HEAT PROCESSING Report: Knowledge management in maintenance of thermal process plants (Vorschau)

International Magazine for Industrial Furnaces 

Heat Treatment & Equipment 

03 I 2014 

ISSN 1611-616X 

Vulkan-Verlag 

HK Special on pages 37-55 

www.heatprocessing-online.com 

The full spectrum 

of heat treatment 

B.M.I. Fours Industriels www.bmi-fours.com 

Vacuum Furnaces for hardening, tempering, carburizing, nitriding, 

sintering, high and low temperature brazing 

IVA Industrieöfen GmbH www.iva-online.com 

Retort Type Furnaces, Sealed Quench Furnaces, Rotary Hearth 

Furnaces, Rotary Drum Type Furnaces, Hood Type Furnaces, Pit 

Type Furnaces 

LOI Thermprocess GmbH www.tenova.com 

Continuous Carburizing Furnaces, Bright Annealing Lines for 

tubes and rods, Heat Treatment Plants for wire 

Mahler GmbH Industrieofenbau www.mahlerofen.de 

Continuous Furnaces with protective gas for bright annealing, 

brazing, hardening, tempering, sintering of powder metal alloys 

RIVA Sp. z.o.o. www.riva-furnaces.com 

Sealed Quench Furnaces, Forging Furnaces, Tempering Furnaces, 

Nitriding Furnaces, Carburizing Furnaces, Endogas Generators 

and Washing Machines 

Schmetz GmbH Vakuumöfen www.schmetz.de 

Vacuum Furnaces for hardening, tempering, brazing, annealing, 

sintering 

Cologne Trade Fair 

22 – 24 October 2014 

Hall 4.1, Booth No. C-060 

LOI Thermprocess GmbH - Tenova Metals Division 

Am Lichtbogen 29 - 45141 Essen / Germany 

Tel. +49 (0)201 1891.1 - Fax +49 (0)201 1891.321 

loi@tenova.com - www.tenova.com 

ITPS ASIA 

Information about the 2 nd 

International Thermprocess 

Summit 2014, Mumbai (India) 

REPORT 

Knowledge management in 

maintenance of thermal 

process plants 

INTERVIEW 

Thomas Brüser about the 

future of energy industry and 

technological challenges 

13002-14 LOI Anz MTH HeatProcess Titel.indd 1 31.07.14 12:30

Read our report on pages 59-62!

EDITORIAL 

70 th HeatTreatmentCongress 

– for the first time in Cologne 

See you next time in Wiesbaden …” has been the conclusion 

of many a conversation in recent years and, indeed, past 

decades. “Wiesbaden”, for sixty-nine years the venue for the Heat- 

TreatmentColloquium and, later, for the HeatTreatmentCongress, 

had come to symbolise the high-level interchange of specialist 

knowledge in the fields of heat treatment and materials science. 

Many will doubtless look back nostalgically on the years in 

Wiesbaden. World-class technical papers, lively and, in some 

cases, controversial discussions between colleagues, an ever 

larger technical exhibition and, not least of all, the evening events 

in the “Eimer” or “Ratskeller” hostelries, which had not a few 

conference participants setting off back to their hotels only in 

the first glimmer of dawn ... 

The 70 th HeatTreatmentCongress will be held in Cologne (from 

22 to 24 October)! Germany’s AWT heat treatment association has 

made an extremely good choice of venue in the great Rhineland 

city of Cologne. The Cologne trade-fair grounds are located centrally 

in the city with excellent transport access, and provide all 

the opportunities needed to meet the requirements of a modern 

technical conference with an accompanying specialist exhibition. 

Cologne, in addition, has the space needed to allow the exhibition 

event to grow even further. Here, the technical advisory stands 

will all be located for the exhibition in a large hall in the immediate 

vicinity of the congress auditorium. Cologne, furthermore, as 

a famous German “Karneval” centre, certainly offers more than 

enough of the right facilities for finishing the day in a convivial 

manner together. The lodge president, Joachim Wüst, will without 

doubt impart one or two reflections on his native city on the 

opening day of the HK, taking as a “Kölsch” (Cologne dialect) motto 

“Hey Cologne, you’re more of an emotion than a city”. 

And this year’s conference agenda is yet again an impressive 

one! The AWT’s organising and planning committee has, once 

again, selected a large number of fitting, high-ranking speakers, 

who will focus on “Simulation of heat-treatment processes”, 

“Production and residual stresses”, “High-energy heat treatment”, 

“Integration of heat-treatment processes into production” and 

“Innovations in materials science, heat treatment, production 

methods and process engineering”. Worthy of special mention 

is, above all, Prof. Harry Bhadeshia’s plenary address on “Out-ofthe-ordinary 

bainitic steels”. 

This year’s event in Cologne will again include a background 

technology seminar for the heat-treatment “practitioners” during 

the morning of the first day, thus preceding the opening of the 

congress itself. Dr. Peter Sommer will report on “Heat treatment 

– errors, harm and causes”, and Marco Jost will speak on “Nitriding 

under gas and under plasma – component-specific process 

selection on economic criteria”. 

“Nothing, as is well known, is as constant as change.” We are, 

therefore, pleased to have found in the new Cologne venue not 

only a “successor solution” to Wiesbaden 

for our heat treatment 

industry, but also at having 

selected a setting 

which will allow the 

“HeatTreatmentCongress 

success story” 

to continue to grow 

and develop. So from 

now on, it’s “See you 

next time in Cologne …”. 

Dr. Ing. Olaf Irretier 

IBW Dr. Irretier GmbH (Industrial Heat 

Treatment Consulting) 

3-2014 heat processing 

1



“10 years of heat processing magazine. 

of high-quality reports about state-of- 

This means 10 years of an impressive 

national authors. And this means 10 

wide range of different technologies 

Happy birthday heat processing!“ 

Dr. Andreas Seitzer 

Managing Director of SMS Elotherm GmbH 

2 heat processing 1-2014

• 10 Years Anniversary • 10 Years Anniversary • 10 Years Anniversary • 10 Years Anniversary 

This means 10 years 

the-art products. 

variety of truly interyears 

of successful gathering a 

in a unique communication format. 


