Furnaces International September 2019

PROJECTS & PRODUCTS

CASTHOUSE TECHNOLOGY

INDUSTRY 4.0

www.furnaces-international.com

SAFETY

SEPTEMBER 2019

Contents

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

Production Editor: Annie Baker

Sales/Advertisement production: Esme Horn esmehorn@quartzltd.com Tel: +44 (0) 1737 855136

Sales Manager: Nathan Jupp

2

Projects & Products

Sustainability 13 Sustainability at the heart of Aludium

nathanjupp@quartzltd.com +44 (0) 1737 8555027

Manuel Martin Quereda manuelm@quartzltd.com +44 (0) 1737 855023

Access ramps 14 Custom-Engineered Kiln Access Ramps Casthouse technology 22 New possibilities in metal transfer and furnace automation Industry 4.0 29 GHI invests in 4.0

Subscriptions: Elizabeth Barford subscriptions@quartzltd.com

Blass furnace 30 Dry blast furnace gas cleaning technology for thermal energy beneďŹ ts

Managing Director: Steve Diprose Chief Executive Officer: Paul Michael

Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000.

Email: furnaces@quartzltd.com www.furnaces-international.com

Furnaces International is published quarterly and distributed worldwide digitally

Š Quartz Business Media Ltd, 2019

Furnaces International September 2019

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Comment

No matter how much we grow up, September always has a feeling of going ‘back to school’ about it. The mornings have more of a nip in the air, but the beginning of a new season is a favourite of mine.

It is certainly business as usual with this issue and it is packed with technical features and projects & product news from across the glass, steel, aluminium and materials industries.

Corundum growth 32 Conquering the aluminium furnace corundum

A serious issue of our time is molten metal explosions, especially in aluminium manufacturing. In a dedicated feature

Melting 34 Material mix: Simultaneous melting of aluminium chips and ingots

by Alex Lowery, we look at a series of casthouse explosions that all occurred across a 10-month period in Europe, China

Crucibles 37 ‘Game-changing’ crucible VAIuStarTM launched for aluminium casting process

and Japan. This article highlights the possible causes and the precautions that need to be taken when working in these

Safety 38 Preventing molten metal explosions

conditions.

Following in our quest to bring you all the latest Industry 4.0 and automation updates, we also have a dedicated article from Dynamic Concept, which looks at new possibilities in metal transfer and furnace automation.

I hope you enjoy the issue and as always, I am happy to hear from any readers who would like to submit an article for consideration. You can find out more online or contact me on the email address below.

Nadine Bloxsome. Editor, Furnaces International E: nadinebloxsome@quartzltd.com W: www.furnaces-international.com 1 Furnaces International September 2019

Projects/Products

FOCU SMS G

SPANISH STEELMAKER UPGRADES WALKING BEAM FURNACE Sidenor Basauri of Spain is planning to upgrade its walking beam furnace with a view to increasing its capacity from 85 tonnes/hr to 130 tonnes/hr.

The furnace was supplied by SMS group in 2016 and originally designed with a capacity increase in mind: Engineers had

already taken into consideration all civil and mechanical modifications required for the future capacity boost in order to guarantee a short plant shutdown and a fast restart. It is hoped that the plant will be restarted some time in H2 2020.

The upgrade will require SMS group

to supply new steel structures with a set of ZeroFlame extra-low NOx burners (already included at stage 1) and designed to emit pollutants of less than 100mg/Nm3 at 1,250 C – meeting stringent European guidelines, claims the company.

For additional information contact www.sms-group.com

LUZHOU XINYANG ORDERS TWO ZERO-BUCKET UHP EAFS Offering excellent performances and the lowest CO2 emissions, Danieli Zerobucket EAF is spreading in China.

Luzhou Xinyang Iron and Steel selected Danieli Zero-bucket EAF technology for two new electric arc furnaces to be installed in the new meltshop in Luzhou City, Sichuan Province, China The two new 100t UHP Ultra-High

Power furnaces feature Danieli original ECS Endless Charging System for continuous scrap charging and preheating.

Each furnace will be equipped with a chemical package based on M-One combined Carbon and Oxygen injectors, and side Palmur lance with dynamic position based on steel level.

More technological packages such

dynamic spray for electrodes, energy saving double layer Q-panel, automatic sampling and automatic tapping systems will allow Luzhou Xinyang to have reduced consumption and higher safety.

EAF startup is expected by beginning of August next year.

2 Furnaces International September 2019

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Projects/Products

NEW WALKING BEAM FURNACE FOR MEGASA

US ON GROUP

For additional information contact www.sms-group.com

And talking of walking beam furnaces, the MEGASA Group has approached SMS group for a brand new one to be installed in the company’s existing bar mill, SN Seixal Siderurgia Nacional in Portugal.

The new furnace is rated at 160 tons/ hr cold-charged and 210 tons/hr hotcharged, claims SMS group. It should be up and running by the end of summer 2020.

The furnace will rely upon SMS

group’s Prometheus Level 2 system, the company’s DigiMod combustion management system and its ZeroFlame burners. SMS believes that by using the combination of these three systems, the furnace ‘will ensure outstanding performance in terms of reductions in fuel consumption, scale formation and pollutant emissions’. They will also lead to reduced NOx emissions (down to 90mg/Nm3), less scale formation (down to 0.4%) and reduced fuel consumption

to less than 27 Nm3/tonne.

According to SMS group, MEGASA will consolidate its leading position in the construction steel market with this investment.

The furnace will be able to reheat billets starting from as slender as 120mm up to 160mm in various lengths of up to 14.5 metres.

The project will be turnkey in nature, including erection, supervision and commissioning.

For additional information contact www.danieli.com 3 www.furnaces-international.com

Furnaces International September 2019

Projects/Products

COGNOR CONTRACTS FIVES FOR FURNACE RENOVATION Polish steel producer Cognor SA has contracted Fives to implement the renovation of a reheating pusher furnace at its Krakow plant. The steelmaker was looking to improve furnace performance, both in terms of production availability and operational cost reduction.

The existing furnace, with an initial production capacity of 90 tons/hr, is integrated into a rolling mill producing merchant bars and rebars. Over recent years, the plant has experienced difficulties with operating the furnace sustainably at the designed production rate. Furthermore, the furnace required frequent maintenance and consumes an excessive amount of gas. The project faced a technical constraint inasmuch as the furnace foundation could not be

modified. Therefore, the dimensions of the furnace have to remain the same. Fives claims it was the only company capable of offering its proprietary technology to sustain production capacity at reduced operational costs and with the same footprint.

Fives further claims that in order to ‘significantly improve furnace performance’, it will use its AdvanTek proprietary combustion system technology, which fully separates the burner capacity control and flame length control. It is also the only combustion technology that operates the burners at the optimum capacity at any production rate and operating conditions, says Fives.

As a result of this renovation, pusher furnace capacity will be sustained at the

designed level. The operational costs will decrease thanks to a 25% reduction in fuel consumption and a 40% decrease in scale. The scope of work also includes repairs of the refractories and steel structures of the soaking zone.

Work is planned to start in March 2020 with the first hot product being scheduled in Q2 2020.

Fives’ subsidiary in Spain will be responsible for the project. Traditionally, the company specialises in long product thermal solutions globally, but recently, its offering has been expanded through the acquisition of certain activities of RDI-Met, a subsidiary of Fagor Arrasate (Spain). Today it covers mechanical engineering for strip processing lines, including coating lines.

For additional information contact www.fivesgroup.com

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Projects/Products

HEINZ-GLAS’S END-FIRED FURNACE STARTS OPERATION Heinz-Glas has started operation of its Sorg end-fired furnace.

The state-of-the-art furnace replaced the previous incumbent, as it no longer met the necessary standard.

The new furnace has a melting capacity of 150 tpd, and with use of electricity expandable up to 180 tpd.

The furnace, with an STW working end is connected to six STF production lines, two of which are equipped with Sorg colouring forehearths.

The equipment for melting end and forehearths is industry standard, and includes integrated cooling systems designed by Sorg.

The safety technology is said to be at the highest level of DIN/EN 746-2 and was implemented with redundant Sorg gas supply and safety control for melting end and forehearths.

Sorg’s burner holders WSH, modular stirrers as well as the Sorg Conti-Drain were also used.

The completely different furnace concept required extensive construction measures as well as an intervention in the existing structure and was reportedly challenging for everyone involved.

The project was completed successfully on time and with the start of production, the glass quality met the high demands of Heinz Glas and the total energy consumption was lower than specified.

For additional information contact www.sorg.de

SOLAR ATMOSPHERES ADDS ALL-METAL HOT ZONE FURNACE Solar Atmospheres recently installed another unique, all-metal hot zone vacuum furnace at its 1969 Clearview Road facility in Souderton, PA. This is Solar’s third all-metal hot zone furnace installation for their climatecontrolled room. The additional furnace increases Solar’s capacity for processing sensitive materials such as PH stainless, nickel-chrome based superalloys, titanium, and ferritic and austenitic stainless steels.

