Furnaces International June 2022

INDUSTRY NEWS

COMPANY PROFILE

SUSTAINABLE SOLUTIONS

GLOBAL INNOVATIONS

www.furnaces-international.com - JUNE 2022

Furnaces line SOLO® Profitherm Max. load 500 kg, temp. up to 1050°C

42

52

C Editor: Nadine Bloxsome

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Jack Homewood

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Editorial Assistant: Zahra Awan

Managing Director: Tony Crinnion

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INDUSTRY NEWS

COMPANY PROFILE

SUSTAINABLE SOLUTIONS

GLOBAL INNOVATIONS

www.furnaces-international.com - JUNE 2022

Tel: +44 (0) 1737 855038

zahraawan@quartltd.com

Published by: Quartz Business Media Ltd, Quartz House, 20 Clarendon Road,

Production Editor: Annie Baker

Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000.

Sales Manager/Advertisement

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production: Esme Horn

www.furnaces-international.com

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FRONT COVER: Furnaces line SOLO® Profitherm Max. load 500 kg, temp. up to 1050°C

Solo Swiss

Furnaces International is published quarterly and distributed worldwide digitally

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Furnaces International June 2022

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2 Global Furnaces News 8 Company profile: Mechatherm International Ltd 22 Heat Treat Today: The “Known - unknown” Preparing your facility for unpredictable world events

LIFE OF A FURNACE 30 Life of a Furnace News 34 Furnace shell monitoring to increase safety while reducing energy consumption and CO2 emissions 42 Stealing back profits with Aluminium Bricking machines

CONTENTS AND COMMENT

GLOBAL FURNACES Welcome to the June issue of Furnaces International.

Hopefully you will have noticed that these issues have now settled into a rhythm with the content and layout - we are very pleased with the reaction from readers and hope this new look is easy to follow in an online format and provides all of the latest information you need to keep up-to-date with technical and topical developments.

As always, we start with a look at what has been happening across the global furnace industry and this issue sees a special company profile and interview with UK-based company Mechatherm. Our Editorial Assistant, Zahra Awan, found out all about the company’s history and it’s plans for furnace world domination!

The Life of a Furnace feature section includes a number of articles on how smart technologies are coming into play and what this means for the industries these furnaces serve.

And finally, greener technologies and manufacturing is here to stay, so the Green Furnaces features are a great read to find out more about improving industrial sustainability and renewable melting.

GREENER FURNACES 48 Greener Furnaces News 52 Pilkington’s renewable furnaces 62 Reducing energy waste in EAFs

Keep an eye out for our next issue, which wil be printed and distributed at the Furnaces North America event.

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

© Quartz Business Media Ltd, 2022

Editor: Nadine Bloxsome

Sales Manager/Advertisement

Published by: Quartz Business Media Ltd,

nadinebloxsome@quartzltd.com

production: Esme Horn

Quartz House, 20 Clarendon Road,

Tel: +44 (0) 1737 855115

esmehorn@quartzltd.com

Redhill, Surrey RH1 1QX, UK.

Tel: +44 (0) 1737 855136

Tel: +44 (0)1737 855000.

Email: furnaces@quartzltd.com

Editorial Assistant: Zahra Awan Tel: +44 (0) 1737 855038

Subscriptions:

zahraawan@quartzltd.com

Jack Homewood

www.furnaces-international.com

subscriptions@quartzltd.com Furnaces International is published quarterly

Production Editor: Annie Baker Managing Director: Tony Crinnion

www.furnaces-international.com

and distributed worldwide digitally

Furnaces International June 2022

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NEWS GLOBAL FURNACE

Gerresheimer’s Indian investments boost global production Gerresheimer has boosted its global glass and plastic production capabilities with advanced facilities in India.

Glass production was updated at the company’s Kosamba site with state-of-the-art, sustainable furnace technology.

Gerresheimer installed the latest Type I Borosilicate melting furnace for flint and amber glass production using cross-fired oxygen technology. The melting furnace also has an increased portion of electric heating to melt the company’s new Barium free type I glass formulation.

The furnace is further equipped with the latest production machines, including sensitive inspection equipment to comply with Gerresheimer’s moulded glass production standards.

A new modern plant to produce high quality plastic containers and closures was also built at the Kosamba site. The innovations in glass and plastic were both ceremonially commissioned by Gerresheimer management in April.

By adding capacities in India, Gerresheimer intends to ensure consistent supply for critical pharmaceutical and healthcare facilities supporting increased packaging demand and public health.

Stefan Rieder, Global Senior Vice President of Commercial Moulded Glass, said: “With this technology, we will substantially enhance our product quality and address additional market segments.”

2 Furnaces International June 2022

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NEWS GLOBAL FURNACE

Tenova Received Two Contracts from TenarisDalmine for the Steelmaker’s Ne Investment in Special Steel Production Tenova was awarded two contracts by Tenaris for its mill in Dalmine (Italy). Both contracts are related to the steelmaker’s new investment in special steel production. The two companies belong to the Techint Group.

The Dalmine project is divided into three phases, two of which will be supplied by Tenova. The first phase consists of a state-ofthe-art melt shop ladle furnace.

The ladle furnace will be used for secondary metallurgical treatment of the liquid steel.

The second project phase will consist of a Tenova’s designed and supplied heat treatment furnace for special steel bars. This movable hood-type furnace is

specifically designed to charge very large bars with a length of 12 meters and is equipped with thirty-four hydrogen-ready self-recuperative burners. These environmentally friendly burners will be capable of using up to 100% hydrogen as a fuel source. Tenova self-recuperative burners provide energy savings compared to traditional preheated air burners, playing a significant role in reducing CO2 emission levels in steelmaking plants. In addition to fuel savings, Tenova burner flameless technology produces the lowest NOx emission level. Optimal thermal uniformity, extended combustion stability, advanced control technology, low maintenance costs, and continuous product evolution are Tenova regenerative burners main and distinguished features. Flexibility in fuel combustion is also another important advantage, as they are already designed and manufactured to be hydrogen-ready.

“The installation of a new furnace 100% H2 ready is part of Tenaris commitment to reducing the environmental impact of its activity, embracing innovation and technological change” comments Giuseppe Pandini, Tenaris Senior Project Manager, “Beside selecting the best energy saving technology for the burners, we took the opportunity of this project to make a step forward. Working with Tenova’s engineering and R&D, we designed a plant ready to start the substitution of natural gas with hydrogen as fuel for our industrial furnaces”.

4 Furnaces International June 2022

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SMS group secures order from Jindal Stainless Limited for a new blast furnace SMS group has been chosen by Jindal Stainless Limited to build a new blast furnace at their Kalinganagar unit in India. The blast furnace will have a production capacity of two million tons of hot metal per year. The plant will serve both existing downstream steelmaking facilities, as well as future ones.

The contract for the equipment, to be designated Blast Furnace Number 1, was signed between SMS group company Paul Wurth and Jindal Stainless Limited (JSL) in November 2021. The scope of agreed work includes the blast furnace, hot blast stoves, a dry gas cleaning plant, a pulverized coal injection and an INBA® slag granulation plant, to be supplied on an Engineering and Procurement basis.

“Jindal Stainless Limited is the leading stainless steel manufacturer in the country”, said Anil Anand, Chief Operating Officer of SMS group, Gurugram.