3

TABLE OF CONTENTS 3-2014 

10 

HOT SHOTS 

Multi-frequency hardening 

106 

REPORTS 

Energy efficiency – potential options 

Reports 

Heat Treatment 

by Maciej Korecki, Piotr Kula, Emilia Wołowiec, Michał Bazel, Michał Sut 

59 Low pressure carburizing and nitriding of fuel injection nozzles 

by Hartmut Steck-Winter, Axel Filounek 

63 Knowledge management in the maintenance of thermal process plants 

Measuring & Process Control 

by Karl-Michael Winter 

71 Impacts of allowed tolerances in temperature on nitriding results 

Induction Technology 

by Valentin Nemkov 

79 Magnetic flux control in induction systems 

by Dirk M. Schibisch, Jochen C. Huljus 

87 Modular induction solutions for drive and axle components 

Burner & Combustion 

by Dirk Mäder, Octavio Schmiel Gamarra, Mario Schulze, René Lohr 

91 Efficiency-enhancing maintenance of heating systems 

by Frank Hammer 

95 Sensory combustion optimisation of gas combustion systems 


3-2014 heat processing


52 

HEAT TREATMENT CONGRESS 

All information about the HK 2014 

63 

REPORTS 

Knowledge management in maintenance 

Energy Management 

by Christian Sprung 

101 Energy efficiency – potential options for industrial furnaces 

Research & Development 

by Jörg Neumeyer, Bernard Nacke 

111 Induction assisted hybrid- welding processes to join heavy-walled steel components 

HEAT TREATMENT CONGRESS 2014 – SPECIAL 

39 General Information 

40 Basic Data 

42 Program 

46 Product Preview 


ADVANCING 

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TECHNOLOGY 

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12 122 

NEWS 

Vacuum oxygen decarburization plant launched 

PROFILE+ 

Chair of Thermodynamics and Combustion 

of the University Magdeburg 

Focus On 

115 Edition 11: Thomas Brüser 

“The labour shortage is definitely affecting us” 

Profile+ 

121 Edition 7: Chair of Thermodynamics and Combustion of the University Magdeburg 

Technology in Practice 

125 90 th anniversary of Otto Junker 

128 High-precision control of metal heating elements 

130 New kiln and dryer system for terracotta tiles 

Companies Profile 

156 Process-Electronic GmbH 

News 

12 Trade & Industry 

25 Events 

28 Diary 

32 Personal 

36 Media 

heatprocessing 

Stay informed and follow us on Twitter 

heat processing 

@heatprocessing 

heat processing is the international magazine for industrial furnaces, 

heat treatment & equipment 

Essen · http://www.heatprocessing-online.com 


SENSOR LOGIC ACTUATOR 

117 

FOCUS ON 

Edition 11: Thomas Brüser 

Business Directory 

134 I. Furnaces and plants for industrial heat 

treatment processes 

144 II. Components, equipment, production and 

auxiliary materials 

151 III. Consulting, design, service and engineering 

152 IV. Trade associations, institutes, universities, 

organisations 

152 V. Exhibition organizers, training and education 

COLUMN 

1 Editorial 

10 Hot Shots 

132 Index of Advertisers 

U3 Imprint 

Elster Kromschröder has developed tailor-made 

solutions for fitting out thermoprocessing installations 

across all sectors such as the iron and steel, 

non-ferrous metals, ceramics or glass industries. 

This applies in particular for SIL/PL: 

our products, design tools, calculation software, 

example applications and, of course, our customer 

service department facilitate the safe design and 

operation of your heating system. 

Visit us! 

Härtereikongress 2014, Cologne 

22. – 24. October 2014 

Hall 4.1, Stand C-089 

Elster GmbH 

Postfach 2809 

49018 Osnabrück 

T +49 541 1214-0 

F +49 541 1214-370 

info@kromschroeder.com 

www.kromschroeder.com 


Anz_PW2014_SILPL_89x255_de_en.indd 1 07.08.14 15:24

HOT SHOTS 


HOT SHOTS 

Multi-frequency hardening in action 

The simultaneous multi-frequency hardening process 

patented by EFD Induction achieves true contour hardening 

of small gears in far under one second. Notable is the 

absence of through hardening in the teeth. 

(Source: EFD Induction GmbH) 


11

NEWS 

Trade & Industry 

Vacuum oxygen decarburization plant from Siemens 

launched at voestalpine 

vacuum oxygen decarburization 

A (VOD) plant from Siemens Metals 

Techno logies with a capacity of 50 t commenced 

operation at voestalpine Giesserei 

Linz GmbH. The Austrian company is 

thereby adding to its equipment for secondary 

metallurgical treatment of steel 

castings for sophisticated applications in 

the energy and mechanical engineering 

industries. The plant features electrically 

driven mechanical vacuum pumps instead 

of steam injectors and therefore does not 

require any steam generator. 

For the new vacuum oxygen decarburization 

plant, Siemens handled the 

configuration and supplied all the core 

components. These included, for example, 

a special ladle hood made of copper-plated 

sheet. This minimizes the occurrence of 

baked slag on the upper edge of the ladle 

and on the vacuum lid. The scope of supply 

also included the vacuum lid, an oxygenblowing 

lance system, a gas cooler and a 

filter system, mechanical vacuum pumps 

and the hydraulic system. The order also 

included a water management system 

matched to the overall plant as well as the 

complete automation technology and 

instrumentation. 

As one of the first VOD systems worldwide, 

the plant in Linz uses a combination 

of electrically driven, mechanical vacuum 

pumps to generate a vacuum. This includes 

roots blowers and screw compressors. 

Unlike the conventional steam injectors 

used in secondary metallurgy, these do not 

require any process steam, so there is no 

need for any external steam or the installation 

of a separate boiler to generate steam. 

voestalpine Giesserei Linz GmbH is 

completing its secondary metallurgical 

treatment options with the new vacuum 

oxygen decarburization plant. This enlarges 

the product portfolio and will play a major 

part in achieving cost-efficient production. 

ABB installs EFD Induction system for short-circuit ring brazing 

Power generation and distribution 

company ABB recently installed the 

largest single-shot short-circuit ring brazing 

system yet developed by EFD Induction. 

The system, which was installed at 

the ABB plant in Vittuone outside Milan, 

Italy, can braze rings with a diameter up to 

1,500 mm. The company’s previous record 

for a one-shot short-circuit ring brazing system 

was 1,200 mm, so the system developed 

for ABB represents quite an increase. 

The system comprises customized coils, 

an EFD Induction Sinac 250/320 power 

source, and a mounting table. The system’s 

first project was to braze a 1,500 mm 

diameter short-circuit ring for a wind tunnel 

motor. The end user is one of the world’s 

most famous sports car manufacturers. 

