatile alternative to any gas nitriding process. A layer of any structure and thickness can be produced and various technological options such as ferritic nitrocarburizing and oxidation can be realized. At the same time, it is a method that provides great benefits to those who choose to use it. The most important advantage is the minimization of ammonia consumption and postprocess gas emissions. Simplified gas and measurement installation and increased process control accuracy translates directly into reduced process costs and environmental care, while improving production quality.

Q. What affects the gas requirements and the cost of nitriding processes?

A. When it comes to costs, the main influences are the energy consumption to achieve and maintain the elevated process temperature and the nitriding gases. Gas demand is mainly influenced by the method and quality of nitrogen potential control. In traditional solutions, a given nitrogen potential is obtained by applying a continuous flow of atmosphere in an amount resulting from the method adopted and the furnace condition,

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Heat treatment

ABOUT THE SPEAKER Maciej Korecki is a graduate of Zielonogórski University, where he received a Master of Science degree in Electrical Engineering, in 1988. He earned the academic degree of PhD Eng. at the Mechanical Department of the Technical University of Lodz in 2008 in the field of vacuum furnace design and testing. He is the author of numerous international SECO/WARWICK patents and regularly holds technical lectures at international conferences, specialising in heat vacuum treatment technology.

His career started at Elterma in 1988 as a vacuum furnace service engineer. In 1991, he joined SECO/WARWICK, where he gained competencies in the technique and processes as well as development and innovation, specialising in vacuum carburizing and high-pressure gas quenching.

Currently, he serves as the Vice-President of the Vacuum Furnace Segment, appointed by the Board of SECO/WARWICK in 2012. PhD Eng. Maciej Korecki actively promotes the development and improvement of vacuum heat treatment equipment and processes as well as their applications in new industry and technology areas. He is an inventor and advocate of vacuum heat treatment with the “single-piece flow” method.

generally with a large excess compared to the charge demand. This can be compared to maintaining a constant water level in a leaky bucket, where there must be a continuous supply of water depending on the size of the hole. The ZeroFlow method uses the optimum and minimum amount of ammonia necessary to deliver the required amount of nitrogen to the surface of the machined parts. In this case, the

bucket is sealed and there is no leakage.

In fact, one of our customers, a renowned automotive company, used about 160 tons of ammonia per year in its traditional nitriding processes. After ZeroFlow was implemented, consumption dropped to about 20 tons per year. This represents a reduction in ammonia consumption of up to 87.5%.

Q. Does this mean that ZeroFlow nitriding is both economical and an environmentally friendly process?

A. Definitely yes. It uses many times less ammonia, one of the main cost factors of the process, and similarly emits many times fewer exhaust gases including, ultimately, nitrogen oxides (NOx), making ZeroFlow significantly more environmentally friendly. �

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Refractories

Safer Refractory Installation Specialized equipment to optimize the maintenance process.

Heather Harding*

Using a conveyor, workers can easily move materials twice as fast as manual methods with significantly less physical strain.

*Bricking Solutions Managing Director

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Refractories

With advancements in kiln technology, size and applications, factories and facilities around the world are replacing outdated refractory installation techniques with more sustainable methods that use specialized equipment rather than backbreaking manual labor. Throughout the process, these machines and tools help bring about safer and more productive maintenance.

However, not all refractory maintenance equipment comes with industry-leading safety benefits. Consider these options to optimize safety during inspection and installation.

Safety Cages and Personnel Tunnels Starting with initial inspection, safety cages and personnel tunnels protect workers from falling debris. Not all regions allow workers to enter kilns before coating and clinker is removed, but in areas where this practice is used, facilities that employ cages and tunnels have been able to reduce injuries.

Like many pieces of refractory inspection equipment, cages and tunnels appear deceptively simple. However, careful material selection and design are key to optimizing safety. Models manufactured with T6-6061 aircraft aluminum offer the best strength-toweight ratio. The material is strong enough to protect workers from debris up to 140 kilograms (250 pounds) falling from a height of up to 2.44 meters (96 inches), but can be as much as 50% lighter than comparable steel models.

Additional safety features are also incorporated in safety cages from industry-leading manufacturers for even more protection. Crumple zones, for example, absorb the energy of a collapse, preventing serious injury or death.

Stainless-steel netting protects workers from falling debris, as well. To increase peace of mind, look to partner with manufacturers that perform a battery of destructive tests to ensure these features perform as intended in an emergency situation.

Kiln Access Ramps Custom-engineered kiln access ramps also provide a significant safety benefit for refractory maintenance applications.