“This is the first ‘high magnitude’ contract we have worked on together with JSL. It is the beginning of an important new chapter in our shared story”.

ew

This blast furnace will be the first in the JSL’s new stainless steel complex, which is currently based on electric arc furnace technology. The new blast furnace will be the core of JSL’s Kalinganagar plant expansion. With an inner volume of 2,307 m3, the furnace will be equipped with modern copper and cast iron staves, two tap holes with complete TMT machines, and a 46 m3 MIDI central feed Bell-Less Top (BLT).

“We are particularly proud to be part of this new investment

by TenarisDalmine, that confirms Tenova’s continuous innovation for higher efficiency and sustainable solutions”, said Marcello Tomolillo, Customer Service Manager at Tenova Italimpianti.

With this investment, Dalmine will produce high-grade special steel resistant to corrosion in carbon dioxide and hydrogen sulphide environments. The special steel product will also be used for renewable energy technologies such as geothermal wells.

Tenova’s equipment will start production within the first half of 2022.

Furthermore, a number of auxiliary plants will be installed, including internal combustion stoves incorporating all the latest efficiency improvements, a fully dry gas cleaning system (axial cyclone and bag filter) – the first such installation by SMS group for a blast furnace application in India – and an INBA® slag granulation plant based on cold water technology.

All the units will be connected to a Level 1 automation system designed and supplied by SMS group company Paul Wurth. For the Level 2 automation, the customer will rely on BFXpert, the integrated Level-2 process control and operator guidance system for superior blast furnace operation.

“The commissioning of the new plant is expected by the end of 2023, and we are looking forward to work getting underway”, concluded Anil Anand.

This project is another step towards India’s goal of bringing the country’s domestic production to 300 million tons by the end of the decade – and is the first large scale ironmaking project being undertaken by SMS group’s local team.

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Furnaces International June 2022

NEWS GLOBAL FURNACE

Orora secures $12.5 million oxygen glass furnace grant Australian glass manufacturer Orora has secured a grant to support the construction of an oxygen-fuelled furnace at its Gawler production facility.

The $12.5 million grant was awarded from the federal government under the under the Modern Manufacturing Initiative – Manufacturing Translation Stream, Recycling and Clean Energy programme, to accelerate development and commercialisation of low emissions technologies.

Orora Beverage Group General Manager, Simon Bromell, said: “Our plan to introduce oxygen fuelled furnace technology to our site in

Gawler, which would be a first for Australia, supports Orora’s ongoing commitment to reducing greenhouse gas emissions.

“This grant is an important step in achieving that plan, which we intend to progress through to 2024.

“The project would also assist Orora to meet the growing demand from consumers for recycled and sustainable packaging and support our wine industry customers to be competitive in their export markets.”

Globally, Orora Group has committed to achieving net zero Scope 1 (direct) and Scope 2 (indirect

emissions from purchased energy) greenhouse gas emissions across its operations by 2050.

Orora also has an interim goal of a 40% reduction from 2019 levels by 2035, and a target of 60% recycled content for glass bottles by 2025.

The oxygen fuelled furnace, which would replace existing furnace technology, would contribute to this goal together with the construction of a $25M glass beneficiation plant at Gawler, which is expected to be commissioned in Q4 FY22.

6 Furnaces International June 2022

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Granco Clark supplies APEL Extrusions with a complete heating, handling, and UBE press system APEL Extrusions, Inc. has announced it is expanding their production capacity quickly in the new Phoenix, AZ facility.

Apel has officially commissioned Granco Clark and UBE to provide equipment for a second press line in their new facility. This news comes while Apel awaits installation and commissioning of their first press for this facility. Press #1 is expected to be online by mid-year 2022, followed quickly by press #2.

Apel is taking full advantage of the latest technology that Granco Clark has to offer. Both systems feature: The best High-Performance Spray Quench technology available, a Cut-On-The Fly Double Puller, High-Velocity Cooling Ducts, truly operator free Stretcher, an Automated Belt/ Conveyor Handling System, HighEfficiency Log Furnace with Hot Billet Saw, FusionBond™, and Taper Quench for iso-pressure and iso-thermal extrusion.

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Furnaces International June 2022

GLOBAL FURNACES

Company Profile: Mechatherm International Limi

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GLOBAL FURNACES

ited

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Furnaces International June 2022

GLOBAL FURNACES

“Mechatherm is targeting a more sustainable future. With climate change being the biggest challenge on the agenda, we all need to take action to become part of the solution.

”

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GLOBAL FURNACES

In between early morning calls to Austria and the Middle East, and prior to preparing for a meeting with a US client on an un-disclosed automotive project later that afternoon, Mark Allen* took some time out of a busy schedule to provide Aluminium International Today with the past, present and future of Mechatherm International Ltd. Speaking with Zahra Awan**, Mark Allen discusses Mechatherm’s sustainable mindset. Mechatherm has worked with a lot of the big players in the Aluminium industry, at the forefront of the sustainability race. He states that “despite the company being in the top tier of what we do, we aim to be the best in the world,” as he continues to talk about the exciting projects that the company is working on.

*Sales Director, Mechatherm ** Editorial Assistant, Furnaces International

Q: Could you give a brief history on Mechatherm?

Mechatherm is a company that provides tailored industrial solutions to its clients in the Aluminium industry. Specialising in casthouse equipment, Mechatherm’s expertise ranges from upgrades of existing plant right though to complete casthouse projects.

The company was founded in 1973 by three furnace engineers and started work modestly in an unused spare bedroom. The company was immediately successful both in UK and abroad.

Within the first 10 years two of the founders’ sons, both highly qualified, had joined to boost capabilities. Although the company has advanced from those humble beginnings in both size and capability, the second generations still own and work in the com11 www.furnaces-international.com

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GLOBAL FURNACES

pany and it still feels very much like a family business to all those who work there.

We initially started in steel furnaces and predominantly heat treatment but eventually focused our attention to Aluminium.

The company began with small projects in the UK only; over the mid-nineties we slowly started to expand into Africa and the Middle East, where we had several large projects, the success of which allowed us to grow.

After this initial growth, Mechatherm was thriving, taking on larger orders and investing in technological development. As the company grew so did our recognition, winning the Queen’s Award for Export on three occasions. We have now worked in more than 30 countries and have supplied more than 300 furnaces across the world.

Most projects Mechatherm undertake are on a ‘turn-key’ supply basis, whereby the client awards a single source contract for the complete supply of our equipment plus the ancillaries required for the overall process. Mechatherm then completes all the design work, project management and co-ordination between client, suppliers and subcontractors providing a complete project from start to finish.

Mechatherm has a team of around 60 staff that bring our projects to life. All design work is conducted by our experienced engineering team, most of which have been with the company for more than a decade. Without a manufacturing facility of our own, we specialise in coordinating shipments from our network of partners in multiple countries across the world to ensure all parts are delivered on site to complete the equipment installations we design.

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Q: Why did Mechatherm choose to specialise in Aluminium?

We chose to focus our attention on aluminium for several reasons. Firstly, the decline of the steel industry in the UK during the seventies, making Aluminium more accessible and cheaper to recycle than steel. Due to the UK manufacturing decline, we started to look abroad and the high demand for Aluminium meant we followed it naturally.

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Q: What sustainable projects has Mechatherm become involved in?

Mechatherm is targeting a more sustainable future. With climate change being the biggest challenge on the agenda, we all need to take action to become part of the solution.