According to Stefano Chieregato of ABB, 

he and his colleagues examined proposals 

from six companies before opting for the 

EFD Induction solution. He says that there 

were several reasons behind the choice 

of EFD Induction for this critical piece of 

equipment. First, their proposal made 

technical and economic sense. Second, 

the company has deep expertise in the 

field. And third, ABB in Italy has had positive 

experiences with EFD Induction heating 

solutions for other applications. 

EFD Induction is one of the world’s leading 

suppliers of induction-based shortcircuit 

ring brazing systems. The company 

has even devised a specialized induction 

coil that equalizes the temperature around 

the ring. This coil minimizes energy input 

into laminations, thereby protecting the 

shaft from heat and preserving the ring’s 

integrity. 



NEWS 

Air Liquide invests in a new Research and Technology Center 

in China 

At the end of July Air Liquide broke 

ground on its new Research and Technology 

Center, the Shanghai Research & 

Technology Center (SRTC), located in the 

industrial park of Xinzhuang, in the Minhang 

district of Shanghai, China. This new 

center will ultimately house 200 highly 

skilled employees – who include researchers, 

experts in customer applications, and 

business development teams – to contribute 

to the acceleration of the Group’s 

innovation in Asia-Pacific. The scientific 

experts will be working in several different 

areas of research, such as energy efficiency, 

technologies designed to reduce industrial 

emissions of CO 2 , water treatment, and processes 

for preserving and freezing food. 

The center will be operational at the end 

of 2015. 

The company’s new Research and 

Technology Center bolsters the group’s 

research capabilities in Japan and South 

Korea. It will be connected with the innovation 

teams based in Europe and in North 

America. It will first focus on bringing to 

market innova tive solutions adapted to the 

usages of Chinese customers and consumers. 

It will leverage the main innovation 

ecosystems in China, building on existing 

partnerships with Shanghai Jiao Tong University, 

as well as Zhejiang University and 

the research institutes affiliated with the 

Chinese Academy of Sciences. 

Covering 12,000 m 2 , the center represents 

an investment of nearly € 25 million. It 

will house laboratories as well as large pilot 

platforms with equipment for designing 

and testing technologies in industrial-scale 

conditions for the group’s customers. The 

building is designed in compliance with 

LEED certification (Leadership in Energy 

and Environment Design), a global standard 

in sustainable building that factors in 

the efficient water management, good use 

of energy, and the reduction of emissions. 

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13

NEWS 


Deutsche Edelstahlwerke orders cooling bed from SMS Meer 

University orders induction heating system from Ambrell 

Deutsche Edelstahlwerke has ordered 

a new rake-type cooling bed from 

SMS Meer for its Siegen works in Germany 

as part of the modernization of 

its bar mill. The new cooling bed allows 

controlled cooling of the bars, surfaceprotecting 

transport and very straight 

finished products. Thus, all demands on 

quality steel are met. In addition to round 

steel bars with dimensions from 21.5 to 

90 mm, it will also be possible to cool 

hexagonal sections on the cooling bed 

in future. 

According to Jens Eisbach, Manager 

Bar Mill, the aim of the modernization 

Ambrell, a leading manufacturer of 

induction heating systems, has 

sold an Ekoheat 45-kW/100-kHz induction 

heating system to a large research 

university for “superalloy” research. The 

application involves melting up to 20 g 

of tungsten to 3,500 °C (6,332 °F) in a 

cold crucible. A cold crucible involves 

levitation and requires virtually no contact 

between the crucible and melting 

bath. This method maximizes the purity 

of the melt. 

The university, which had previously 

used Ambrell induction heating systems 

for research applications, purchased this 

system because they needed to melt 

larger batches. The Ekoheat enabled them 

to meet their objective. Ambrell offers its 

is to achieve a homogeneous temperature 

distribution in the bar layer. That will 

enable the company to prevent inaccuracies 

when cutting the bars and to 

improve the productivity and quality in 

the finishing section. 

Deutsche Edelstahlwerke operates the 

world’s first 3-roll PSM ® (Precision Sizing 

Mill) with hydraulic roll adjustment under 

load from SMS Meer. It is additionally 

equipped with the Meergauge ® precision 

measurement system and a dynamic 

monitor control. Commissioning of the 

new cooling bed is scheduled for the 

third quarter of 2015. 

clients complimentary application testing 

to ensure their new system will meet their 

process requirements. 

The company offers a full line of induction 

power supplies that can be used for 

melting applications. For those that need 

complete melting systems, Induction Technology 

Corporation is Ambrell’s melting 

partner. 

Sandvik and Tenaris sign new five-year strategic alliance 

agreement 

Sandvik and Tenaris have signed a new 

five-year strategic alliance agreement on 

the exclusive joint supply of corrosion resistant 

alloy OCTG materials and technology 

to the oil and gas industry. By this agreement 

Sandvik and Tenaris look to build on 

an already long established and successful 

alliance that goes back over a decade. 

According to Michael Andersson, Head 

of the Tube Product Area of Sandvik, 

this strategic alliance will facilitate closer 

co operation on future innovations targeting 

the most demanding applications in 

the market. Together, their research and 

development capability will be unmatched 

in the industry allowing them to develop 

and offer unique solutions for the most 

challenging operational environments 

faced by the customers. 

The prospect of bringing together the 

companies’ high-end technologies – with 

Sandvik’s corrosion resistant alloy tubes 

and TenarisHydril premium connections 

with Dopeless ® technology – will bring 

many benefits including a complete offer 

for the market. This is particularly true in 

the most challenging oil and gas exploration 

and production environments, such 

as High Pressure/High Temperature and 

deep water, where harsh conditions call 

for safe operational material solutions while 

red ucing environmental impact. 

Sebastián Salenave, Sales Manager of 

Tenaris added that the product port folios 

of both companies complement each 

other perfectly and together they can 

reach every location with their extensive 

global network supporting oil and gas 

exploration and production worldwide. 



NEWS 


15

NEWS 


SMS Siemag is expanding the hot strip mill at Xichang 

Steel with a slab sizing press 

PIETC Panzhihua Co., Ltd. has awarded 

SMS Siemag, Germany, the contract 

for expanding the roughing mill in its hot 

strip mill in Xichang City, China, through 

the addition of a slab sizing press. The aim 

of the revamp is to make the production 

process more flexible. With an edging force 

of up to 22,000 kN, the slab sizing press 

will reduce the slab width to the required 

dimension, by up to 350 mm in one pass. By 

casting slabs with a higher average width 

and a reduced number of casting sizes, 

Xichang Steel can increase the throughput 

rate of its continuous casting machine. The 

slab sizing press additionally allows more 

flexibility in the scheduling of the rolling 

programs. 