While a simple plank bridge might have sufficed in the past, today’s refractory installation relies on heavy equipment, such as skid steers and tear-out machines, to expedite the process. To get people and

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Refractories

ABOUT BRICKING SOLUTIONS Bricking Solutions manufactured the industry’s first bricking machine in 1966 to give refractory installers a safer, more efficient alternative to manual installation methods. From that time the company has believed that machines should do the heavy work rather than the people and customer feedback should drive product development. Bricking Solutions manufactures a wide variety of equipment for the cement, foundry and steel industries, including bricking machines, conveyors, pallet transfer systems, suspended platforms, ramps and safety cages.

For more information: Bricking Solutions, Inc., 1144 Village Way, Monroe, WA 98272; 1-360-794-1277; info@brickingsolutions.com; www.brickingsolutions. com; Facebook; Twitter or YouTube.

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Refractories

tools safely across the cooler, metal access ramps have become standard in facilities worldwide.

Keeping in mind that every burn floor, cooler and kiln is unique, partnering with a manufacturer that provides individualized products will help maximize safety benefits and efficiency for this vital installation component.

Again, heavy-duty aluminum equipment provides durable, long-lasting results at half the weight of steel. An access ramp manufactured with this material can support as much as 6,804 kilograms (15,000 pounds) live load. Customdesigned equipment can also incorporate features such as curbs and fall guards, when necessary, to protect workers as equipment moves across the ramp.

Conveyors Incline and hydraulic conveyors are tools refractory installers find increase employee safety and efficiency. Parts of the world with access to large labor pools might still find so-called “bucket brigades” a viable option for transferring refractory materials up kiln.

However, this method results in excess brick handling, which could damage refractory — not to mention a number of unnecessary sprains, strains and repetitive motion injuries. So, with safer options readily available, progressive facilities and contractors are embracing a more automated approach.

Using a conveyor, workers can easily move materials twice as fast as manual methods with significantly less physical strain. Additionally, refractory equipment specialists provide lightweight, modular equipment that is easily adapted to fit a specific kiln, including kiln diameter, burn floor length and terrain adjustments. With sections weighing just 16-19 kilograms (35-42 pounds), transportation and installation is easy for a small crew.

Bricking Machines Bricking machines from leading manufacturers provide the most innovative and cutting-edge technology such as adjustable dual-arch systems with pneumatic cylinders to push bricks into place, greatly reducing the risk of injuries from unsupported overhead bricks.

While support equipment has played a major role in increasing refractory installation safety, perhaps the most significant gains have been made in the bricking process itself. The widespread adoption of bricking machines in recent decades has revolutionized the speed and overall safety of installation applications.

Features and safety benefits vary among bricking machine models, but their overall contributions to installation efficiency are undeniable. Decades-old,

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Refractories

Safety cages manufactured with T6-6061 aircraft aluminum offer the best strength-to-weight ratio.

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Refractories

first-generation machines can still reduce physical strain and safety risks compared to outdated installation methods — as long as they are well maintained. Newer models provide the most innovative and cutting-edge technology such as adjustable dual-arch systems with pneumatic cylinders to push bricks into place, greatly reducing the risk of injuries from unsupported overhead bricks.

Machines featuring ergonomic design elements further increase worker comfort and safety. For example, models from innovative manufacturers offer a cut-away

section for unobstructed keying access to increase ease and visibility for closing out a ring. Additional safety features are also available from specialized manufacturers including non-slip decks, dual braking systems and fall guards.

An experienced crew using a bricking machine can install 1 meter (3.3 feet) of brick per hour, compared to roughly .6 meters (2 feet) with other techniques. The end result is better refractory installation which increases longevity and decreases downtime and repairs. The widespread use of bricking machines has also

contributed to a significant decrease in refractory installation-related injuries and fatalities.

And Many More From tear out to clean up, original equipment manufacturers offer a full range of support equipment to make refractory installation faster, safer and more efficient. Facilities that take advantage of these specialized tools can see significant savings through streamlined maintenance, minimized downtime and reduced jobsite injuries.

Keeping in mind that every burn floor, cooler and kiln is unique, partnering with a manufacturer that provides individualized kiln access ramps will help maximize safety benefits and efficiency.

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7-9 JULY 2021 Shanghai New Int'l Expo Centre N1-N3

Organized by:

Co-organized by:

Concurrently Held Shows: 2021 2021 Asia 2021

Asia’s Lightweight Automotive Trade Fair