The placement of isolation valves, an all-metal moly/stainless steel hot zone, and a stainless steel chamber allows this furnace to attain the level of cleanliness mandated by the demanding aerospace and medical markets. The ability to achieve vacuum levels lower than 5 x 10-6 Torr produces clean, bright results without contamination.

BELVAL BLAST FURNACES COME ALIVE IN FIRE AND DANCE

Additionally, this furnace incorporates Solar Manufacturing’s latest SolarVac Polaris HMI control system for complete process automation.

Jamie Jones, President of Solar Atmospheres states: “The increasing demands for cleanliness levels in critical aerospace and medical applications, and the growth in these markets, paved the way for Solar Atmospheres to add capacity through this investment.”

Acrobats ziplined between the two former blast furnaces in Belval recently in a spectacle of dance and acrobatics.

The Blast Furnace Festival is a celebration of the former industrial site with exhibitions, guided tours, music and fire displays.

Taking place just after sunset, performance troupe 'La Salamadre' took to the stage surrounded by wild dancing and fireworks.

The performances gave the Blast Furnace Festival the climactic moment it deserved in celebrating the reinvented landscape of Luxembourg's industrial heartland.

After the blast furnaces shut down in 1997, the government had 120 hectares of land on its hands and transformed Belval into a rejuvenated site with housing, retail businesses and learning centres.

For additional information contact www.solaratm.com 5 www.furnaces-international.com

Furnaces International September 2019

Projects/Products

Bricking Solutions, a full solution provider of refractory installation equipment, is offering the Radialign Laser Alignment Device, which is claimed to increase radial alignment accuracy during refractory installation and, therefore, extend brick life, minimise downtime and reduce mechanical stress on the kiln. Radialign is part of Bricking Solutions’ fullservice product offerings for refractory maintenance.

“The key to efficient refractory maintenance is making sure it’s done right the first time,” said Heather Harding, Bricking Solutions’ managing director.

“Bricking Solutions’ tools ensure accuracy and efficiency for refractory installation.

Radialign helps masons achieve highly accurate measurements in less time than the plumb line method as well as ensure the quality of their work as they move forward for long-lasting results.”

Radialign is described by Bricking Solutions as ‘a cutting-edge replacement for the traditional practice of using radial welds and a plumb line to determine alignment’. According to the company, the latter is ‘a time-consuming method with a high risk of calculation errors due to distorted or worn away weld seams’.

Radialign produces a continuous laser light parallel to the kiln’s axis that is intercepted by a rotating pentaprism device. The laser is refracted perpendicularly onto the circumference of the kiln shell, allowing masons to accurately mark along the kiln before beginning refractory work and creating an exact reference for installation, claims Bricking Solutions.

The precision of the Radialign’s laser and pentaprism, says Bricking Solutions, allows exact placement of each row of brick to be perpendicular to the kiln, reducing wear and extending brick life.

The laser system can be assembled and ready for use in 20 minutes, enabling masons to mark over 100 feet (30 metres) of kiln shell in less than an hour, significantly reducing downtime required by other methods, claims the company.

Additionally, Radialign allows masons to project a display on the kiln surface every five to 10 feet (1.5 to 3 metres) for more accurate marking, compared to the variable spacing between radial welds. “In some cases, Radialign’s accuracy has even identified improperly installed retaining

Title GREATER ACCURACY OFFE

rings that contributed to less efficient refractory installation,” said Bricking Solutions.

The Radialign laser alignment device is comprised of three parts – the laser assembly, pentaprism assembly and

plumb bob assembly. The laser Class IIIA has an effective range of 500 feet (150 metres) and is claimed to be ideal for new refractory installation in rotary kilns 10 feet (3 metres) and larger. It comes with a durable transport box to keep the laser

For additional information co 6 Furnaces International September 2019

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ERED BY RADIALIGN

safe and ensure continued accuracy. The case also contains laser safety goggles, marking card and chalk, rechargeable batteries for both the laser and pentaprism assemblies and an A/C adapter. The device is covered by a one-year limited warranty.

ontact www.brickingsolutions.com 7 www.furnaces-international.com

Furnaces International September 2019

Projects/Products

SISECAM’S FLAT GLASS FURNACE FIRED UP FOR THE FIRST TIME AT VIP CEREMONY Sisecam Group’s €42 million flat glass furnace in Targovishte Bulgaria was fired up at a ceremony on July 2nd.

The ceremony was attended by over 300 attendees. These included Sisecam’s European flat glass customers, architects, sector professionals and government dignatories as well as company employees.

Vice Chairman and CEO Professor Ahmet Kirman stated that the Group had made its first investment in Bulgaria under Sisecam Chemicals since 1997.

He said: “We took our first step for new investments in Bulgaria in 2004.

“Our group laid the foundation for the flat glass, automotive glass and glassware production facilities in 2004.

“With this investment, we were bestowed with the title of the ‘Largest Greenfield Investor in Bulgaria’.

“After the glassware plant commenced production in 2005, our group commissioned the first float line in flat glass followed by the mirror, laminated glass and tempered glass lines in 2006, and put the automotive glass plant into operation in 2010.

“In 2013, the energy-saving coated glass production started. As Sisecam Group, we continue our operations with Trakya Glass Bulgaria EAD, Sisecam Automotive Bulgaria EAD and Paşabahçe Bulgaria EAD as well as Solvay Sodi in which we have ownership interest.”

He concluded: “Our group’s investments in Bulgaria have reached 600 million Euros in total so far.

We will continue our investments in modernisation and capacity increases in our Bulgarian manufacturing facilities.”

The ceremony was attended by the Minister of Economy of Bulgaria Emil Karanikolov, the Member of Paårliament Venka Stoyanova, Targovishte Governor Mitko Staikov and Targovishte Mayor Dr. Darin Dimitrov.

For additional information contact www.sisecam.com.tr/en

FIFTH GENERATION METALS HEAT TREAT MANUFACTURER PARTNERS WITH FURNACE SUPPLIER A fifth-generation furnace manufacturer supporting the metals processing industry recently entered into a strategic partnership with a Floridabased furnace equipment supplier.

Gillespie & Powers Inc., headquartered in St. Louis, Missouri, will continue to offer Remelt Technologies’ homogenizing furnaces, DC casting machines, and DC casting automation to the North American aluminium industry.

“Gillespie & Powers Inc. is proud that Gary Bowden, president of Remelt Technologies, has entrusted them to continue providing equipment and services that will continue this legacy,” said Jack Gillespie, vice president of Gillespie & Powers.

Remelt Technologies, founded and owned by Bowden, has a 26-year history of supplying quality equipment and is involved in the design, manufacture, and installation of homogenizing

furnaces and DC casting machines for secondary aluminium extrusion cast houses.

Gillespie & Powers is a 5th Generation family owned design, build, supplier

of specialized furnaces supporting the metals processing industry. The company has over 80 years of experience in the design, supply, and installation of furnace equipment

For additional information contact www.gillespiepowers.com 8 Furnaces International September 2019

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Projects/Products

NEW FURNACE TECHNOLOGY FOR MATERIAL MIX ZPF, manufacturer of highly efficient aluminium melting furnaces, has developed a melting furnace that melts down aluminium chips as well as recycle material and ingots, ensuring a sustainable utilisation system.

In the past, different shapes of ingots, return material and aluminium chips were melted in different furnace types according to their material. This method does not pay off for die casting foundries with very low volumes of aluminium chips or return material, so only ingots were molten down.

The new plant from ZPF is equipped with an automatic charging system and can melt up to 500 kg of raw material per hour, for eg., 250 kg of aluminium

chips and 250 kg of ingots. The company says its new melting furnace technology will be premiered at GIFA 2019 in Düsseldorf. The production of by-products such as scrap material, runner systems and even aluminium chips are usually collected and recycled externally in most foundries, which are not melted right away for economic reasons. This results in high storage and transport costs, not forgetting the logistics involved. “A material mix of ingots and recirculation aluminium parts was previously only possible to a limited extent because of the desired boundary parameters such as melting loss and melting rate,” Sven-Olaf Sauke, R&D at ZPF notes.

For additional information contact www.zpf-gmbh.de

GLASS SERVICE HOSTS SUCCESSFUL FURNACE SEMINAR Glass Service (GS) held a successful 15th International Seminar on Furnace Design – Operation and Process Simulation.

The event was attended by approximately 150 glass experts from 25 countries including USA, Mexico, Japan, India, Saudi Arabia, Russia, New Zealand and several European nations including UK. Feedback from participants was positive.

In conjunction with the Seminar, the ICG's Technical Committees 15 and 21 held their meetings, while a User Meeting of the GS Glass Furnace Model (GFM) also took place, attended by 40 glass specialists.

The Seminar highlighted the latest developments in furnace optimisation and CO2 reduction with support from simulations and advanced control.

There were contributions from: Johns Manville, Owens Corning, AGC, SEFPRO and FIC UK among others.

It continued on new developments around Industry 4.0 - what it will bring to further automatise and optimise the glass melting process, such as automatic

batch monitoring integration.

The 7th GS Modeling Award was given to Bruno Purnode from Owens Corning. Bruno has made a significant contribution to the use of simulation tools within his company and at conferences globally.