Xichang Steel produces carbon steels for 

pipelines as well as for the construction of 

ships, bridges and buildings, among other 

things. SMS Siemag already delivered the 

hot strip mill for Xichang Steel’s plant in 

2011. The revamp of the 2,050-mm-wide 

plant will now take place during a short 

downtime. The major part of the preparatory 

work will take place parallel to production. 

SMS Siemag will manufacture the core 

components of the slab sizing press, such 

as press sleds with drive unit, width adjustment 

system and main gear unit, at its 

workshop in Hilchenbach, Germany. The 

completion of the revamping phase at 

Xichang Steel is scheduled for the second 

half of 2015. 

Ipsen delivers vacuum furnace to Mexico 

Ipsen recently shipped a horizontal TurboTreater 

® thermal processing vacuum 

system to an international company’s plant 

in Mexico, where it will function as a substitute 

for another Ipsen furnace, substantially 

modernizing their operations. This company 

is part of the Metal-Casting industry, 

and they will use this TurboTreater to process 

stainless steel parts for a French car 

manufacturer and, eventually, a German 

car manufacturer as well. In both cases, the 

cars are assembled in Mexico and exported 

all over the world. 

The company has a long history with 

Ipsen, having purchased multiple furnaces 

over the last few decades. In 2013, they 

contracted the company for a critical 

relocation of a large heat-treating furnace 

from one of their plants in Mexico to the 

same plant where this new TurboTreater 

will be installed – all to best support their 

customers in the automotive industry. 

Overall, the order and shipment went 

smoothly – the various milestones were 

met either ahead of schedule or on time, 

and the Factory Acceptance Test was 

seamless. 

This specific TurboTreater features 

a 24” x 24” x 36” (610 mm x 610 mm x 

914 mm) all-graphite hot zone with a 

2,000-pound (907 kg) load capacity. It 

utilizes gas cooling to 2-bar absolute pressure 

and operates at temperatures of 1,000 

to 2,400 °F (538 to 1,316 °C). The furnace 

is also equipped with a 20-inch Varian 

diffusion pump and Ipsen’s CompuVac ® 

control system. 

The TurboTreater line operates as a 

“build-your-own” furnace, allowing customers 

to order heat treatment furnace 

systems specified to their unique needs. 

Possible modifications include variations 

on features such as the hot zone insulation 

package, heating elements, pumping 

systems and control system. 



NEWS 

TimkenSteel to invest in continuous heat-treat operations 

TimkenSteel Corporation, a leader in 

customized alloy steel products and 

services, announced plans to open an 

additional continuous heat-treat facility in 

the U.S. to produce more value-added steel 

for demanding applications. Shawn J. Seanor, 

executive vice president of Energy and 

Distribution said that many of the applications 

the company serves require higher 

performance steels that give the customers 

confidence as they push the limits of 

what’s possible. He added that this investment 

is foundational to the company’s ability 

to grow some of its most unique and 

sophisticated product lines to meet those 

needs. Additional continuous heat-treat 

capa bilities provide the flexibility to create 

more customized steels to serve energy 

and other markets that have a strong longterm 

outlook. 

The company is evaluating locations for 

the continuous thermal heat-treat operations 

and plans to make that decision in the 

third quarter of 2014. The facility would be 

fully operational within two years and have 

capacity for 50,000 process-tons annually of 

4” to 13” bars and tubes. It would be larger 

than each of the company’s three existing 

thermal treatment facilities in Canton, OH. 

The investment is approximately $ 40 million. 

TimkenSteel’s energy offerings serve 

global equipment manufacturers and service 

companies with customized products 

and services for their most demanding 

applications in down-hole tools and topof-hole 

infrastructure. 

Heraeus acquires Vulcan Catalytic Systems Ltd. 

Heraeus Noblelight, the specialty light 

sources business group that is part of 

the Heraeus precious metals and technology 

group, has concluded an asset deal to 

acquire the business activities of US-based 

Vulcan Catalytics Systems Ltd. The American 

company manufactures gas catalytic 

infrared systems especially for industrial 

powder coating processes. 

Rainer Küchler, Managing Director of 

Heraeus Noblelight explained that with 

the acquisition of Vulcan Catalytic, Heraeus 

Noblelight is expanding its application 

know-how in the area of coatings as well 

as its portfolio in the sphere of long-wave 

light. Vulcan Catalytic has decades of experience 

in the development of gas catalytic 

systems, which, in certain applications, are 

an ideal complement to Heraeus’ electric 

infrared product line. Using the combined 

expertise offers the possibility of developing 

new solutions. 

According to Michael Chapman, President 

of Vulcan Catalytic Systems, both 

companies share a common goal: to consistently 

exceed customer expectations. He 

said that joining the Heraeus network will 

offer Vulcan Catalytic Systems numerous 

opportunities to introduce its products and 

expertise to new markets. 

ALD Vacuum Technologies 

signed a Memorandum of 

Understanding 

The AMG Advanced Metallurgical Group N.V. announces that its AMG 

Engineering unit, ALD Vacuum Technologies GmbH signed a Memorandum 

of Understanding with Nukem Technologies GmbH, and E.ON 

Technologies GmbH to develop a concept for local melting services to 

recycle radioactive metallic wastes from closed nuclear power plants. 

ALD is a leading global supplier of vacuum furnaces and vacuum 

processes and holds a patent for the recycling of radioactive metallic 

waste treatment. Nukem Technologies GmbH of Alzenau, Germany, 

is globally active in the areas of management of radioactive waste 

and spent fuel, decommissioning of nuclear facilities, engineering and 

consulting. Nukem Technologies GmbH has been part of the Rosatom 

Group since 2009. 


17 

GFW-Xtra_89x62_07-2014_DEU-ENG.indd 1 01/08/14 10.33

NEWS 


Edwards’ steel degassing 

system brings benefits to 

Italian steel manufacturer 

Edwards has installed a modular steel degassing system in a 

large steel producer in Italy, replacing an existing steam ejector 

system which had high running costs and energy usage. The 

steel manufacturer, which produces 1.5 million t/a of high quality 

steel for the automotive and power industries, has had six Edwards’ 

mechanical steel degassing modules installed. Key in the decision 

to use this steel degassing vacuum equipment was that the system 

is modular – its standardized concept provides an easy installation 

and integration, securing immediate reduction of running costs. 