Sustainability has always been the front and centre of my career. Fifteen years or so ago, I was a Commissioning Engineer and my role was making furnaces more efficient. We would try and take what the client already had and increase its efficiency by improving cycle times, minimising waste and reducing fuel usage, we were very successful at this. So now in the core sales team we look to give people something that provides those benefits from the start Right now, we are working with the world’s largest aluminium recycler to convert the first working aluminium melting furnace to Hydrogen fuel. The project, which is at the feasibility and safety stage, will be the world’s first, which will put Mechatherm at the forefront of this new market.

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Q: What is your view on scrap material?

Mechatherm has developed technology specifically to process post-consumer (or contaminated) scrap, taking compounds that you could never typically burn, and processing them to produce high quality recycled Aluminium. Recycling the by-products into usable fuel, making savings on energy consumption and improving sustainability.

It is clear from record enquiry levels for our X-Series technology that more and more recyclers are turning to post-consumer scrap, and as such would expect increased demand for this material and in particular an increase in smaller recycling centres to locally process this kind of material, thereby reducing the carbon footprint associated with shipping scrap around the globe.

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Q: What are the next steps in making Mechatherm more sustainable?

Although Mechatherm have and are continuing to develop specialist sustainable recycling technology, more can still be done with the sourcing of material used to manufacture furnaces and the implementation of our projects to make the entire process as sustainable as possible.

Mechatherm’s job now is to look at all aspects of furnace design and production, sourcing green components from our network across the world to make a truly sustainable series of furnaces.

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“Our goal is to

grow Mechatherm to be the biggest furnace manufacturer in the world” 18 Furnaces International June 2022

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GLOBAL FURNACES

Q: What would you say if you could address global leaders in the industry?

I would like to see the industry place more of an emphasis when sourcing equipment on sustainable manufacturing to allow those companies making significant efforts in this area to shine through during the procurement process.

In addition, I feel the aluminium industry tends to look inwards to a large extent. Specifically in relation to sustainability, a lot could be learned from other industries if only we could, as a group, look outwards more and create forums by which to discuss key issues in sustainable aluminium production with leaders in other industrial sectors.

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Q: How do you view Industry 4.0 in relation to Sustainability?

The first fifteen years of my career were spent designing, implementing, and commissioning our automation systems. This knowledge has carried over into the way we run the sales team, and in particular, to our service projects where we consult and propose automation improvements, including the integration of Industry 4.0 solutions.

The pinnacle of this was a recent trial project at one of the world’s largest suppliers of aircraft plate where we installed a Big Data based Artificial Intelligence system to improve the efficiency of a large melting furnace, based on our understanding of the way our furnaces operate. Before this project was halted, due to COVID, we were seeing potential efficiency improvements of between 5 and 8%.

But new technology, such as big data analytics and machine learning, is where we can differentiate ourselves. Allowing furnaces to learn how to be more efficient rather than engineering them to be that way, or providing a furnace with the tools to analyse patterns in its performance and warn of a possible problem before it is detected by sensors, is how we are defining our X-Series range of sustainable melting furnaces.

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Q: What can we expect in the future of Mechatherm?

Our goal is to grow Mechatherm to be the biggest furnace manufacturer in the world.

As part of this, we will be opening operations in our major markets; the Middle East and the United States and others over the next few years. This growth, combined with a dedicated local presence in these territories, will provide a high level of customer service for our clients, help with our sustainable sourcing efforts and to reduce our carbon footprint. �

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HT

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GLOBAL FURNACES

The “Known – Unknown”: Preparing your facility for unpredictable world events

By John Clarke* The “Known – Unknown,” the “Undiscovered Country,” the “Movement from cocksure ignorance to thoughtful uncertainty,” it doesn’t matter if you get your catch phrase from Donald Rumsfeld, Star-Trek, or that plaque your mother kept above the sink in the kitchen, the implication is the same: we really don’t know what the future holds. Obviously, given this series of articles, the Unknown of which I speak is natural gas prices. *Technical Director, Helios Electric Corporation

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Does “What happens in Eastern Europe stays in Eastern Europe?” hold true? Unfortunately — no. We have learned from recent and ongoing supply chain issues just how interconnected our economy and manufacturing sector is with the rest of the world. The standoff in Ukraine has the potential to impact the world energy markets for years to come, and I suspect this impact will be felt no matter what transpires. I am certainly no expert, but I have a sinking suspicion that our country (the United States of America) offered some American methane molecules to Germany to stiffen their resolve to cancel the Nord Stream 2 pipeline. If the EU works to reduce their dependency on Russian natural gas, a significant portion of worldwide exports are removed from the supply side of the equation. From a practical standpoint, these shifts in supply will take some years to achieve, but we have seen a new realization on the part of business and governmental leaders about the importance of robust and reliable supplies of commodities, and manufactured goods and manufacturing capacity. So, less natural gas supply with rising demand equates to higher prices. And as we have discussed previously, liquefied natural gas transportation from the USA to the rest of the world is connecting our natural gas market with the world market — and our natural gas price will be affected by consumption and production factors worldwide, just as the price we pay for petroleum oil today is determined in New York, London, and Riyadh — following the consumption patterns in Beijing, Sydney, and Tokyo.

Ok — let’s get back to what we can do in our own facilities to insulate ourselves, to some degree, from unpredictable world events.

Recuperation, or preheating combustion air using the waste

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GLOBAL FURNACES

heat exiting the furnace or oven is a time proven method to reduce fuel gas consumption. Before we quantify the effect of preheating air, we need to briefly discuss what affects this heated air has on the combustion process. Higher combustion air temperatures are associated with the following:

1.

Peak flame temperatures are increased. As less energy is used to heat the incoming

air, the energy in the natural gas can raise the products of combustion (CO2, H2O and N2) to a higher temperature than would be achieved without combustion air preheating. This can be either beneficial or problematic for a specific application. If the work being heated can accept increased radiation from these higher temperatures — heating rates are improved and throughput increased, but these higher temperatures may reduce the life of furnace components, or, in extreme cases, lead to a catastrophic failure.

2.

Flame speeds

3.

Total products of

4.

NOx formation is

are increased, so the

combustion required for

increased. Burner tech-

combustion process

any quantity of heat input

nology has come a long

concludes in less space.

is reduced. Mass flow is

way in recent years to

Again, this is a

especially important in

allow for systems to use

double-edged sword,

systems where the operat-

these higher temperatures

benefiting some and

ing temperature is below

without greatly increasing

leading to a loss on

around 1200°F. If the

NOx emissions, but the

temperature uniformity

energy saved leads to a

rule of thumb is that by

in others.

loss in temperature uni-

increasing the combustion

formity, it may be a Pyr-

air temperature from 70°F

rhic victory.

to 800°F, we basically double NOx formation.

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GLOBAL FURNACES

Each of these drawbacks, other than NOx formation, may be a plus rather than a minus for any application. Float glass furnaces (plate glass used in windows) and ingot reheat furnaces are examples of applications where recuperation was applied a century or so ago, at a time where fuel costs where not much of a factor.

In both cases, the increased flame temperatures accelerated the heat transfer to either the glass or the steel, increasing production. These applications required furnace temperatures where combustion without preheating would have been impractical — as most of the energy would have been lost in the flues, and very little heat would be available to do any useful work.