The seminar took place at the Hotel Horal mountain resort in Velke Karlovice, Czech Republic on May 22 and 23.

The event takes place every two years and brings together glass experts from around the world to discuss the use of simulation and control tools, with the goal of optimising the glass melting and forming process. The next event will take place on June 16 and 17, 2021.

For further information, email seminar@gsl.cz

For additional information contact www.gsl.cz

U.S. STEEL TO IDLE FURNACES United States Steel Corp on Tuesday said it would idle two blast furnaces in the United States and a third in Europe, as lower steel prices and softening demand led the steel producer to forecast currentquarter earnings below the Wall Street estimates.

Steel producers in the United States have brought old capacity online after President Donald Trump’s imposed tariffs on imported steel from countries including China, resulting in a surplus supply of steel at a time when manufacturing demand has weakened, suppressing prices.

U.S. Steel said it will also idle one of its blast furnaces in Europe where increasing levels of imports and higher raw material costs are hurting the company’s operations.

“We are idling two blast furnaces in the United States and one blast furnace in Europe to better align our global production with our order book,” U.S. Steel said in a statement.

U.S. Steel will idle a blast furnace at the company’s Gary Works facility in Indiana, where early this year it was negotiating a $47 million tax break package from the city and state in return for promises of modernisation.

The Gary Works facility has four blast furnaces with an annual raw steel production capability of 7.5 million tons.

The second furnace to be idled is in the company’s Great Lakes Works facility, located in Ecorse and River Rouge, Michigan, which has three blast furnaces with annual raw steel production capability of 3.8 million tons.

The company forecast second-quarter adjusted earnings before interest, tax, depreciation and amortization (EBITDA) to be about $250 million, below the average analysts’ expectation of $291.1 million, according to IBES data from Refinitiv.

Shares of steel producers rose earlier in the day after Steel Dynamics Inc’s betterthan-feared results, signaling of rate cuts by the European Central Bank and news of Trump and Chinese President Xi Jinping getting together to restart trade talks.

For additional information contact www.ussteel.com 9

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Furnaces International September 2019

Projects/Products

TWO COMPANIES TO ACQUIRE INDUCTION FURNACE, HEATING SYSTEMS MANUFACTURER

A manufacturer of induction furnaces and heating systems is scheduled to be acquired by two global corporations from a Chicago-based private equity firm.

Mitsubishi Heavy Industries (MHI) and Primetals Technologies will acquire ABP Induction Systems (ABP), which offers a variety of products and services to automotive OEMs and suppliers,

industrial manufacturers, independent foundries as well as steel plant manufacturers and steel producers.

“ABP’s induction heaters are one of the most crucial elements for endless strip production, a flagship process for Primetals Technologies. With ABP becoming one of MHI’s group companies and the further close ties that will bring, we can develop and provide customers with even more advanced technologies,” said Satoru Iijima, Chairman of the Board and CEO of Primetals Technologies.

ABP will be a group company of MHI under the ownership of Mitsubishi Heavy Industries America, Inc., headquartered in Houston, Texas, and Primetals Technologies USA LLC, of Alpharetta, Georgia. The acquisition is planned to close around the end of August 2019.

Tenova was recently awarded an EAF (Electric Arc Furnace) Consteel® Evolution by Sichuan Guanghan Desheng Iron & Steel Co., LTD, in Sichuan Province, China. This contract represents the 14th state-of-the-art EAF Consteel® Evolution project in China, in the last eighteen months.

The shift from BF-BOF (integral steelmaking) plants towards EAF technology, sustained by the reforms of the Chinese government, has led to the demand for advanced equipment and technologies that increase production and provide environmentally friendly solutions.

Tenova EAF Consteel® Evolution offers high quality standards as well as a more environmentally friendly approach to production compared to traditional steelmaking methods.

With more than seventy-five references worldwide, Tenova EAF Consteel® is considered the best available proven technology in terms of balance/mix between innovation, reliability and sustainability.

Safety and increased productivity are enhanced by tailor made solutions in

For additional information contact www.abpinduction.com

REFRACTORY SUPPLIER CELEBRATES MANUFACTURING FACILITY EXPANSION

A supplier of refractory products and services in North America recently celebrated the completion of its phase one facility expansion plan.

HarbisonWalker International (HWI) hosted a ribbon-cutting event at its

manufacturing operations in White Cloud, Michigan, to celebrate completion of the first phase of an expansion that increases the floor space of the facility by 35%. The project is part of a $9 million investment being made this year

to significantly increase warehousing space along with the addition of new, advanced manufacturing and hydraulic press technologies.

“White Cloud is an extremely important facility that has been vital to our company and the community for more than four decades,” said Carol Jackson, chairman and CEO at HWI. “Historically, and especially in the past two years, the team at White Cloud has helped fuel our steel industry customers’ success by consistently delivering on their tremendous demand for the refractory products we produce here. We’re so proud of the great work our White Cloud employees do every day for our company and our customers.”

HWI’s White Cloud operations primarily produces refractory products that are utilised by the steel industry.

For additional information contact www.thinkhwi.com 10 Furnaces International September 2019

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Projects/Products

TENOVA CONTRACTED FOR 14TH EAF CONSTEEL® EVOLUTION IN CHINA For additional information contact www. addition to Tenova standard technologies.

Chinese steel makers are paying more and more attention to these topics in order to stabilising productivity and quality.

“Once again our technologies were

recognised by the client with whom, from the first technical discussion, the co-operation was fruitful and satisfying”, stated Mario Marcozzi, Sales Director in Tenova Metals. “Our previous reference

pays a fundamental role in building this environment of trust. This is in line with Tenova’s top priority: to be a reliable partner and to always improve our service.”

AERO SERVICE PROVIDER RECEIVES UPGRADES FOR FURNACE CONTROLS A US provider of fuel and control systems for aircraft engines recently had its furnace control improved by a company who services the thermal processing industry, helping both furnace OEMs and equipment end users.

Woodward Inc., which develops and delivers motion control and integrated propulsion systems, recently had its vacuum furnace controls and automation platform upgraded by United Process Controls (UPC). The new generation controls provide streamlined reporting for NADCAP compliance as well as seamless integration with the company’s enterprise planning (ERP) system.

In addition to complying with NADCAP, the enhanced controls also meet AMS 2750E specification for thermocouple tracking. Now, the Protherm 710 controller tracks the thermocouple,

its serial number, and usage history; identifies when a thermocouple needs to be replaced based on running hours, days in service, and temperatures reached; and alerts the operator when it’s time to change the thermocouple.

“The workplace at Woodward is top notch. Their commitment to ongoing improvements is an excellent example of a manufacturer understanding the potential of new technology to drive

better overall equipment effectiveness, to maximise furnace availability, and to deliver well-engineered, quality products.

UPC process controls and control systems add more automation and real-time visibility of production, which will ensure that furnaces continue to operate at maximum efficiency for years to come and at the same time uphold Woodward’s high quality standards of its operations and products,” said Jason Walls, UPC engineer responsible for the Woodward project preparations and start up.

Future upgrades of furnace controls and automation are planned at Woodward, and UPC will participate by supplying Protherm series and Atmosphere Engineering series process controllers and connecting them into the SCADA platform.

For additional information contact www.woodward.com 11 www.furnaces-international.com

Furnaces International September 2019

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Sustainability

Sustainability at the heart of Aludium Aludium was founded at the beginning of 2015 from the Spanish-French rolling assets of Alcoa. While sustainability was already a key focus in these facilities, we knew that we needed to develop our infrastructure and company culture to put sustainability at the core of our business choices.

Environmental sustainability was a key focus from day one. The management team and the Board worked out an investment plan which would allow Aludium to recycle more scrap in our own facilities. That has two benefits for the business. Firstly, it makes us more sustainable from a business perspective as we reduce our dependence on external suppliers and can control costs better.

The second benefit is the positive impact the new facilities have on our carbon footprint. Before the installation of the rotary furnace, our existing furnace could only process clean scrap from our internal processes. It will continue to be used for this purpose in the future.

New melting capacity in Amorebieta and Alicante When the rotary furnace came onstream in 2017, we could process secondary metal including clean and coated scrap for the first time. December 2018 saw the reopening of our Alicante cast house which can utilise the clean scrap produced in our operations.

The rotary furnace increased Aludium’s production of sheet ingots by 15,000 tonnes annually. Due to its relatively small batch size, it can be quickly adapted to produce different alloys. This gives Aludium increased flexibility to meet customer demand for small batches of specific alloys.

Energy efficient Herwich Ecomelt installed in Amorebieta Later this year our melting capabilities will get a huge boost when our new Herwich Ecomelt PS275 multi-chamber furnace becomes fully operational. The furnace

is equipped with a preheating shaft, enabling Aludium to melt both clean and contaminated scrap. It will increase Aludium’s slab output by 55,000 tonnes annually.

Located in Amorebieta, in the same cast house as the rotary furnace, the furnace can produce up to 275 tonnes of liquid metal daily. The multi-chamber furnace will operate continuously, producing large quantities of alloys from the 3xxx and 5xxx families.