The mechanical steel degassing system enables the customer 

to enjoy the immediate readiness of the system compared 

to steam ejectors, which require heating up time, providing an 

increase in productivity, reliability and consistency. In the unlikely 

event of pump failure the modular design of the system ensures 

high uptime in a simple, reliable way, and provides improved 

stability. 

The company’s mechanical steel degassing system uses 

multi stage mechanical boosters supported by dry screw primary 

vacuum pumps. Increasingly mechanical dry pumps are 

replacing traditional steam ejectors as the vacuum technology of 

choice. Lower running costs, higher pumping speeds, predictable 

maintenance and lower environmental impact all lend weight 

to the case for mechanical dry pumps. The savings in energy 

costs from using dry mechanical pumps are high compared to 

steam ejectors. 

Outokumpu steel extends 

the water heater life for 

PVI Industries 

P 

VI Industries LLC, an American water heaters manufacturer 

has chosen Outokumpu’s proprietary lean duplex 

grade LDX 2101 ® to replace carbon steel in its water heaters. 

Using lean duplex has significantly reduced PVI Industries’ 

waste stream and increased the useful life of its water heaters. 

PVI Industries produces water heaters for large commercial 

end-users like hotels, restaurants, schools, universities and 

hospitals. Water heaters can be as large as 11 x 2 m, and 

contain as much as 17,000 l of water. 

In 2009, PVI Industries built a water heater prototype using 

Outokumpu LDX 2101 ® . The prototype went through an accelerated 

life testing equivalent of 30 years of normal life use at 

highly elevated temperatures. Five years after development, 

the prototype is still operational. The useful life expectancy 

of carbon steel water heater tanks was five to fifteen years, 

depending on application. PVI now warranties standard 

duplex water heater tanks for up to 25 years. 

Previously, the company was using electroless nickel plating 

to reduce corrosion in the carbon steel water heater tanks. 

The process generated nearly 600,000 kg of waste a year. Now 

clear savings are achieved since no maintenance is required, 

because stainless steel does not require any coating or plating. 

Moving to duplex stainless steel also reduced PVI’s 

waste stream to nearly zero. The efforts were recognized 

in May 2014 by the State of Texas at the 2014 Environmental 

Excellence Awards where PVI received the honour for 

Pollution Prevention. 

New electrical power unit helps ArcelorMittal cut energy use 

ArcelorMittal Bottrop in Germany has 

invested in a cutting-edge electrical 

power unit for its coke plant which not only 

produces electricity but also doubles up as 

a pressure reducing station. The new technology 

has been in use since September 

2013. The electrical power unit – known as 

Energy Module and supplied by ENVA Systems 

GmbH – partially substitutes a pressure 

reducing station (in which the pressure of 

the incoming steam is reduced) and uses 

the resulting energy to produce electricity 

for the coking plant’s wash water treatment. 

The energy is also fed into the coking 

plant’s power grid and consumed by various 

machines, plant sections, and pumps. 

With a production of 80 kWh, the Energy 

Module’s annual output would be sufficient 

to supply around 100 four-person 

households with electricity. Using the new 

electrical power unit also positively impacts 

operating costs, as it eliminates the need 

for steam turbines which are significantly 

more expensive and require more intensive 

maintenance. 

According to ENVA Systems GmbH, when 

used at full capacity the Energy Module 

allows a return on investment in only three 

years. But beyond economic benefits, the 

optimised use of steam through the new 

technology also results in CO 2 and primary 

energy savings – considerably improving 

Bottrop’s environmental footprint. 



NEWS 

4 

ALUMINIUM 2014 

7 – 9 Oct 2014 | Messe Düsseldorf 

10th World Trade Fair & Conference 

www.aluminium-messe.com 

Organised by 

Partners 


19

NEWS 


Loesche wins the Deutscher Bildungspreis 2014 

In the sector category “Production: small 

and medium-sized enterprises”, Loesche 

managed to come out on top against 

numerous competitors due to its best 

practice training and talent management 

and has received the Deutscher Bildungspreis 

2014. The TÜV Süd Academy and EuPD 

Research Sustainable Management present 

the Deutscher Bildungspreis (German Education 

Award) every year under the motto 

“Learning from the best”. In four sector categories, 

companies are awarded for best 

education and talent management under 

Andritz to supply new furnace plant for production 

of railroad tracks 

International technology Group Andritz has 

been awarded an order to supply a new 

walking beam furnace for the Donawitz plant 

of voestalpine Schiene GmbH, Austria, one of 

Europe’s leading suppliers of railroad tracks. 

Start-up is scheduled for the beginning of 

2016. Andritz Maerz will supply the turnkey 

furnace plant with an output of 185 t/h, 

including steel structure, refractory lining, 

transport system, combustion system, instrumentation 

and control system, mathematical 

furnace model to optimize the various 

the auspices of the Bundesministerium für 

Bildung und Forschung (Federal Ministry of 

Education and Research). 

Since 2012, over 250 companies have 

applied for the Deutscher Bildungspreis. 

The winners are selected using a practiceoriented 

and expert-based valuation method, 

which was developed in collaboration 

with personnel and training experts from 

companies of different sectors and sizes as 

well as scientists of different technical fields. 

Along with 120 other companies, Loesche 

GmbH applied for the Bildungspreis 

thermal furnace processes, buffer bed with 

separating systems, feed conveyor with automatic 

billet identification, and a complete 

hot water cooling plant with recooling and 

emergency cooling systems. 

In order to make best possible use of 

the residual heat from the waste gases, a 

heat recovery plant is planned to supply 

the district heating system. Thanks to this 

heating technology, heat consumption can 

be reduced to a minimum in spite of the 

very uniform temperature maintained, and 

2014 and was able to come out on top of the 

competition in the sector category “Production: 

small and medium-sized enterprises”. 

The award ceremony took place as part of a 

ceremonial event in the historic Munich Künstlerhaus 

(House of Art). According to Christian 

Trzeczak, Loesche Corporate Human 

Resources, the company owes this success 

to the instruments of the demand-oriented 

personnel development introduced in 2008 

as well as the close cooperation with the 

Loesche Training Center and the benefits 

for the staff associated with this. 

maximum reductions can be achieved in 

emissions of NO X and CO. 

AFC-Holcroft retrofits Tier One’s generators for new gas supply 

global Tier One automotive supplier has 

A placed an order with AFC-Holcroft for a 

production gas modernization project involving 

the purchase of new multiple-retort E-Z 

Series endothermic generators. The facility 

receiving the equipment is located in Mexico. 