What questions should I ask? How much can I save? What is my project’s estimated payback? All are critical questions. To start with, can your existing furnace accept these higher flame temperatures, and can you capture the heat and apply a cost-effective heat exchanger? An example would be a radiant tube furnace. Applying recuperation may require an upgrade in the alloy used in the burner and radiant tube. In direct fired applications, will my uniformity suffer? In general, this is a greater concern at temperatures below 1600°F. As the operating temperatures increase, we can generally expect better uniformity. (I can hear the furnace and burner experts reading this cry “foul,” and they are right, it is not wise to rely on my generalizations — always consult an expert about your specific application.)

How much will it cost? With recuperation, it is best to take advantage of an experienced person’s mistakes, rather than making them on your own. Consult a qualified contractor, OEM, or consultant to help with the application and costs.

How much can be saved? To answer that question, I provide 27 www.furnaces-international.com

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the following graph. It is not the end all and be all but will provide a rough estimate of potential savings. It is for an application with an exhaust temperature of 1600°F operating with 15% excess air.

Preheat Air Temp Savings

As we can see, in this application, if we apply recuperation to preheat the air to 800°F, we will save 28% of the natural gas we would otherwise consume.

Before investing your money, an individual analysis of each application is required. This article’s purpose is simply to motivate the reader to invest the time necessary to properly determine, as I mentioned last month, if they have “uncashed checks” lying around their shop.

As always, please let me know if you have any questions. � 28 Furnaces International June 2022

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NEWS LIFE OF A FURNACE

Reduce risk of failures in glass furnace refractories with solutions from AMETEK Land AMETEK Land helps to reduce failures and deterioration in glass furnace refractories with monitoring and detection systems.

Deterioration of refractories can increase fuel costs and may cause glass breakouts or failure, which is why it is vitally important to maintain the condition of a glass furnace refractory as it will ensure safety and process efficiency.

The LWIR-640 monitoring system from AMETEK Land monitors the exterior of the melt tank and identifies any hot areas that may indicate refractory damage. It also gives an early warning of potential glass breakouts.

This long-wavelength thermal imager provides a full temperature measurement range of -20 to 1000 °C (-4 to 1832 °F) in three ranges with a choice of different optics and lenses. It combines cutting-edge, high-resolution radiometric camera technology with sophisticated data processing and powerful software support, delivering detailed thermal images with unrivalled precision.

The thermal imaging provided by the LWIR-640 camera allows a continuous view of the entire target at any distance. Thermal data generated by the camera is presented in real-time, making it faster and easier to detect anomalous hot spots, alerting plant

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In addition to providing a fast-response safety monitoring system, the LWIR-640 solution also supplies the thermal data necessary to detect damage or wear to the refractory lining. This allows corrective maintenance to be scheduled at the least disruptive times. By increasing the reliability of safety monitoring, the LWIR-640 system can also reduce insurance premiums for an added return on investment.

Continuous thermal imaging can also be used for accurate interior monitoring using the NIR-B-2K borescope thermal imaging system, establishing temperature trends throughout the furnace. It also detects cooler spots, which may indicate

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d

NEWS LIFE OF A FURNACE

Stoelzle begins €45 million Polish furnace rebuild Stoelzle Glass Group has invested €45 million in a furnace rebuild at its production site in Częstochowa, Poland.

Earlier this month, the group started to empty its flint furnace at Stoelzle Częstochowa, the largest of seven plants belonging to the group.

The furnace will be demolished and rebuilt, as well as enlarged, within the next two and a half months.

The new flint furnace will reach a daily capacity of 480 t and will allow the installation of three more efficient production lines.

The construction work is scheduled to take 78 days, including the installation of the three new production lines. The investment will amount to €45 million in total.

Artur Wołoszyn, CEO Stoelzle Częstochowa, said: “This investment has been a huge challenge for Stoelzle, above all, the timing of the project, which has been planned in detail over the past two years.

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refractory damage.

LWIR-640 and NIR-B-2K thermal imagery can be combined within AMETEK Land’s advanced thermal imaging software, IMAGEPro, to show a view into the furnace for thermal distribution and batch coverage functions, as well as monitoring the outside of the furnace for hot spots.

“Being 140 t larger than the old one, the new furnace will allow more efficient and faster production lines. This investment will help increase the product portfolio for current customers, as well as to acquire new ones and meet their purchase expectations efficiently,” In the area of packaging glass production, the Częstochowa glass furnace will be one of the largest in Europe and the largest in the entire Stoelzle Glass Group.

The contractors for the project are mainly Polish, regional companies such as: TechGlass, Kobnext, Zremb, MAKO, Alpinet, and El-Logic, Tech-Met, and Forglass.

Philippe Kerbois, Global Industry Manager – Glass, said: “Around 70% of container glass production costs come from energy, so preventing cracks and lost heat produces significant savings.

Early detection of glass breakouts enhances plant safety, so using thermal imaging solutions from AMETEK Land ensures fast detection of glass breakouts, allowing for early maintenance, increased safety, and longer lifespan of the tank.”

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Horn optimises Wiegand-Glas furnace Horn has produced a melting furnace with an energy value below 3 GJ/t at Wiegand-Glas’s Großbreitenbach plant, Germany.

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In spring 2021, Horn was commissioned to significantly optimise an end fired furnace with three forehearth lines and a melting capacity of 350 tonnes per day at the Großbreitenbach plant.

After a successful order, it was discovered that the specific energy values were only slightly higher than the theoretically required energy demand of 3 GJ/t glass.

Consequently, the guaranteed values were already exceeded.

For this reason, Wiegand-Glas and Horn agreed to carry out further optimisation of the melting furnace. The aim was to reproduci-

bly fall below the value of 3 GJ/t glass over a longer period.

During the production of Wiegand-Glas’s olive green bottles, the furnace’s energy value was permanently below 3 GJ/t over a one-week period; cullet content was greater than 85%.

The melting furnace was characterised using Horn e-Fusion Boosting with an input of 15% electrical energy and the technological know-how from Horn’s R&D department.

Forglass experimental furnace enters second phase Polish technology company Forglass has begun the second phase of tests for its experimental furnace.

Forglass invested in the construction of an experimental furnace two years ago. This was to allow the company to test its technologies for improving energy efficiency and reducing harmful emissions.

Following the initial phase of tests, the furnace was cooled and a number of parameters were assessed.

The furnace has been brought up to working temperature again and the second phase of tests have begun to make sure that the innovative solutions are safe to be

fully implemented in the industry.

Despite the furnace being costly, Forglass felt the investment was necessary to ensure the performance and safety parameters of its inventions are met.

32 Furnaces International June 2022

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LIFE OF A FURNACE

FURNACE SHELL MONITOR WHILE REDUCING ENERGY EMISSIONS 34 Furnaces International June 2022

www.furnaces-international.com

LIFE OF A FURNACE

RING TO INCREASE SAFETY Y CONSUMPTION AND CO2 35 www.furnaces-international.com

Furnaces International June 2022

LIFE OF A FURNACE

With the global focus on decarbonisation and reducing harmful emissions, energy efficiency has become an increasingly important consideration for industrial furnace operators, for reasons of both economic and regulatory compliance.

By ensuring the efficient operation of plant equipment such as reheat furnaces, glass melt tanks, rotary kilns, and annealing furnaces – to name but a few – the operator can save on primary energy costs and reduce the quantities of greenhouse gases emitted to the atmosphere.

Over time, the refractory deteriorates to a point where it must be relined. Traditionally, the timing of a reline is based on guidance from licensors, and previous experience of refractory issues.

However, this approach is not data-driven and can lead to critical and dangerous leaks of toxic gases, or an explosion resulting in plant damage, income loss and in the worst case, injury to personnel.