The multi-chamber furnace reuses pyrolysis gases to reduce the consumption of gas significantly. Aludium estimates gas consumption will be around 300 kWt per tonne of metal (depending on the scrap used). As well as reducing energy consumption and operating costs, gas emissions are minimised. With this one project, Aludium expects to reduce CO2 emissions by 250,000 tonnes annually.

The furnace has been positioned so that all loading and unloading operations can be completed safely. Systems have been installed to ensure that operators do not need to come close to the furnace during operation.

Additional works mitigate emissions, improve processes When Aludium installed the equipment rotary furnace in Amorebieta, we also built a fume treatment plant to reduce emissions to air to an absolute minimum. Due to the size of multi-chamber furnace, an additional and much larger fume treatment

plant was built to handle its gas emissions.

As part of the renovations to the Amorebieta plant to accommodate the new melting technologies, Aludium has also enlarged the existing scrap yard.

The total cost of the changes (including the installation of the multi-chamber furnace) is just under €19 million. The work has taken 18 months but has been completed on time and on budget.

The project also complies with all environmental health and safety standards and national regulations.

Demand for recycled scrap increased Installing these furnaces creates a huge demand for recycled scrap. One way we are sourcing that is by involving our customers and closing the loop with them. Where it makes logistic and operational sense, we will recuperate their scrap and use it in our processes. We have already started a scrap take-back programme with a lithography customer. This reduces our carbon footprint significantly, but we also believe it is also the right thing to do.

Aludium’s initial investment strategy will be largely realised when the multichamber furnace is fully operational. But that doesn’t mean it’s the end of efforts to enhance our sustainability. Now we need to track our performance to see where we need to improve. And we need to be transparent with our stakeholders about that performance.

In 2018 we published our first sustainability report which allows us to track, in a very public way, Aludium’s sustainability. We’re in the process now of gathering data for the second edition and that report will be released later this year.

At Aludium we understand sustainability isn’t a destination, it’s a journey. We’ve only just begun on that journey, but I think we are already showing we have what it takes.

13 www.furnaces-international.com

Furnaces International September 2019

ACCESS RAMPS

Custom-Engineered Kiln Access Ramps Partner with a Pro for Increased Productivity and Safety, By Heather Harding*

14 Furnaces International September 2019

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ACCESS RAMPS

Each burn floor, cooler and kiln present unique obstacles. Working with a manufacturer whose engineers review each burn floor, cooler and kiln for a custom design ensures safety and efficiency unmatched by in-house options.

Purchasing specialty equipment is often a difficult decision. Even in a good economy, plant managers have to keep a close eye on the bottom line. Kiln access ramps are an important part of safe, efficient kiln maintenance. They have a tremendous impact on both productivity and safety. Producing one in-house may seem cost efficient but poor design and lengthy installation often end up costing more in the long run. Partnering with a specialised manufacturer offers added benefits that result in a better return on investment.

Original equipment manufacturers offer custom-engineered designs, easy installation and service options that inhouse engineers can’t match. So, when weighing outside manufacturers against the cost of self-producing, keep these things in mind.

Custom-Made Design Features One of the biggest benefits of working with an original equipment manufacturer is the quality and experience they bring to the project. Each burn floor, cooler and kiln present unique obstacles. Because of this, each access ramp should be specially designed to ensure proper fit for optimum efficiency, portability and safety. Original equipment manufacturers have worked with hundreds of customers to solve specific challenges and, in partnering with them, managers can tap into that knowledge and success to find the custom-made designs, building materials and specialised solutions for their unique needs.

This individualised approach is the first and perhaps most important factor managers should consider when partnering with a specialised manufacturer. No one knows their facility better than an in-house engineer, and in many cases, this is the argument for producing an access ramp onsite.

While not all manufacturers offer custom-made designs from a certified engineer, the custom approach far exceeds relying on an in-house engineer.

Working with a manufacturer whose engineers review each burn floor, cooler and kiln for a custom design ensures safety and efficiency unmatched by inhouse options. But it’s critical to ask the right questions and ensure the custom approach. Off-the-shelf ramps might be quicker to fabricate, but they fail to address the individual challenges of each facility. From approach angle to threshold height, custom-made access ramps are

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ACCESS RAMPS

Industry-leading manufacturers incorporate high-strength 6061 T6 aluminium, which makes the ramp as strong and durable as steel but at half the weight. Ramps constructed from this material will support as much as 15,000 pounds (6,804 kilograms) live load and offer a 3:1 safety factor.

engineered to fit the specific parameters of the project with precision and forethought that increases maintenance productivity and safety.

A custom design is only one consideration. Manufacturing materials are also important for increased efficiency, portability and safety.

Specialised manufacturers have access to unique materials that make their ramps lighter and safer than steel – the material used by most in-house engineers for do-it-yourself ramps. Although steel ramps are strong, they’re also very heavy, requiring additional time and equipment to erect. Industry-leading manufacturers incorporate high-strength 6061 T6 aluminum, which makes the ramp as strong and durable as steel but at half the weight. Ramps constructed from this material will support as much as 15,000 pounds (6,804 kilograms) live load and offer a 3:1 safety factor.

To further ensure safety, many customengineered ramps also incorporate standard safety features, such as curbs and fall guards, to protect workers as equipment moves across the ramp.

Some original equipment manufacturers also offer accessories like safety cages, personnel tunnels and accessories that integrate seamlessly with their ramp designs to protect workers on the bridge

section of the ramp from castable falling from the hood. These are all part of a catalogue of specialised solutions developed over hundreds of builds that allow custom manufacturers to create a ramp system for any site.

In addition to safety features, some manufacturers offer solutions that minimise site damage, like articulated landing feet that ensure the ramp is always sitting properly in the kiln.

Others increase productivity, like outrigger matting support to make ramps compatible with third-party demolition equipment. Partnering with an original equipment manufacturer gives customers access to features and options that result in a customised access solution for increased safety and efficiency.

Ease of Installation Another important benefit realised with a specialised manufacturer is easier and safer installation. The combination of lighter materials and more experience results in ramps that can be assembled in a few hours with limited equipment.

Most facilities that choose to create their own kiln access ramps end up with heavy steel behemoths that get the job done but are difficult to assemble.

These complex systems require extra equipment, like a hoist system, more

manpower and extensive assembly times – sometimes up to 12 hours – to be safely installed, quickly eating up any savings from in-house design and fabrication.

Custom manufacturers, on the other hand, use their experience to design ramps that will make installation safe and efficient. By using lightweight aluminium and a modular design, these ramps can be assembled in as little as 1 1/2 hours, depending on ramp length and burn floor configuration. That’s up to 80% less time than most alterative aftermarket or self-built ramps. Items such as lifting lugs are engineered into the plans, as well, and are built into the finished ramp to make installation as fast and easy as possible. Most manufactured ramp assemblies are easily maneuvered by basic equipment like a forklift and don’t require a hoist system. And when maintenance is complete, the modular system is quickly disassembled and easily stored until the following year.

Sales and Service Perhaps the biggest benefit of partnering with a specialised manufacturer, however, is the customised care you get from a dedicated sales and service department over the life of the ramp.

Experience means a lot when it comes to design features and ease of installation,

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ACCESS RAMPS

To further ensure safety, many custom-engineered ramps also incorporate standard safety features, such as curbs and fall guards, to protect workers as equipment moves across the ramp.

Kiln access ramps are an important part of safe, efficient kiln maintenance and have a tremendous impact on both productivity and safety. Choosing the right partner for a custom ramp that fits your unique site offers added benefits that result in a better return on investment.

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ACCESS RAMPS

Custom manufacturers use their experience to design ramps that will make installation safe and efficient. By using lightweight aluminium and a modular design, these ramps can be assembled in as little as 11/2 hours depending on ramp length and burn floor configuration.

but it is also an important factor of customer service. When a do-it-yourself ramp falters, diagnosing the problem eats away at valuable time. Working with an original equipment manufacturer means having a partner to keep downtime to a minimum. From planning to installation, a professional manufacturer is able to think of all little things that could inhibit efficiency. Experts are available to answer questions and are better prepared to handle hiccups that might slow down maintenance. And when things don’t go to plan, extensive experience allows them to quickly offer solutions to keep the project on schedule.

Partnering with a specialised manufacturer also provides access to aftersales service. Many manufactures make themselves available for ramp inspections for several years. Custom manufactured ramps are also continuously tested to maintain industry safety ratings. If an issue is discovered, manufacturers will

work with customers to fix defects.

Choosing a specialised manufacturer also means customers will have access to spare parts, should a component be misplaced or damaged during storage. Even though each design is custom made, a specialised manufacturer will keep designs on hand and can easily remake the necessary component.

Optimise ROI While building a kiln access ramp in house might seem cost-effective at first, the benefits of partnering with a specialised ramp manufacturer can quickly add up to a better investment. Kiln access ramps are a necessity for safe kiln maintenance.