The E-Z Series endothermic generators will 

provide the customer with a lower cost 

gas production option than their existing 

nitrogen/methanol systems. The return on 

investment for the new endothermic gas 

generators is typically less than two years. 

Production furnaces in the facility will 

keep their existing nitrogen/methanol gas 

systems, but the operator will now be able 

to switch between nitrogen/methanol 

supply or the less expensive endothermic 

gas produced by the new E-Z generators. 

Multiple furnaces consisting of pusher 

lines, batch integral quench units and 

mesh belt furnaces will be field retrofit 

to receive this lower-cost gas option. 

AFC-Holcroft will provide two 13,500 CFH 

units each equipped with an additional 

4,500 CFH expansion module and one 

13,500 CFH unit. Each E-Z Series generator 

will be equipped with a back-up 

mixture and blower. Three endothermic 

gas header distribution systems will also 

be field installed for endo supply into the 

existing production furnaces. To minimize 

downtime during the project, the work is 

provided as a “continuous flow” project, 

spread across three phases to provide the 

customer with uninterrupted project flow 

schedule. 


Market breakthrough for Paul Wurth’s 

tuyere phenomena detection system 

Within the past three years, Paul Wurth has 

developed a new monitoring technology 

for the tuyeres and raceway area of blast furnaces. 

An integrated system employing digital 

cameras provides continuous visualisation of 

all tuyeres on any computer connected to the 

network. Machine vision methods (extraction 

of process relevant information out of pictures) 

are applied for automatic phenomena detection, 

which is backed-up by an integrated 

mathematic blast furnace model for the raceway 

zone. This feature also includes detection 

algorithms especially designed for the use with 

tuyere-injected auxiliary reducing agents like 

pulverised coal. Direct link to the furnace’s automation 

system helps to implement additional 

emergency measures (for instance, immediate 

shut-off of PCI) improving safety for personnel, 

equipment and plant. In the course of normal 

operation, continuous remote monitoring of 

the tuyere area improves the BF process stability 

and opens potential for higher PCI rates with, 

subsequently, reduced hot metal cost. 

Paul Wurth’s new tuyere phenomena detection 

system (TPDS) has now been operating for 

more than eight months on four blast furnaces 

in Belgium and Germany, fully equipped (each 

tuyere) with 117 units in total. While two plants 

in Germany and Spain are currently evaluating 

the system’s benefits on individual tuyeres, Paul 

Wurth has recently received orders for equipping 

four more blast furnaces (in the Netherlands 

and in Germany) completely (128 tuyeres) 

with this technology. 

Vacuum furnace from Solar Manufacturing 

well received by market 

The furnace manufacturer Solar Manufac turing 

from Souderton, PA, USA has sold seven 

“Mentor” vacuum furnaces over the last twelve 

months. This illustrates that this small size furnace 

is well received by the market. When William R. 

Jones, CEO of the Solar Group of Companies, 

decided to donate a small horizontal vacuum 

furnace for use as a teaching tool in the ASM International 

training facility in Materials Park, Ohio, this 

furnace was given the name “The Mentor” as it 

would serve to teach and guide students seeking 

to advance in the metals processing world. 

At the same time that this furnace was 

engineered and manufactured, a second unit 

was built for the Solar Atmospheres Plant in 

Hermitage, PA. This furnace proved to be 

very useful for testing various materials and 

for processing smaller production loads economically. 

Because of the usefulness of this 

smaller furnace in handling many different 

needs, Solar Manufacturing elected to offer 

this furnace to the general marketplace. Several 

companies realized that such a unit could 

be a very useful piece of equipment. 

The furnace is a horizontal model HFL-2018- 

2IQ and is mounted on a single, portable platform 

for easy shipment and manoeuvrability. 

The Mentor’s work zone measures 12” x 

12” x 18” deep which allows heat treaters the 

convenience of running smaller workloads 

more economically. The hot zone design 

incorpor ates a graphite foil hot face backed 

by four layers of ½” thick, highly efficient Rayon 

graphite felt supported in a stainless steel ring 

structure. It is rated to a maximum operating 

temperature of 3,000 °F and is AMS2750E 

compliant with a temperature uniformity of 

+/- 10 °F between 800 °F and 2,400 °F. The 

furnace hearth is capable of supporting loads 

up to 250 pounds at 2,150 °F. 

22.–24.10.2014 

HK Köln 2014, 

Hall 4.1, 

Booth A-011 


21

NEWS 


Praxair builds presence in Petrochemical Park in China 

Praxair, Inc., through a subsidiary, has 

signed a long-term contract to supply 

industrial gases to Nanjing Jinling Huntsman 

New Materials Co., Ltd., a joint venture 

between Sinopec Jinling and Huntsman. 

Jinling Huntsman will use the gases to help 

build a state-of-the-art propylene oxide 

(PO) and methyl tertiary butyl ether (MTBE) 

plant located in Nanjing, East China. PO is a 

high-quality intermediate compound used 

to make polyurethane materials, and MTBE 

is a clean fuel additive. 

Praxair will construct its new air separation 

unit (ASU), with a capacity of 900 t/d 

of oxygen, in the Phase II area of Nanjing 

Chemical Industrial Park (NCIP), a leading, 

state-level interconnected chemical 

production facility. The company will also 

build a pipeline in the park to help meet 

the industrial gas requirements of Jinling 

Huntsman and other customers throughout 

NCIP. The ASU is expected to start up 

in 2016. 

According to Ju Zhengyu, general 

manager of Nanjing Jinling Huntsman 

New Materials Co., Ltd., the company is 

very pleased to select Praxair as its industrial 

gas supplier and cooperative partner, 

because as a leading global industrial gases 

company, Praxair has developed a safe and 

reliable gas solution for the project. 

The air separation plant that the company 

will build will establish Praxair as the first 

industrial gases pipeline supplier in NCIP, 

with great potential to supply more customers 

in the new phase of this top-notch 

chemical park. Praxair has a strong track 

record of developing industrial gases supply 

networks in leading chemical industrial 

parks such as Shanghai Chemical Industry 

Park, Huizhou Daya Bay Chemical Industrial 

Park and Yangzhou Chemical Industry Park. 

Sciaky to provide EBAM system to major aerospace parts maker 

Sciaky, Inc., a subsidiary of Phillips Service 

Industries, Inc. (PSI) and provider 

of large-scale additive manufacturing 

solutions, announced that it received a 

purchase order from a major aerospace 

parts maker to provide an electron beam 

additive manufacturing (EBAM) system. The 

EBAM system will help the manufacturer 

save significant time and cost on the production 

of large, high-value metal parts. 