Additionally, the thermal inspection of industrial kilns is, in many cases, carried out only rarely or sporadically. This means that trends indicating deterioration of the furnace condition are not identified, while signs of increasing leaks or damage to the refractory are either not recognised or are recognised too late.

The continuous maintenance and monitoring of vessels and furnaces are therefore essential to production reliability and a plant’s throughput.

Undetected faults or leaks not only consume unnecessary energy and increase costs, but can negatively affect the process, allowing unwanted gases to penetrate the process, and can lead to higher emissions from the process. This may

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LIFE OF A FURNACE

lead in turn to a failure to comply with environmental regulations, which could result in significant financial penalties.

A thermal imaging solution Automated monitoring of the temperatures at critical areas on the shell enables their condition and safety to be continuously assessed to avoid leaks or identify dangerous outbreaks.

The most effective solution for monitoring the outer shell of an industrial furnace or kiln is to use a fixed thermal imager which can continuously measure the shell temperature.

Portable measurements only record the temperature at specific points, and so rely on the operator for adequate coverage of the exterior. A stationary thermal imaging camera, however, allows a continuous view of the entire target at any distance.

Thermal data generated by the camera is presented in real-time, which makes it faster and easier to detect anomalous hot spots, alerting plant staff to take immediate action.

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LIFE OF A FURNACE

In addition to providing a fast-response safety monitoring system, the imager also supplies the thermal data necessary to detect damage or wear to the refractory lining at an early stage.

This allows corrective maintenance to be scheduled at the least disruptive times.

Using the LWIR-640 thermal imager AMETEK Land recommends the advanced LWIR-640 long-wavelength thermal imager for this application, together with options for industrial cooling and a protective enclosure.

38 Furnaces International June 2022

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Atmosphere furnaces for metal heat treatment Bell type furnaces line SOLO® Profitherm

www.soloswiss.com

Max. temperature 1050°C, max. load 500 kg

Processes: carburizing, carbonitriding, hardening, tempering, annealing, nitriding, brazing, oxydation, oil/salt/water/polymer/gas quenching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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LIFE OF A FURNACE

It combines high-resolution radiometric camera technology with sophisticated data processing and powerful software support, delivering detailed thermal images with unrivalled precision.

LWIR-640 thermal imagers offer temperature measurements from -20 to 1000 °C (-4 to 1832 °F) in three ranges with a choice of different optics and lenses.

An integrated webserver with multiple I/O options means the camera may be used autonomously or easily integrated into a new or existing process control system. This web server provides easy camera access, control and setup, using a standard browser.

The LWIR-640 measures and streams live true-temperature images at up to 60 frames per second, providing high-precision temperature measurements and thermal profiles to continuously control, document, and visualise industrial processes.

Depending on the furnace design, the camera locations and fields of view are selected to monitor most of the critical outside shell of a furnace, allowing detection of evolving hot spots at an early stage.

The online camera images can be monitored, and pre-alarms and high alarms are clearly reported to the control system and the furnace operator.

The LWIR is supported by IMAGEPro AM asset monitoring software, specifically designed by AMETEK Land for continuous monitoring of the shell temperatures of critical vessels and furnaces.

Based around the IMAGEPro Windows PC software system, it reliably recognises and captures changes and trends, initiating appropriate early warnings and alarms. It can monitor and control up to sixteen imagers, offering real-time analysis of thermal

40 Furnaces International June 2022

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LIFE OF A FURNACE images.

Alarms and change rates are logged in the integrated database

tifying problematic areas of the shell at an early stage, and

and monitored in the trend view function. For single-camera in-

allowing early repairs can be

stallations, the camera’s on-board alarming and I/O functions can

carried out at a convenient

be used for stand-alone furnace monitoring applications, too.

time, minimising the risk of further damage to the furnace,

Conclusion By introducing a thermal imaging system to monitor their furnace

and break-outs.

Additionally, it allows op-

or other critical vessels, operators can effectively lower their

erators to evaluate different

energy consumption, reducing waste energy and costs. They can

refractories to assess their

also support their decarbonisation goals by reducing harmful

effectiveness. �

emissions of carbon dioxide.

Thermal imaging also supports maintenance and safety, iden41 www.furnaces-international.com

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LIFE OF A FURNACE

Lightweight, high-strength aluminium is as strong as steel and only 40% of the weight, providing a power-to-weight ratio that increases safety, productivity and ROI.

Stealing back profits wit Bricking Machines Heather Harding* 42 Furnaces International June 2022

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LIFE OF A FURNACE

To minimise profit-stealing downtime, plant managers need reliable, efficient maintenance methods that get production back up and running quickly. This requires the right equipment — made from the best materials.

Bricking machines, suspended platforms and kiln access ramps safely speed up the refractory installation process, saving thousands of dollars in lost revenue. These useful tools are available from equipment manufacturers but can also be engineered in-house.

Small differences in construction and materials can add up, though, so it’s important to thoroughly consider all op-

th Aluminium

tions.

For many cement and lime producers, using their in-house engineers to construct kiln maintenance equipment made from steel is the go-to material because it is readily available.

*Managing director for Bricking Solutions, a world leader in kiln refractory installation solutions.

However, there are more efficient materials.

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LIFE OF A FURNACE

Lightweight, high-strength aluminium, for example, isn’t typically used by in-house engineers, but offers productivity and safety benefits that make it an ideal choice for kiln maintenance equipment construction. This material is as strong as steel and only 40% of the weight, providing a power-to-weight ratio that increases safety, productivity and ROI. Partnering with an equipment manufacturer that uses highstrength aircraft-grade 6061-T6 aluminium can be the best choice for a facility’s bottom line and efficiency. Here’s how.

Get Going Fast With every minute of downtime leading to a loss in revenue, the performance of a bricking machine or kiln access ramp during refractory installation is a manager’s top concern. Setup and teardown times are equally important when it comes to overall productivity. Getting crews in and out faster requires a machine that is just as easy to put together as it is to remove once the job is done. Much of this comes down to construction materials: heavier materials — like steel — simply take more time and energy to erect.

For example, a steel kiln access ramp can take a full crew 6 to 12 hours to assemble, increasing downtime both before and after maintenance and negatively impacting cost efficiency.

The weight of the steel components also requires the use of heavy-duty equipment and complex hoists and rigging methods, increasing cost and risk of injury.

A similar ramp manufactured with lightweight, heavy-duty aluminium can be assembled in as little as 1.5 hours — depending on burn floor configuration — with a small crew and only light 44 Furnaces International June 2022

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MOTING PRO TH

YEA R

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FOR MOR ET TRY US

INIUM IN LUM D EA

CONNECTING THE INTERNATIONAL ALUMINIUM INDUSTRY Published six times a year, Aluminium International Today is dedicated to the production and processing of aluminium.

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LIFE OF A FURNACE 46 Furnaces International June 2022

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LIFE OF A FURNACE

equipment, such as a forklift. Maintenance equipment that em-

The result? Custom engi-

ploys a modular design can further increase installation efficien-

neered bricking machines with

cy. These lightweight components can be transported into the

a 3-to-1 safety factor. Crews

kiln by just one or two people and can be quickly erected using

with that kind of assurance can

pin connections, rather than nuts and bolts. By eliminating the

work with confidence know-

need for extra equipment and manpower in the assembly pro-

ing their bricking machine, kiln

cess, aluminium ramps, bricking machines and platforms increase

access ramp or work platform

productivity and safety while reducing overall costs with every

can comfortably handle heavy

setup and teardown.

loads.