Good design and easy assembly are vital to limit downtime and increase maintenance productivity. Year after year, a custom-engineered ramp system allows maintenance crews to get the job done safely and efficiently, ramping up productivity and optimising ROI.

*Heather Harding is the managing director for Bricking Solutions, a world leader in kiln refractory installation solutions. heather@brickingsolutions.com

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ACCESS RAMPS

While building a kiln access ramp in-house might seem cost effective at first, the benefits of partnering with a specialized ramp manufacturer can quickly add up to a better investment.

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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Furnaces International September 2019

SAVE THE DATE

25-27 MAY 2020 Centre des congrès de Québec, Québec City, Canada

The Future Aluminium Forum will return on 25 – 27 May 2020!

Now in its third year, the Forum has established itself as the key event to show case studies, discuss optimisation through machine learning and examine robotics, automation and augmented reality across the value chain.

Join us to hear from experts on:

The automated casthouse Data capturing and handling Cyber-security: Prevention and cure Implementation & challenges

Industry 4.0 maintenance

Additive manufacturing

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FROM PILOT TO EVERYDAY If you want to know what’s happening in the world of digitalisation then look no further than the only aluminium conference in the world dedicated to Industry 4.0 and how it – and its related technologies – can aid and optimise the aluminium manufacturing process.

To find out more and be part of the future, contact: Nadine Bloxsome Conference Director nadinebloxsome@quartzltd.com +44 1737 855115 Nathan Jupp Sales Manager nathanjupp@quartzltd.com +44 1737 855027

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CAN-ENG FURNACES ENGINEERING SOLUTIONS TO LAST CUSTOM SYSTEMS FOR CUSTOM PRODUCTS

CAN-ENG Furnaces International Limited specializes in the design of unique, high-volume batch and continuous industrial furnace systems for today’s and tomorrow’s demanding Foundry applications.

Propelling industry toward tomorrow’s opportunities, whether for Automotive, Aerospace, Steel, Military, or Oil and Gas applications, CAN-ENG has the experience and expertise to enable your success.

Visit us at Heat Treat 2019, Booth 1103 at the Cobo Conference Center, Detroit, Michigan October 15 - 17, 2019 Visit us at Booth 102 at NADCA Die Casting Congress & Tabletop, October 1 - 3, 2019 at the Huntington Convention Center, Cleveland, OH To explore how CAN-ENG’s custom systems can help with your individual needs, visit us online www.can-eng.com or email furnaces@can-eng.com.

P.O. Box 235, Niagara Falls, New York 14302-0235 | T. 905.356.1327 | F. 905.356.1817

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Retort furnaces with controlled atmosphere Laboratory furnaces 1100–1600°C

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CASTHOUSE TECHNOLOGY

New possibilities in metal transfer a

By Jean-Francois Desmeules*

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CASTHOUSE TECHNOLOGY

and furnace automation

Industry 4.0 is the new buzzword in the business. The aluminium industry is climbing in the train like all others.

However, many plants still have to implement classic 3.0 automation and in most cases we are far from reaching autonomous 4.0 plants. Still, it is desirable to make every effort to improve the automation level and tend towards autonomous processes.

Many factors put pressure to do so, including manpower cost and availability, especially in the Western countries. Increasing energy cost and fierce competition force casthouses to be imaginative and innovative to improve and optimize their processes. Since it is not always realistic to invest in new machinery when existing equipment is performing well, it makes sense to work on improving the existing technology.

Many possibilities are available to do so, some of which described hereafter.

Siphoning: The most efficient method for metal transfer Metal transfer is omnipresent in the casthouse. A common configuration is having a direct chill casting pit or other casting machine that is fed from a tilting casting furnace, itself fed from a stationary melting furnace. Metal transfer from a furnace to another must be done in minimal time, using high metal flows.

The most common transfer system is by removing a plug in the melting furnace to fill the casting furnace via a launder. This promotes the generation of dross due to exposure of the turbulent metal flow to atmosphere. The metal chute and the splashing in the furnace also create a lot of air exposure to the metal.

Siphoning is often used in smelters to transfer metal from potroom crucibles to furnaces. It is also used to transfer metal from furnace to furnace but to a lesser extent. Some systems use refractory lined siphons with mostly manual operation.

Dynamic Concept developed a fully automated furnace to furnace siphon metal transfer system that uses a large bore, state of the art one-piece cast iron siphon tube. An automated system positions the tube and creates a vacuum to initiate the transfer. The vacuum level is automatically controlled to provide the proper flow. Refractory is shaped in both furnaces to minimize the amount of remaining metal in the melting furnace as well as metal heel required in the casting to prime the siphon. This facilitates alloy changes by allowing to fully empty the

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CASTHOUSE TECHNOLOGY

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CASTHOUSE TECHNOLOGY

casting furnace. The metal heel for the next batch is created by melting a small amount of metal in the casting furnace, typically around 1000 kg.

This system can transfer metal in minimal time without operator intervention. No skimming is required after transfer, saving operation time and minimizing melt loss and tooling cost.

Dynafeed: A craneless crucible discharge system Although siphoning is often preferred over other transfer methods, other considerations can direct to different transfer technologies. Among them, discharging a crucible by tilting it is a very popular means to get 100% of the metal from a crucible. It can be done using a crane with an auxiliary hoist or a tilting table. In both cases, a high capacity overhead crane is required.

Moreover, skilled operators are required since these cranes are not automated and fine movements are required to latch the crucibles on the lifting beams.

A technology called the Dynafeed was developed to eliminate the need for an overhead crane for crucible tilting.

Different configurations are available depending on the crucible transport truck configuration. The crucible is simply deposited by the transport truck (or AGV) within reach of the Dynafeed.

An automated locking sequence follows and the metal transfer can then be done automatically. The weight of the crucible is monitored in real time. This means that mass flow transfer of the metal is possible thanks to an advanced PID sequence. Having a controlled flow of metal helps reduce the formation of dross due to minimized turbulence. Moreover, the full and empty weight of the crucible is provided, eliminating the need for a separate scale.

With operator reduction and fully automated sequences, the Dynafeed is a great step towards casthouse automation and can even be used to feed casting machines directly from the crucible.

Furnace level measurement Knowing the amount of metal in a furnace with accuracy is very important for furnace charging, alloy preparation and general casthouse cycle time. Having to adjust alloy composition can cause great losses of production time. This is why there is a need for accurate measurement.

Many technologies are available for this, including direct measurement of the

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CASTHOUSE TECHNOLOGY

metal weight for tilting furnaces which is even better than measuring the metal level. However, for stationary furnaces, except using load cells which is only possible for small furnaces, there is no direct weight measurement possible.

Thus, metal weight estimation must rely on level measurement.

The two choices are radar and laser measurement. The radar must be mounted in the roof while it is possible to use a laser through a wall and use a correction factor for the angle. In both cases however, presence of dross, especially when preparing reactive alloys such as high magnesium alloys or when processing potroom metal which can contain pieces of solidified electrolyte, the measurement can be overestimated.

The FLASER was developed to overcome this. It uses a state of the art blue laser level measurement system from Precimeter, with an enclosure specially designed to be mounted on the furnace wall. A high accuracy mechanism rotates the laser to sweep a part of the molten metal surface, measuring the level over a series of points. An algorithm then determines the elevation of the baseline and the percentage of the readings that are affected by dross accumulation. It is then possible to use these values to determine the amount of metal in the furnace or even to decide if skimming is required. The measurements are made on an on-demand basis since the level only changes after metal addition or transfer.

When the unit is not measuring, the laser is positioned in a standby position to shut the reading orifices and keep the unit cool.

Furnace temperature measurement In addition to proper level measurement, temperature of the melt is another parameter that can affect many aspects of the process, including global cycle time. Problem is, for many furnaces there is no automatic stirring of the melt. This causes the metal temperature to be variable from the top to bottom, with higher temperatures at the surface due to lower density of the molten metal. Therefore, when measuring the temperature using a thermocouple, the location thereof will have an influence on the reading. A thermocouple with depth control is the solution to evaluate the correct temperature distribution.

Coupled with a system like the Flaser, the thermocouple can be used to properly evaluate the average temperature of the melt and provide information for process decisions.

Since the temperature of the metal in a furnace is a parameter that is long and expensive to control, an increase in accuracy when measuring it can help a casthouse operate more efficiently.

Conclusion The trend towards Industry 4.0 automation is only at its beginning.

New equipment is mostly 4.0 ready, however the existing casthouses are working to integrate the concept in their daily operations. Many technologies are available to upgrade existing equipment to further automation levels, some of which are presented above* but there are many other possibilities. These upgrades then allow for streamlining and automation of the global casthouse process from charging to casting.

About Dynamic Concept Our mission is to increase the competitiveness of light metals producers by supplying custom-fit equipment and systems adapted to the specific conditions of each process line.

We assist our clients at all stages of a project, from preliminary studies to start up, including design, engineering, fabrication, testing, erection of equipment, and the supervision of commissioning and start up.

Our success is measured by the longevity of our business relationships with our customers as well as their satisfaction. *All the technologies described above are patent pending.