In July Sciaky announced the availability 

of EBAM systems to the marketplace. 

This is the first of two multi-million dollar 

orders from a major global manufacturing 

company since the announcement. In addition, 

the company is working with over a 

dozen other companies and entities within 

the aerospace, defence and manufacturing 

sectors to provide EBAM systems for their 

unique needs. 

Sciaky’s EBAM technology combines 

computer-aided design (CAD), electron 

beam welding technology and layer-additive 

processing. Starting with a 3D model 

from a CAD program, the fully-articulated, 

moving electron beam welding gun deposits 

metal, layer by layer, until the part reaches 

near-net shape. From there, the near-net 

shape part requires minor post-production 

machining. The 110” x 110” x 110” (L x W x H) 

build envelope of the EBAM system will 

allow the manufacturer to produce large 

parts, with virtually no waste. 

Besides offering innovative additive 

manufacturing solutions for metal parts, 

the company provides state-of-the-art 

electron beam and advanced arc welding 

systems, as well as job shop/contract welding 

services, for manufacturers in the aerospace, 

defence, automotive, and healthcare 

industries. 


The best of 10 years 


heat processing – 

10 years – anniversary edition 

The anniversary issue celebrating ten years of the “heat processing“ technical journal 

showcases the best articles published during the past decade in this, the international 

journal for thermoprocess technology. This edition opens with prefaces 

from Dr. Timo Würz, of the VDMA (German Engineering Association) and Dr. Hermann 

Stumpp. The editorial team has selected two articles from each year of publication. 

Burners & Combustion, Induction Technology, Heat Treatment – the range of topics 

encompasses the entire thermoprocessing field. 

The expert articles track, in a retrospective, the technological and economic developments 

in the thermo-process industry. Numerous well-known industry figures from 

the business, management and academic worlds have also contributed. Technical articles 

with up-to-date contemporary content and an industry perspective for the future 

round off heat processing‘s anniversary issue. The final, essential, feature: the Hot Shots 

– selected series of high-impact images focussing on fascinating technological topics. 

Edition hp, 1st edition 2014, approx. 180 pages, in full colour, 

Brochure, DIN A4 

ISBN: 978-3-8027-2975-1 

Price: € 40.-- 

Publication: late August 2014 

Hot-Hot-Heat 

www.vulkan-verlag.de 

Events 

NEWS 

Pre-order now! 

Vulkan-Verlag GmbH, Friedrich-Ebert-Straße 55, 45127 Essen 

KNOWLEDGE FOR THE 

FUTURE 

Order now by fax: +49 201 / 82002-34 or send in a letter 

Deutscher Industrieverlag GmbH | Arnulfstr. 124 | 80636 München 

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1 st edition 2014 (ISBN: 978-3-8027-2975-1) 

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It is approved 3-2014 that heat this data processing may also be used in commercial ways by mail, by phone, by fax, by email, none. 

This approval may be withdrawn at any time. 

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Date, signature 

PAHPAE2014 

23

NEW COURSE: 

METAL 2015 

MIDDLE EAST 

INTERNATIONAL TRADE FAIR FOR METALLURGICAL TECHNOLOGY, 

THERMO PROCESS TECHNOLOGY, FOUNDRY MACHINERY AND 

METAL WORKING 

10 – 13 JANUARY 2015 

DUBAI INTERNATIONAL 

CONVENTION & EXHIBITION CENTRE, 

DUBAI, UAE 

WWW.METAL-MIDDLE-EAST.COM 

SUPPORTED BY: 

IN CONJUNCTION WITH: 

Foundry Machinery 

Metallurgical Plants and Rolling Mills 

Thermo Process Technology 

Metallurgy 

European 

Metallurgical Equipment 

Association 

5 th INTERNATIONAL 

TRADE FAIR FOR 

THE TUBE & PIPE 

INDUSTRIES 

2 nd INTERNATIONAL 

TRADE FAIR 

JOINING, CUTTING, 

SURFACING 

IN CO-OPERATION WITH: 

Messe Düsseldorf GmbH 

P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany 

Phone +49 (0) 2 11/45 60-77 93/-77 07 _ Fax +49 (0) 2 11/45 60-77 40 

RyfischD@messe-duesseldorf.de _ BurbullaK@messe-duesseldorf.de 

www.messe-duesseldorf.de

Events 

NEWS 

ITPS 2014 goes Asia 

The first ITPS (International Thermprocess 

Summit) was held successfully 

last year in Düsseldorf, Germany. 147 

participants from 16 different countries 

and exhibitors used the conference as a 

welcome opportunity to hold in-depth 

exchanges of ideas and information for 

the thermo process industry. This year, 

the industry demanded to hold the ITPS 

2014 from 27 to 28 October in Mumbai, 

India. 

The world economy is expected to 

bounce back by the year 2015 and emerging 

economies like India are expected to 

drive the global economy. With all these 

positive vibes around the entire thermo 

process industry, the organizers – Messe 

Düsseldorf India, CECOF, VDMA and “heat 

processing” – are gearing up to host ITPS 

2014 in the commercial capital of Mumbai. 

ITPS 2014 will welcome 150-200 top industry 

experts from 10+ countries worldwide. 

Excellent speeches will come from 30+ 

speakers in highly attractive sessions. 

Moreover, ITPS exhibition is staged concurrently 

to the biggest metal trade fair 

platform in India, i.e., Wire & Cable India, 

Tube India International, Metallurgy India 

& India Essen Welding & Cutting which 

will take place in the Bombay Convention 

& Exhibition Centre, Goregaon (East), 

Mumbai. 

In addition to the high-level information 

supplied, the ITPS will also have a networking 

function. Contacts between highranking 

representatives of the participating 

companies are established and maintained. 

Companies have the opportunity to present 

themselves to participants at an exhibition 

held in conjunction with the summit 

or to achieve heightened awareness during 

the event and in connection with marketing 

through various forms of sponsorship. 

The organizers’ competence guarantees an 

event of the highest quality with optimum 

benefits to participants. 

For further information please visit: 

www.itps-asia.com 

Composites Europe 2014 with new themes and special areas 

Composites are one of the key technologies 

in lightweight construction, and 

the Composites Europe trade fair reflects 

the growing market for lightweight materials. 

From 7 to 9 October, the Düsseldorf 

trade fair will once again showcase the full 

range of fibre-reinforced plastics. In addition, 

the trade fair will provide an outlook 

on the future of composites through a 

number of forums and new special areas 

such as the “Bio-based Pavilion” and “Industry 

meets Science”. 