More Durability = More Productivity

Greater Profits

In addition to faster setup, plants will see increased durability

When it comes to increasing

from high-strength aluminium kiln maintenance equipment. With

efficiency during refractory

equal strength and significantly less weight, equipment manu-

installation — and in other

factured with aircraft grade aluminium offers some of the high-

areas of kiln maintenance —

est load capacities on the market. Some custom-made bricking

strong, lightweight aluminium

machines can hold as much as 6,000 kg (13,200 pounds) with an

equipment is an easy decision

optional capacity upgrade, allowing them to easily handle three

for plants looking to minimise

full pallets of brick. This is up to twice the capacity of the alter-

downtime and get processing

native steel machines — maximising productivity without risking

back on track. �

safety.

Industry-leading specialty manufacturers who incorporate high-strength aluminium into their kiln maintenance support equipment designs do so because of its increased load capacity over other metals. These companies use certified engineers and aluminium welders to ensure their products address the unique needs of each kiln site. The products are manufactured to international safety standards and are subjected to rigorous safety tests to ensure the materials and designs won’t falter even when working at capacity.

left image: With equal strength and significantly less weight, equipment manufactured with aircraft grade aluminium offers some of the highest load capacities on the market.

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NEWS GREENER FURNACES

Groupe Pochet plans electric furnace at French glassworks

French luxury glass bottles manufacturer Groupe Pochet plans to invest in an electric furnace at its Guimerville plant.

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The furnace will be operational by the end of 2024 and is part of Groupe Pochet’s global decarbonisation plan, which aims to reduce CO2 emissions by 50% by 2033.

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Courval’s Director of Operations.

48 Furnaces International June 2022

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NEWS GREENER FURNACES

NEG successfully melts glass with hydrogen

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Nippon Electric Glass (NEG) has succeeded in melting glass with combustion technology using a hydrogen-oxygen burner.

The company has demonstrated the melting of glass using hydrogen fuel from a hydrogen-oxygen combustion burner, developed in collaboration with Taiyo Nippon Sanso Corporation.

The newly developed hydrogen-oxygen combustion burner can change the mixing ratio of natural gas and hydrogen as appropriate.

In the demonstration, it was confirmed that in either combustion method used, only hydrogen or a mixture of hydrogen and natural gas, a melting capacity equivalent to that from natural gas combustion could be obtained by adjusting the flow rate of fuel according to the mixing ratio.

This enabled oxygen combustion technology and hydrogen combustion technology to be combined, thereby resulting in zero CO2 emissions from combustion.

Oxygen combustion technology removes more excess nitrogen than air combustion, thereby reducing the amount of exhaust gas/heat. It has been introduced in almost all melting furnaces of the company.

State of Combustion: (see image below) For glass melting, NEG promoted the switching of fuel from heavy oil to LPG and natural gas, which generate less CO2, and completed the

conversion to natural gas in 2010.

The company has set the “promotion of carbon neutrality” as a priority measure and is working on the technological development of CO2-free fuels, such as hydrogen, to achieve carbon neutrality by 2050.

Hydrogen-oxygen combustion technology is expected to contribute significantly to carbon neutrality through its combination with the power ratio of melting energy, which the company has been working on for some time.

The company will continue to develop the technology toward application as a mass production process.

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NEWS GREENER FURNACES

Innovative charging, melting and e stirring solution for Arvedi’s EAF Leading metals industry suppliers ABB and Tenova have now obtained final acceptance from their customer Acciaieria Arvedi, after partnering to deliver an innovative technology package, enabling optimal charging, melting and electromagnetic stirring for the world’s highest-yielding EAF. The powerful solution combines a Tenova Consteel® EAF continuous scrap charging system with Consteerrer®, a model of the well-established ABB ArcSave® electromagnetic stirrer designed specifically continuous charging EAF systems.

The record-breaking electric arc furnace has a 300-ton tapping size and utilises a charge mix which include Hot Briquetted Iron (HBI). It was installed to meet the demand for increased output following the recent revamp of the continuous Endless Strip Production (Arvedi-ESP) casting and rolling mill line at the plant.

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“We’re really thankful for the seamless collaboration between Tenova, ABB and the Arvedi technicians and site personnel, and for the great efforts our teams have made during this world-class project. We’re very proud of the contribution our technologies are making to Acciaieria Arvedi’s ambitions as a steel industry trailblaser,” said Silvio Reali, Tenova Senior Vice President.

“The metals industry is essential for the transition to a net zero world.

Working together on this milestone project will support Acciaieria Arvedi to have one of the most sustainable, efficient and modern steel operations,” said Zaeim Mehraban, Global Sales Manager, Metallurgy Products at ABB. “We are already working with a modern plant based on Arvedi patented technologies, fulfilling productivity, technological, environmental, and safety objectives. An important achievement has now been reached on the melting side thanks to the work with our partners Tenova and ABB,” said Andrea Bianchi, R&D Director at Acciaieria Arvedi. “We are showing that it is possible to produce high-quality steel for our customers with the highest output from a single EAF, reducing the resources and the energy we need to use, and minimizing CO2 emissions.”

Acciaieria Arvedi chose Tenova Consteel® EAF for the second time in 2018, strengthening the plant supplied in 2008. The new installation, built to comply with the higher productivity of the recently improved continuous casting and rolling line, takes into account the requirement for increased productivity and operational flexibility, particularly in relation to the metallic charge mix that is of strategic importance in the EAF process.

The careful design of the equipment and the operational results achieved demonstrate the reliability of the technology involved and the

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NEWS GREENER FURNACES

electromagnetic validity of this approach for the safe production of steel with minimal environmental impact. The new electric arc furnace has a diameter of 9.1 meters and is continuously fed by a Consteel® conveyor and the latest generation of Tenova injection system. A plant of advanced and innovative technology, as demonstrated by the integration, since the beginning of the project, of the Consteerrer® system designed in collaboration between ABB, Arvedi and Tenova.

At the core of Consteerrer® is a unique, patented, non-contact electromagnetic stirring technology that has repeatedly been shown to deliver a wide range of metallurgical improvements. Site results confirm that the Consteerrer® electromagnetic stirring system has delivered a range of process improvements, thereby increasing EAF productivity, energy and resource efficiency at Acciaieria Arvedi. These include an 18 degrees Celcius lower tapping temperature and a 3.6 percent reduction

in electrical energy consumption resulting in a 38,000-tonne annual reduction in CO2 emissions at the plant. EAF productivity has increased by 5 percent and final oxygen content in the EAF steel has decreased by 17 percent.

Other benefits can be seen in increased scrap yield, reduced electrode use, lowered refractory wearing, reduced carry-over slag while processing is more stable and final tapping conditions more easily controlled.

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GREENER FURNACE

15th Feb 2022 St Helens MBC at NSG Pilks Greengate site

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GREENER FURNACE

Pilkington’s renewable furnaces

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GREENER FURNACE

With a global shift towards greener manufacturing, Pilkington United Kingdom Limited, part of the NSG group, has taken steps to further their commitment in sustainable production. Pilkington has become the world’s first flat glass manufacturer to fire its furnace on 100% biofuel, as part of an industry trial to find sustainable alternatives to natural gas, and has also announced developments regarding their Hydrogen powered furnace.