References “Past, Present and Future Cast House Technology”, C. Weaver, Aluminium Cast House Technology, 2007, edited by JF Grandfield and JA Taylor “Oxidation, Dross and Melt Loss Issues Involved in the Aluminium Cast House”, JA Taylor, Aluminium Cast House Technology, 2007, edited by JF Grandfield and JA Taylor “Design Considerations for Holding and Casting Furnaces”, Migchielsen, Grab and Schmidt, Light Metals 2008, edited by D.H. DeYoung

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*Vice-President Technologies and R&D jean-francois.desmeules@dynamic-concept.ca Dynamic Concept, 2400 Alexis-Le-Trotteur, Jonquière Québec Canada G7X 0J7

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WWW.NAKAL.RU/EN

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CONNECTING THE INTERNATIONAL ALUMINIUM INDUSTRY Aluminium International Today is an English language journal

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SIGN UP TO RECEIVE YOUR FREE COPY Furnaces International brings readers a selection of technical features focusing on all aspects of the international furnaces market, as well as industry news, events, and regular columns from the British Industrial Furnace Constructors Association (BIFCA).

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INDUSTRY 4.0

GHI will invest in improving its facilities and processes after growing 20% in 2018 After a successful 2018 in which GHI has doubled its growth forecast, reaching almost 20% growth and surpassing 30 million euros of turnover, this year the investments of GHI will be focused “to the improvement of our facilities and processes with the goal of increasing our efficiency and productivity “, according to José Domingo Berasategui, General Manager of the company.

To the aforementioned growth in last year’s turnover was added the reinforcement of the workforce with more than 25 new employees. The firm also expanded the resources allocated to innovation, which by 2019 will exceed 1.5 million euros. Primarily, this amount will focus on digitisation and industry 4.0, areas for which GHI have created a specific department.

Leader in Spain and international leader in its sector, the Biscayan company GHI Smart Furnaces has important portfolio projects for this year, in which GHI will also seek to consolidate its position through a strategy based on constant innovation, a trained and committed human team, technology 4.0 and collaboration with customers, suppliers and technology centres.

For this part, among the main technological milestones of GHI in 2018 include the supply of the “largest in the world” rotary tilting furnace with which the firm has beaten, for the second time, a world record. It was a project subsidised by the Basque Government in which the company has worked together with Befesa and Tecnalia. Result: the development of an equipment of 65 tons of capacity that exceeds by 30% its previous record and which is equipped with a multi-door system and 4.0 technology that makes it “more efficient and automatic”. The furnace started in September and GHI already has a new order to supply another 65 tons rotary furnace this year for the same customer.

The firm is also in the process of patenting the ‘On Stamp’ rolling beam furnace for hot stamping, developed with one of the leading suppliers of automotive components worldwide. It is about, according to Berasategui, installations

that are in constant evolution, so that each one of the eight furnaces supplied until now has notable improvements.

Another relevant event in 2018 was the recognition of GHI as one of the ‘Hidden Champions’ companies by the “Diputación de Bizkaia” and “Beaz”. These companies are industrial SMEs with a history, a product or a star technology and a high level of export that allows them to have a relevant position, sustained growth and profitability above the industry average.

In this regard, its solutions include the fact that, as a result of its commitment to maintaining a constant innovation process, 80% of sales in recent years correspond to new product, increasingly more comprehensive and with clear competitive advantages. The strategic focus of the company in three main segments - hot stamping, aluminium recycling and wheel heat treatment plants - has also facilitated today’s multiple references to the world’s technological forefront.

Finally, underline that nontechnological innovations have also been an important chapter in recent months.

Among others, the company has made an adaptation of its production facilities and offices based in lean manufacturing principles, as well as the implementation of a new ERP. It has also carried out its

connection to the natural gas network, which has facilitated that since early 2018, its equipment has already been tested both cold and hot, thus achieving the assembly and start-up times in the facilities of the customer have been reduced to one third of the previous time and that the number of incidents has significantly decreased.

Beyond 4.0 The development of its ‘Smart Furnace’ model and its ‘Beyond 4.0’ platform for data capture and monitoring also focused a good part of GHI’s work during the past year. It is worth noting that GHI accomplished the 100% connection in ‘Beyond 4.0’ of the first complete plant for aluminium recycling in Europe, composed of seven aluminium melting furnaces and their auxiliary equipment.

With regard to the present 2019, GHI will continue to deepen the improvement of energy efficiency, automation and digitalisation of its furnaces while continuing to be immersed in projects related to industry 4.0, with the aim to have smart furnaces to ensure its features throughout its useful life.

And as the trend for the future also passes through the after-sales technical service and industry 4.0, for both areas it has created separate departments (Customer Care Service and 4.0 Engineering), with the aim of improving its value proposal.

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BLAST FURNACE

Dry blast furnace gas cleaning tech and no water consumption Proven, maintenance–friendly solution with smallest footprint and absorbent injection for removal of gaseous pollutants. Peter Klut* Dry gas gleaning introduces the benefits of reduced CO2 emissions due to the higher temperature and quality of blast furnace gas as well as the elimination of water consumption and water chemicals.

The Danieli Corus system offers the clear advantage of a strongly reduced footprint while being based on technology that has been proven in large scale applications for decades.

Similar to other metallurgical processes, blast furnace ironmaking produces substantial amounts of gas that is high in dust content. For an optimized carbon footprint the thermal energy and calorific value of this gas can be utilized, but this requires the gas to be conditioned and cleaned. Cyclones are the current industry standard for the first stage of dust removal, at an efficiency of around 85 %.

Traditionally, the second stage is based on wet dust removal, using a scrubber followed by a demister. Wet scrubbing wastes much of the thermal energy of the gas while consuming large amounts of water and creating the requirement for further sludge treatment and – as an option – beneficiation.

In recent years, several technologies have been introduced for dry dust removal in the second stage of the blast furnace gas cleaning system. With dry gas cleaning, a sharply reduced amount of thermal energy is wasted with the water and sludge, offering benefits for power generation. As an additional benefit, sludge treatment is no longer required.

Danieli Corus has developed a dry blast furnace gas cleaning system based on proven, proprietary technology for dry scrubbing of aluminum smelter gases. This new system consists of a gasconditioning tower, re-agent injection system and (pressurized) filter modules with low-pressure pulse cleaning.

To protect the downstream filters, conditioning of the gas is required in case the temperature of the gas exceeds 250°C. This is usually connected to process

anomalies within the blast furnace; therefore, the conditioning tower is only in operation on rare occasions. In the Danieli Corus design, the gas enters at the top of the tower and water is injected in co-current flow. As proven in the primary

aluminum industry, all water droplets are fully evaporated at the outlet of the conditioning tower. The laminar gas flow prevents droplets from touching the walls, ensuring that the walls are dry and dust depos-its are minimal.

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BLAST FURNACE

hnology for thermal energy benefits The applied raw materials or pulverized coal injection practice may require absorbent injection for the removal of gaseous pollutants. This takes place after the conditioning and before the dust removal step. For the removal of sour components, such as hydrochloric acid, the injection of alkali is foreseen. Optimal distribution of the absorbent in the gas stream is of great importance: maximum

removal efficiency is achieved when the absorbent is fluidized in the gas stream.

The proprietary Vertical Radial Injector (VRI) injects the absorbent particles into the gas stream radially, covering the full circumference of the gas duct.

The conditioned blast furnace gas and the injected absorbent is directed to a number of filter modules, in which filter bags separate the dust from the clean gas.

Development of the new Danieli Corus dry gas cleaning system based on proven solution with low-pressure pulse cleaning of bag filters and conditioning tower for protecting the filter bags.

Sopra: Tangential cyclone design with single or dual inlet.

The filter bags are configured in a circular array to fit as many filter bags as possible within the round pressure vessels. This allows for more square meters of filter cloth per module. Owing to the principle of Low-Pressure Pulse Cleaning, the filter bags also can be made longer than with standard designs, minimizing the system’s footprint. Bag cleaning is done with three slowly rotating arms, on which the gas-injection nozzles are positioned.

For access to the filter bags, the rotating arm can be pushed away manually for much easier bag replacement than with competing designs, which usually require the laborious removal of pulse pipes.

Dry gas gleaning introduces the benefits of reduced CO2 emissions due to the higher temperature and quality of blast furnace gas as well as the elimination of water consumption and water chemicals.

The Danieli Corus system offers the clear advantage of a strongly reduced footprint while being based on technology that has been proven in large-scale applications for decades.

*Senior Technologist & Blast Furnace Gas Cleaning, Danieli Corus

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CORUNDUM GROWTH

Conquering the aluminium furnace

Effective controls for corundum growth that improve quality an

Advanced Corundum

Aluminium processors face constant challenges to their aluminium melt operations. Due to robust demand, processors often operate these furnaces at higher temperatures to maximise production rates. As a result, one of the costliest operational challenges is the aggressive formation of corundum deposits in their furnaces.

Excessive, damaging, and costly corundum growth can be mitigated with the right refractory materials, coupled with the correct maintenance and watchful operation.

Root causes of corundum growth Corundum growth in a refractory lining of an aluminum furnace occurs due to a reaction between the alumina-silicate refractory and molten aluminium.