Biofuel trial by St Helens glass giant marks new world-first towards decarbonisation A sustainable biofuel made from organic waste materials powered the St Helens glass manufacturer’s furnace entirely for four days, creating 165,000 m2 of the lowest carbon float glass ever made. The fuel emits circa 80% less CO2 than traditional natural gas used in the sector.

The trial forms part of a £7.1 million project led by industry research and technology organisation Glass Futures, working under the Department for Business, Energy and Industrial Strategy’s Energy Innovation Programme. It aims to demonstrate that the furnace could run safely at full production on the low-carbon fuel without impacting product quality.

Neil Syder, managing director at Pilkington UK, said: “Our world-first trial with Glass Futures proves how biofuel presents a realistic low-carbon alternative to natural gas, which will allow manufacturers to cut thousands of tonnes of CO2 from their production years ahead of alternative zero-carbon options becoming more readily available.

“Last Summer, we became the first glass manufacturer in the world to fire a furnace with hydrogen, which represented a major 54 Furnaces International June 2022

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GREENER FURNACE

step forward towards our future as a net-zero industry. But a significant body of work remains before hydrogen and electrification become feasible alternatives to natural gas for glassmakers, making biofuels an important transitionary fuel.

“The success of this trial is also important for the many sectors that rely on glass as an integral supply chain material. We’re now far closer to glass with less embodied carbon being accessible, which will help developers to create a more sustainable built environment.”

In a glass furnace, burning gas is pumped into a 20-metre-long chamber to heat it to 1,600 degrees celsius, causing raw materials including sand and recycled glass to melt to the consistency of treacle. This is then floated on top of a bath of molten tin, making the glass perfectly flat before being cooled.

Aston Fuller, General Manager at Glass Futures, said: “It is great to see a technology demonstrated on a container furnace one year ago be adopted onto a float line just one year later. Bio-

Pilkington tour for DGA Roadshow

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Furnaces International June 2022

GREENER FURNACE Steve Rotheram visiting Pilkington UK HyNet project

fuel represents a real short-term opportunity for the UK glass sector to lead the way in sustainability among energy intensive industries, and this trial is another great example of what can be achieved when industry, academia and public partners work together to tackle the major challenges and opportunities of the future.”

Energy & Climate Change Minister Greg Hands said: “These fuel switching trials, backed by over £7 million in government funding, demonstrate how we are supporting industry to decarbonise and move away from relying on fossil fuels. This is vital to reducing emissions and driving forward the UK’s green industrial revolution.”

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Speaking at a recent site visit, Councillor Mancyia Uddin, St Helens Borough Council’s Climate Change Champion, said: “It was an honour to be invited to this demonstration in what was another world-first here in St Helens - the home of glass - to see how biofuel can become a sustainable alternative to natural gases, cutting CO2 emissions from the glass making process by an incredible 80 percent.

“As a council that has set its own targets to become net zero by 2040, it’s great to see how industries are playing their part to cut carbon from everyday use, and we will continue to work closely alongside them to achieve this.”

In 2022, Pilkington UK marks 70 years since Sir Alastair Pilkington first began working on the float glass process from the company’s base in St Helens. The United Nations is also recognising 2022 as the International Year of Glass, celebrating the past, present and future of the material.

Architectural glass production powered by hydrogen in world first Following a world-first trial, Pilkington has successfully manufactured architectural glass at ait St Helens facility using hydrogen power.

Pilkington UK fired hydrogen on its glass furnace in August 2021 in a world-first trial as part of the ‘HyNet Industrial Fuel Switching project’ to decarbonise industrial processes across the North West of England. By 2030, it is expected to cut 10 million tonnes of carbon per year – the equivalent of taking four million cars off the road.

In February 2020, the HyNet project was awarded funding of 58 Furnaces International June 2022

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Energy & Climate Change Minister Greg Hands said:

“These fuel switching trials, backed by over £7 million in government funding, demonstrate how we are supporting industry to decarbonise and move away from relying on fossil fuels. This is vital to reducing emissions and driving forward the UK’s green industrial revolution

”

£5.3M from BEIS through its Energy Innovation Programme.

The trial to create architectural glass was a key step in the manufacturer’s plans to decarbonise and could see a transition to using hydrogen to power all production at the site, which currently uses natural gas. The switch means that the float glass furnace – which accounts for the majority of the company’s overall carbon emissions – would be able to run with hugely lower emissions.

The aim of the trial was to demonstrate that the furnace, in which the raw ingredients of the glass are heated to around 1,600 degrees centigrade, could run safely at full production without impacting product quality.

Matt Buckley, UK MD of Pilkington United Kingdom Limited, part of the NSG Group, said: “The trial was a significant success.

Thanks to NSG’s advanced fuel combustion expertise, and the preparation and efforts of the team, we managed to achieve a seamless transition between the two different fuels. It proves that hydrogen is just as capable as natural gas in achieving excellent melting performance, and that it could be possible to operate the furnace with vastly reduced carbon emissions.

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“Decarbonisation of the construction supply chain is a vital part of the UK’s ambition to achieve net-zero by 2050, and the ability to produce float glass in this way is an important step in this journey.

“It was in St Helens that the float glass process was developed in 1952, revolutionising how glass is made around the world.

Now, 70 years later, this trial represents another major milestone for the global glass industry and it’s appropriate that it has once again been pioneered here.”

David Parkin, Director of Progressive Energy and Project Director of HyNet North West said: “Industry is vital for the economy but is difficult to decarbonise. HyNet is focused on removing carbon from industry through a range of technologies including the capturing and locking up of carbon and the production and use of hydrogen as a low carbon fuel.

“This trial at Pilkington UK is a significant step in demonstrating that is it possible to use hydrogen to power glass production and provides a valuable blueprint for further trials and implementation.”

The three-week trial on the float glass line used approximately 60 road tankers of hydrogen, but the longer-term plan is to create a network of hydrogen pipelines to supply key industrial sites, avoiding the need for road transport.

�

For more information, visit: https://www.pilkington.com/en-gb/uk 60 Furnaces International June 2022

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CONNECTING THE GLASS MANUFACTURING INDUSTRY MAGAZINE

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Vol.42 No.3

March 2019— TIONAL.COM

S-INTERNA

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Reducing energy waste in EAFs

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On average, every tonne of steel produced in 2020 led to the emission of 1.851 tonnes of carbon dioxide (CO2) into the atmosphere. In that year, 1.86 billion tonnes of steel were produced, and total direct emissions from the sector were approximately 2.6 billion tonnes, representing between 7% and 9% of global manmade CO2 emissions.

By Peter Unwin*

These astounding figures from the World Steel Association reveal that the global steel industry currently faces a huge decarbonisation challenge, driven by more stringent carbon emission regulations, growing customer demand for carbon-friendly steel products, and increasing investor interest in sustainability.

The cost is not purely environmental; according to a McKinsey report, approximately 14% of global steel companies’ potential value is at risk

* Global industry manager – metals, Ametek Land

if they are unable to decrease their environmental impact, making decarbonisation a high priority.

There is no single solution to carbon reduction in steelmaking; several changes to existing practices can each make a significant contribution to decarbonisation in the industry.

One such change is to move from using a basic oxygen furnace (BOF) to an electric arc furnace (EAF) route for 63

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steelmaking.

In an EAF, steel is produced from recycled scrap and direct-reduced iron (DRI). The need for high-quality scrap may limit the use of EAFs and increase costs. However, mixing lower-quality scrap with DRI is a cost-effective option, while DRI alone generates less carbon dioxide than integrated methods. In addition, the EAF can, potentially, be used with hydrogen fuel for nearly emission-free steel production.

How the EAF operates The EAF uses vertical graphite electrodes to melt the iron and scrap via electric current. Metal is added, the lid is closed, and an arc is created between the electrodes.

A huge amount of power is used by the process, so it is of64 Furnaces International June 2022

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GREENER FURNACE ten scheduled to operate during times of low energy demand.

Limestone flux is added and then a ladle vessel is positioned underneath, before a hole in the base of the furnace opens, and the molten steel exits into the ladle. The hole closes when slag is detected or when the ladle is full.

The steelmaking steps for an EAF are: �

Charging scrap metal, iron and limestone.

�

Lowering the electrodes, melting the metal with electric

current. �

Oxidation.

�

De-slagging.

�

Adding new fluxes for the reducing stage to eliminate

sulphur and oxide absorption. �

Tapping.

65

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�

Lining maintenance to eliminate molten steel break-outs

from excessive lining depletion.

Molten steel is tapped at regular intervals. Accurate temperature monitoring ensures steel quality is consistent and improves process efficiency.

While it seems that the steps are straightforward, detecting slag and keeping it from degrading the steel is both an art and a science, and the detection methodology has evolved significantly over time.

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GREENER FURNACE Slag carryover Regardless of furnace type, a molten liquid melt of silicates and oxides – known as slag – is produced during the separation of molten steel from the impurities that are found in iron ore and scrap metal.

The slag solidifies upon cooling, and needs to be removed, as its impurities degrade steel. For example, slag will pull phosphorous from iron and, if not removed, the phosphorus reverts back into the steel, lowering its quality.

The disadvantages of slag carryover in the EAF are exactly the same as those in the BOF: longer processing time, high inclusion formation and steel cleanliness challenges, difficulty in ladle desulphurisation, caster nozzle clogging, and ladle refractory wear. www.furnaces-international.com

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Substantial wear and tear Slag also causes substantial wear and tear on the vessels involved. Its removal can require huge effort and expense on the part of steel producers.

Molten steel is tapped from the EAF vessels into transfer ladles for further refinement of the steel and it is important to prevent slag carryover during this tapping process, by stopping when slag begins to exit along with the steel.

Recent advances in detection now mean that slag can be more reliably and effectively managed.

Technologies to prevent slag carryover Early methods for preventing slag carryover included visual observation, using a ceramic dart to reduce slag flow, and utilising a circular induction coil. However, each of these methods has drawbacks for safety, reliability, and/or efficiency.

Thermal imaging cameras were introduced to improve the process two decades ago, and offer cost and repeatability benefits.

Since steel and slag have different emissivities, a thermal image of the tapping stream, displayed in a control room, will enable operators to recognise the change in brightness very easily and detect when slag begins to appear.

Good results The early devices were all long-wavelength thermal imagers with an 8-14 μm response. The results were good, as the emissivity between steel and slag is accentuated by the long wavelengths.

However, there was still fume obscuration, and the optical materials used were not sufficiently durable for the harsh envi68 Furnaces International June 2022

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GREENER FURNACE

ronment, requiring frequent protective window or lens replacements.

Mid-wavelength thermal imagers offered several new possibilities. A thermal imager working at a more narrow, 3.9 μm waveband can see through hot CO2 and hot water vapour.

This shorter waveband also enabled the use of more practical optical systems using, for example, sapphire protection windows which offer good transmission characteristics from ultraviolet to approximately 5.5 μm in the infrared alongside high durability and chemical resistance.

Hot water vapour or steam and hot CO2 appear in large quantities in the atmosphere around the tapping stream, each having characteristic absorption lines at different wavelengths.

When these lines are combined on the same graph, images from an infrared camera with a spectral response around 3.9 μm are much clearer than those of a camera with a spectral response of 8 to 14 μm.

A specially designed solution These capabilities are built into the AMETEK Land Slag Detection System (SDS), which delivers improved yields, higher-quality steel, and reduces costly downstream processing for EAF steelmaking operations. It is specially designed to withstand the harsh conditions of continuous operation in a steel plant, with minimal maintenance requirements.

The AMETEK Land SDS has an industrial thermal imaging sensor, housed in a rugged, water-cooled and air-purged enclosure, that continuously views the tapping area. As the tap begins, dedicated software automatically records it, producing a log and 69 www.furnaces-international.com

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graph of the relevant steel and slag data.

The high-resolution thermal imaging camera detects the transition between steel and slag, reducing ‘blackouts’ caused by smoke and fumes. Real-time data enables the operator to make informed decisions about the tapping process.

When the slag reaches a pre-determined level, an alarm is generated to stop the tap. Full access to the tapping data is available to the operator for quality control purposes. By warning the operator in a dependable, repeatable and timely manner to stop the tap before slag is carried over, the SDS improves production yields and ensures a lower slag content, improving the steel’s quality. This also reduces energy costs further along the process and lowers the overall maintenance on the furnace vessel.

Using an SDS has been shown to improve operator response time and consistency at the end of each tap. This results in a typical reduction in slag depths of up to 25%, compared to traditional methods for monitoring slag.

Greater detail The new SDS camera has a resolution of almost 300,000 individually calibrated temperature measurement points, providing much greater detail in the image. Combined with the clarity of view through the smoke, this offers a much-improved performance compared with other cameras.

In addition, new IMAGEPro-SDS application software provides improved images for the operator with the additional capability to automatically track the pouring stream within the field of view (Fig 3). When viewing the stream from an acute angle, its position will change during the different phases of the tap and the software 70 Furnaces International June 2022

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Efficient and productive

place, only measuring from the area identified as the stream. This

By making EAF steelmaking

reduces any errors caused by background heat sources in the field

more efficient and productive,

of view.

AMETEK Land’s SDS thermal

As well as detecting slag while tapping steel, the SDS can

imaging system helps to miti-

detect steel as it appears during the de-slagging operation. De-

gate the operating costs of the

pending on each location this can sometimes be achieved with

EAF in steelmaking, protecting

the same camera but if not possible then a second camera may

the investment in this growing

be required.

decarbonisation technology.

The improved image quality, with a larger field of view, is a ben-

Seeing through most of the

efit to the operator for judging when the transfer ladle is full of

smoke, it provides a reliable

liquid steel. This enables the tapping operation yield to be opti-

and effective method of de-

mised and reduces the risk of molten metal spillage. In locations

tecting slag during tapping,

where the camera cannot view the ladle freeboard, a second

and can be used to detect

camera can be provided and the image included on the same

steel in slag during the de-slag-

operator’s monitor using standard IMAGEPro software to provide

ging operation.

regions of interest with alarms.

GREENER FURNACE

accurately tracks any movement that may occur as the pour takes

It uses non-contact infrared technology with no wearing

Significant investment

parts or consumables, and low-

Switching to an EAF for steel production is not an immediate

ers operating costs by reduc-

panacea for achieving decarbonisation. It is a significant capital

ing slag levels and improving

investment that also places an increased draw on the electric

tapping yield, together with

grid supply.

generating savings on addi-

Nonetheless, as decarbonisation gathers momentum, the

tions during steel refinement. �

electric furnace route is likely to become the preferred choice for steelmaking around the world.

According to McKinsey and Co, an approach combining scrap, DRI, and EAF using hydrogen fuel is currently considered the most viable, long-term solution to achieving carbon-neutral steel production, especially in Europe.

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