Corundum formation can occur both

externally and internally in the refractory lining.

There are four identifiable root causes that promote corundum growth: 1.

High temperature 2.

Presence of oxygen 3.

Alloy composition 4.

Use of fluxes and fluoride salts High temperatures accelerate the reduction of oxides in the refractory.

The higher the temperatures, the more quickly non-wetting agents lose their effectiveness. Aluminium begins to penetrate the refractory matrix because of decreases in aluminium viscosity and surface tension. Excessive furnace temperature can be the result of several causes: overfiring, improper furnace control, or inaccurate thermocouple placement. For example, a thermocouple that is recessed into the refractory lining

by 2 inches may underreport temperatures by several hundred degrees.

Oxygen drives the reaction process in two ways: As an atmospheric gas, and as a reducible oxide in the refractory.

Minimising oxygen by controlling negative pressure sources such as doors, windows, and well openings reduces the potential for reaction. Proper flue sizing and burner stoichiometry also reduce excess oxygen and improve furnace energy efficiency.

Alloy composition can be a factor. Some aluminum alloys contain elements that reduce the silica as well as iron oxide, zinc oxide and other oxides in refractories.

Careful attention is necessary in choosing an appropriate refractory for more aggressive aluminium alloys to reduce the potential for reaction.

Use of fluxes and fluoride salts like cryolite Na3AlF6 in aluminium melting

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CORUNDUM GROWTH

corundum

nd cut costs accelerate the reduction of oxides in the refractory. Their alkaline properties also reduce the local melt temperature of the refractory at the bellyband and then infiltrate the furnace lining. Over time, with lack of regular maintenance, the corundum buildup will reduce furnace performance and increase aluminium loss.

processors. They are usually low in free silica and nonwetting. The material bonds chemically to existing refractory, making them easier to install, and phos-bonded plastic refractories are an excellent solution for corundum growth at the bellyband.

Best practices that will help A regular maintenance plan can go a long way to increasing refractory life; a schedule is essential. A knowledgeable refractory expert with genuine experience in aluminum heat processes can help

Trouble spots The spread of corundum growth occurs most commonly in areas where its formation mechanisms of heat and oxygen are present. Typical problem areas include doors, openings, flue areas, and burner cones due to the potential for excess oxygen. Negative furnace pressure can also lead to leakage from the outside.

Other common areas of formation include rear walls and bellyband areas where regular cleaning and maintenance are more difficult.

with ideal schedules and checklists.

Corundum buildup is a common concern among aluminium furnace end users. Optimally, longevity of a furnace lining depends on best practices in refractory materials and installation methods, knowing the past refractory performance history to evaluate future performance, managing expectations of furnace production output, and monitoring regular maintenance and operation of the furnace.

These factors are measurable key performance indicators that will help decision makers design and build good refractory linings for the demanding needs of aluminium producers today.

Considering these factors and balancing them according to the producers’ needs can deliver a higher-quality product for longer life.

For additional information, check out the Resource section at www.plibrico.com/resources/.

Corundum formation illustration

Control and avoidance The key to fighting corundum starts with choosing the proper refractory material for molten aluminum contact.

Plibrico pioneered the development of effective refractory additives that combat corundum, including non-wetting additives, dense oxide barrier formers, and pore-size reducers. These additives can be found in Plibrico products, including the following: � The Plicast Al-Tuff® system, which increases wetting resistance and reduces the potential for oxidation-reduction of the refractory � Plibrico’s Al-Shield™ refractories, which form a reactive layer to resist molten aluminum penetration up to 2000°F � Phos-bonded castables like Plibrico’s Exo-set Uno™, which offer good resistance to metal slag penetration, especially in higher temperatures, and adhere well to the existing refractory for repairs In general, PliPartner refractory contractors tell us that they find phos-bonded plastic refractories to be excellent repair materials for aluminium

Corundum growth at 4mth

Corundum growth at 13mth

You can also contact us at: contact@plibrico.com or 312-337-9000.

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MELTING

Material mix:

New furnace plant enables simultaneou Due to the different shapes of ingots, return material and aluminium chips, different furnace types were previously required for melting the respective material. However, separate plants for the different types of material do not pay off for die casting foundries with too low volumes of aluminium chips or return material, so that only ingots are molten down. ZPF GmbH have now developed a melting furnace which is qualified for melting down aluminium chips as well as recycling material and ingots - a sustainable utilisation of the system is thus always ensured. The plant is equipped with an automatic charging system and is able to melt up to 500 kg raw material per hour, for example 250 kg aluminium chips and 250 kg ingots.

The new melting furnace technology will be presented for the very first time at this year’s GIFA with an exhibit.

Production by-products such as scrap material and runner systems or even aluminium chips are usually collected and recycled externally in most foundries, as they cannot be returned directly to the melting process for economic reasons.

This results in high costs for storage and transport, and the logistical effort should not be underestimated. “Until now, our aluminium melting furnaces were only designed for charging with unmixed material; a material mix of ingots and recirculation aluminium parts was previously only possible to a limited extent due to the desired boundary parameters such as melting loss and melting rate”, reports Sven-Olaf Sauke, head of R & D at ZPF GmbH. “For some foundries, a pure chip furnace is uneconomic, since the metalcutting share in the cast product is often too low.” ZPF has taken this market need as an opportunity to develop a new technology for melting furnaces enabling the simultaneous melting of chips, ingots or return material while still keeping the melting loss values at an extremely

low level. This offers companies greater flexibility in the recycling process and new opportunities to optimize the melting process.

Sump melting furnace with chips as main material For an optimal constructive design of the new furnace, simulations were used in the course of development to be able to assess the basic system behaviour. In addition, power and exhaust gas measurements were carried out under foundry conditions which were used to determine the functional parameters. “The decisive factor for us was the optimum melting of the metal and the required temperature control in the furnace,” explains Sauke.

“In addition to energy consumption, numerous other factors that strongly influence the melting result play a role here in a modern furnace system - for example the quality of the raw material and the melting loss. For practical implementation, ZPF analysed the data collected and determined the parameters required for simultaneous melting of chips and other aluminium materials.

Based on these results, a prototype with the new technology was implemented.

The melting furnace has dimensions of 575 cm x 380 cm x 445 cm.

(L x W x H) at an empty weight of approximately 28 tons. It is dimensioned for a maximum throughput of 500 kg/h in total.

The furnace system is extended by an automatic charging unit. This modular unit is designed in such a way that different types of material can be loaded according to customer requirements.

“For the simultaneous melting of different material forms in one furnace, the first step is to determine the leading material variant,” Sauke says. “For our prototype, we opted for aluminium chips as the main material and therefore designed the furnace as a heel melter. As a result, the chips can be molten down

in combination with return material, return wheels or ingots”. Which variant is added to the chips can be selected by the operator. The only important thing is to pay attention to the optimum quantity ratio between chips and secondary material in order to achieve optimum melting performance.

Foresighted research In addition to R&D projects with universities and other research institutions, ZPF uses the direct dialogue with the foundry industry to continuously further develop its melting furnace technology in order to find out additional optimisation potential through feedback from practical experience. “This helps us to be prepared for future challenges in melting plants. For example, the modularity of the automatic charging unit makes it possible to introduce precisely metered quantities of aluminium scrap into the

furnace,” adds Sauke. “This has the special feature that, depending on the sprue system, it has a large or small weight-to-volume ratio and must be handled accordingly - mechanically but also in terms of melting technology.”

The new system will be presented

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MELTING

us melting of aluminium chips and ingots The prototype of the new plant has dimensions of (L x W x H) 575 cm x 380 cm x 445 cm and an empty weight of about 28 tons. It is dimensioned for a maximum melting capacity of 500 kg/h. Source: ZPF GmbH

“Since there are two different shapes in the case of chips and ingots, we first had to choose the main variant. For our prototype, we opted for chips as the main material and designed the

” reports Sven-Olaf Sauke, head of R & D at ZPF GmbH

furnace as a heel melter.

at this year’s GIFA in Düsseldorf. “We will be demonstrating the new system technology using a furnace at our trade fair stand. This gives us the opportunity to present the innovations to interested users in a detailed and practical manner,” explains Sauke.

Source: ZPF GmbH

“In addition, we will also be showing an automatic charging unit. Which type of material it is designed for will be a little surprise for our visitors.” Sven-Olaf Sauke and the ZPF team will be available in Hall 10, Stand F59, for advice and queries.

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GLASS SERVICE

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CRUCIBLES

‘Game-changing’ crucible VAluStar™ launched for aluminium casting process A technological advance in materials science is supporting customers to increase productivity, by offering more than a 50% increase in the lifespan of crucibles used in the aluminium casting process*. VAluStar™ crucibles are the latest and most advanced range of crucibles developed by Morgan Advanced Materials.

Conceived by Morgan’s Molten Metal Systems business, the crucibles are highly resistant to oxidation at low temperatures

thanks to Morgan’s proprietary glazes.

They are particularly suited to holding aluminium and aluminium alloys in electric resistance furnaces.

VAluStar™ crucibles are high density, clay-bonded, iso-statically pressed crucibles that contain a high graphite and silicon carbide content.

Robin White, General Manager at Molten Metal Systems, said, “We are delighted to launch our VAluStar™ crucibles. We are confident they will add

huge value to the aluminium casting industry by reducing downtime and maintenance, therefore increasing productivity.

“Our new family of crucibles has been developed to resist oxidation, which is a common challenge for operators in modern foundries and cast houses. We’ve rigorously tested them against other crucibles in similar operating conditions, and VAluStar™ has shown that it has a significantly longer lifetime than all other iso-statically pressed crucibles in low temperature applications.”

To demonstrate the difference, Morgan tested the VAluStar™ in a 24-hour aluminium melting and holding application, against a conventional iso-statically pressed crucible. The latter needed to be replaced after eight months due to a reduction in thermal conductivity and when top brim cracks occurred due to oxidation.

Meanwhile, the BNS 200 VAluStar™ crucible’s lifetime was 14 months, exceeding the conventional crucible’s service life by 75% in similar conditions. As well as the extended life of the crucible, thermal productivity was improved by 24%.

Crucially, both crucibles were split in half for analysis. While the conventional crucible showed brim oxidation and oxidation nests, the VAluStar™ crucible only showed a slight brim oxidation, which was caused by the insulation fibre. *when compared to existing Morgan Advanced Materials crucibles.

For more about Morgan’s Molten Metal Systems business and the VAluStar™ crucible technology, please visit http://www.morganmms.com/en-gb/products/crucibles/noltina/valustar/

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SAFETY

1 Pictures 1,2, 3: In Europe

2

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SAFETY

Preventing molten metal explosions This paper was presented by Alex Lowery* at the Norcast Conference in Arendal, Norway in June 2019.

3

Molten metal explosions make the media spotlight shine the brightest on our industry than any other topic.

Many in our industry fear this unwanted attention will be more focused after a series of incidents that made the news in 2017-2018. In a span of 10 months four casthouses suffered molten metal explosions. Each casthouse was destroyed workers were killed, and dozens of local residents were injured. The root causes for each explosion differs. Only through understanding what happened in each incident can we prevent a recurrence in the future.

Explosions can occur when liquid

(aluminium) comes into contact with water. The contact of two liquids with greatly differing temperatures can lead to either a physical or chemical reaction resulting in an explosion with differing outcomes.

To better understand the power of explosions we will consider what could happen if a 20 kilogram mass of liquid aluminium came into contact with water. The water would instantly change from liquid to steam. That change results in the water molecules exponentially expand propelling the metal away. This is a physical reaction where the mass aluminium is not altered. The molten

metal can be thrown 1-30 meters away and property damage would be minimal.

Another alternative is for the molten aluminium to chemically react to water (H20). Oxygen molecules in the water bonds with the aluminium molecules (forming aluminium oxide) releasing hydrogen in the form of energy. Scientists determined that one kilogram of liquid aluminium gives off three kilograms of TNT force. Our 20 kg of liquid aluminium chemically reacting with water would result a force equivalent to 60 kg of TNT exploding. This reaction can be made worse if iron or other chemicals are involved.

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SAFETY

Pictures 4,5,6: In Japan 4

6

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5

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SAFETY

7

8

9 10

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Pictures 7,8,9,10,11,12: In Jiangsu

The aluminium company’s names have been purposely omitted. This was done to protect the identities of those involved.

The goal of this article is for the reader to learn from these incidents and to help their workplace safer.

The first of the explosions occurred in Europe during November 2017.

A casthouse was destroyed from an explosion generated from inside its

furnace. Historically furnace explosions are the result of water or a combination of water and a foreign substance being introduced into a molten bath. Workers charged the furnace with scrap and reported hearing muffled noises coming from inside. The furnace door was closed and the noises continued until an explosion emanated inside the furnace destroyed the casthouse. Two people were

killed, one had severe burns, one had physical injuries and one had no physical injury. The follow-up investigation’s final report stated “The explosion occurred inside the furnace during the scraping process. The investigation team has not found any clear cause for the incident, but the most likely reason is that the enclosed water has fallen into liquid aluminum, ” Recently, other similar incidents have had

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SAFETY

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explosions with a much less magnitude.

Could something else have accidentally been introduced to generate such a large explosion? The muffled noises reported by the surviving workers could have been smaller explosions occurring inside the closed furnace. This facility’s use of low grade scrape could have included cigarette lighters, pressure vessels (welding, oxygen tanks) that if introduced to a furnace could have generated a similar explosion.

This hypothesis is supported by the investigation report recommendations “that scrap metal be cut up before it is melted”. In addition this incident might

have been prevented or at minimalized had the workers opened the furnace door upon hearing the “muffled noises”.

The second of the four explosions occurred in China in April 2018. A casthouse in Shanxi province that produced billet experienced “molten aluminium liquid suddenly flowed into the casting well and exploded”. Three people were killed (two casting operators, and a forklift driver), and three other workers were injured. Unexpected release of molten metal can occur in a casthouse for a variety of reasons including furnace lining failure, launder failure,

mould bleedout, crucible spill, etc. This explosion occurred at a casting station with a 20 strand 310 mm table. One of the moulds was not working and had been blocked with asbestos prior to the start of the cast. The worker responsible for watching over the cast left his station during the casting. The asbestos in the 20th mould “loosened” allowing molten metal to escape into the pit. The sudden release of metal caused the remaining moulds to also bleed out into the pit.

The investigation report findings stated the casting operator should never have left his station during a cast. The report commented how workers worked 18 hours in a row. “The long work is extremely easy for the workers to fatigue, their concentration is lacking, and the reaction is slow”.

The report fails to address why similar bleedouts that have occurred previously in our industry did not result in an explosion. In every previous incident that did not result in an explosion the tooling and pits had been coated with Wise Chem.

The third of the four explosions occurred in July 2018 in Japan. An aluminium plant in the Okayama Prefecture suffered a furnace explosion. The aluminium plant was located a few hundred meters to a nearby town on the west bank of the Takahashi River. The region was warned earlier in the day that heavy rains would lead to flooding. There are conflicting reports on whether or not the aluminium company acted on the weather alert.

One report stated, “Although the danger by heavy rain was coming, the boss of the staff told them to continue casting.”

The aluminium company stated that at 22:00 their workers evacuated when the river over flowed its banks. The 40 ton capacity furnace was half filled when the waters from the Takahashi breached the casthouse at 23:30. The explosion occurred soon thereafter an explosion occurred. The explosion destroyed the aluminium plant and set nearby homes on fire. No workers were killed, but dozens of residents were injured from flying glass and some when their homes collapsed from the explosion. It is unknown if the local prefecture investigated the plant management in allowing 20 tonnes of molten metal to be inside the furnace at the time of flooding or not. Nearby residents and government officials commented in the aftermath that they were unaware of the potential hazard that the aluminium plant posed.

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SAFETY

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14

15

Pictures 13,14,15,16: In Shanxi

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SAFETY

The final explosion occurred in China in August 2018. A casthouse in Jiangsu Province experienced an explosion at a casting pit. The investigation report stated “the shock wave generated by the explosion caused the overall collapse of the workshop and the material warehouse”. The explosion also damaged the worker’s dormitory adjacent to the casthouse. Five workers died from the explosion and several other workers were injured. The surrounding communities reported many local residents were injured from broken glass when their windows shattered from the explosion.

This explosion occurred at a billet casting station with a 30 strand 203 mm table.

The casting station utilized four (4) steel wire ropes to lower and raise the casting base. During a cast one of the wire ropes suffered an “abnormality” resulting in a broken strand or wire. This caused the table, supporting all of the 30 billets to become unstable and incline causing the other steel wire ropes and the base to incline even more. The result was a large volume of aluminium liquid being “instantly dumped into the cooling water” causing an explosion.

Individually any of these explosions would have been disregarded during the course of a year in our industry.

Collectively all of them happening in such a short period of time has forced our industry to pause and re-examine the hazard. The root causes of the explosions

discussed varied from poor management, inadequate worker training, poor maintenance, and the failure to follow industry best practices toward safety. Two, if not three, of the explosions may have been prevented if those plants simply followed the Aluminum Association’s “Guidelines for Handling Molten Aluminum” 4th Edition. This publication was first published more than 39 years ago and is considered the benchmark as the best safety practices for the aluminium industry. “Section 28 Protective Coatings for Casting Pits and Equipment” states Wise Chem coatings “as having the ability to prevent explosions from bleedouts into the pit during DC casting”. The explosions that occurred in China and Japan could have been prevented if Wise Chem was applied. This statement is reinforced by similar incidents that have occurred without an explosion because of the use of Wise Chem. The explosion that occurred in Europe could have been prevented by shredding and preheating the scrap before charging into a furnace.

The challenge for our industry is to learn from these four catastrophes to make operations and processes safer.

If not our industry faces the very real possibility that these incidents will be repeated. As history has shown us those who fail to learn from the past are doomed to repeat it. *Manager, WiseChem

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