More than 400 exhibitors from 25 nations 

– many international key players among 

them – are expected to present new lightweight 

construction concepts, materials, 

and the latest production and automation 

solutions at the ninth edition of Composites 

Europe. A total of 10,000 lightweight construction 

experts representing automotive 

engineering, aviation and boatbuilding as 

well as the wind energy and construction 

sectors are expected at the Düsseldorf Exhibition 

Centre, a third of them from outside 

Germany. Solidly booked country pavilions 

representing Italy, the Netherlands, Russia, 

China and Hungary further underscore how 

important the trade fair has become for the 

international composites sector. 

Thanks to the new special area entitled 

“Industry meets Science”, Composites Europe 

enables visitors to “grasp” – in both senses 

of the word – the latest developments and 

highlights from process engineering, dimensioning 

and quality assurance. The Institute 

of Plastics Processing (IKV) at RWTH Aachen 

University and add itional partner institutes 

will be responsible for implementing this 

special area. 

At the Product 

Demonstration Area 

the trade fair gathers 

new high-tech 

products and brings 

to life the development 

of composites 

components in live 

presentations. Exhibitors 

will include Euro- 

RTM-Group, Büfa, RH 

Schneidtechnik, 3D 

Core and Dresden 

University of Technology. 

Natural fibres are becoming increasingly 

important as biocomposites. The 

“Bio-based Pavilion”, made possible in collaboration 

with the nova-Institute in Hürth, 

showcases the advantages and potential of 

biofibres. In addition to companies from 

the WPC and NFC segments, enterprises 

associated with bio-based thermoset plastics 

and thermoplastics will also be represented 

at the trade fair. 


www.composites-europe.com 


25

NEWS 

Events 

Premiere: International Forum at ALUMINIUM 2014 

From 7 to 9 October, more than 50 nations 

will represent the entire world of aluminium 

at ALUMINIUM 2014 in Düsseldorf. With 

more than 950 exhibitors and as many as 

21,500 visitors at the last event – some 50 % 

of them from outside Germany – the world 

fair provides the most comprehensive overview 

of the industry and emerging markets. 

The trade fair’s new “International Forum” 

will put the spotlight on two of them: China 

and India. Held for the first time, the lecture 

forum in Hall 13 will serve as an information 

exchange for both German and international 

companies interested in expanding their 

activities abroad. 

How do the Chinese and Indian markets 

function? What opportunities and risks await 

European companies when launching there? 

How best to prepare trade fair appearances 

abroad? Officials representing embassies, 

regional aluminium associations and corporations 

as well as tax professionals will provide 

answers to these and other questions. The 

lecture programme starts in the morning 

and concludes with an international reception 

in the afternoon. Trade fair visitors are 

welcome to attend the International Forum 

without prior registration. Admission is free; 

lectures are held in English. The International 

Forum is presented in collaboration with the 

German-Chinese Business Association (DCW) 

and Prexma Limited. Thanks to their ties with 

organisations such as the China Aluminium 

Network, Asia-Pacific Management Consulting 

and the German-Indian Chamber of Commerce, 

both partners have access to a great 

network of experts in both markets. 



indometal 2014 – Trade fair for Indonesia’s metal and 

steel industries 

The indometal 2014 returns with a greater 

focus on the synergistic capabilities 

of foundry technology, casting products, 

metallurgy and thermo process technology 

following its inaugural success in 2013. 

Building on the global expertise of Messe 

Düsseldorf’s internationally renowned 

trade fairs Gifa, Metec, Thermprocess and 

Newcast, indometal 2014 provides the ideal 

launch pad for Asian companies to grow its 

regional and international market share of 

the metal and steel industry within Indonesia 

and around Asia. 

Jointly organized by Messe Düsseldorf 

Asia and local exhibition organizer PT 

Wahana Kemalaniaga Makmur (Wakeni), 

the trade fair brings together leading brand 

names in the metal and steel industry from 

Indonesia and abroad, providing the best 

exposure for companies with medium and 

long-term strategic plans to do business in 

Indonesia and Southeast Asia. 

indometal 2014 will be the right platform 

to meet key industry players and 

decision-makers, share new concepts and 

ideas, establish new relationships and gain 

critical business leads into Indonesia and 

the region. 


www.indometal.net 

7 th International Scientific Colloquium on MEP 

The 7 th International Scientific Colloquium 

on Modelling for Electromagnetic 

Processing is taking place in Hannover, 

Germany from 16 to 19 September 2014. In 

tradition of the international scientific colloquiums 

Modelling for Material Processing in 

Riga in 1999, 2001, 2006, 2010 and Modelling 

for Electromagnetic Processing in 

Hannover in 2003 and 2008 the Institute of 

Electrotechnology of the Leibniz University 

of Hannover and the University of Latvia 

organize the next colloquium Modelling 

for Electromagnetic Processing in Hannover 

2014. 

Recent results of numerical and experimental 

research activities in the field of 

industrial processing technologies for creating 

new and alternative materials, materials 

with highest quality and purity and new 

innovative products will be presented at 

the colloquium. 

The organizers kindly invite those who 

are interested to participate in the international 

colloquium MEP 2014 “Modelling 

for Electromagnetic Processing”. Up 

to 100 international participants from 

universities and research centres as well 

as from industrial suppliers and users of 

electromagnetic and electrothermal processes 

are expected. The colloquium will 

take place in the Leibnizhaus, the guesthouse 

of the Leibniz University of Hannover, 

located in the historical centre of 

Hannover. 


www.mep2014.uni-hannover.de 


Connecting Global Competence 

Events 

NEWS 

Aluminium Brazing 2014 

with record number of visitors 

F 

or the second time, DVS – Deutscher Verband für 

Schweißen und verwandte Verfahren e.V., with the 

support of DVS Media GmbH, had been the organizer 

of the 8 th International Congress Aluminium Brazing and 

Exhibition. From 3 to 5 June 2014, 250 participants and 

13 exhibitors from 28 countries had made their way to 

Düssel dorf to the Radisson Blu Scandinavia Hotel and thus 

set a new record number of visitors for the event. 

22 lectures shed light from different sides on the world of 

brazing of aluminium materials. A wide range of topics from 

research and practice had been offered to interested visitors, 

starting from the materials topic through applications, 

devices, process and quality control, up to research and 

development. The participants largely came from industry, 

and they assessed the lectures for the most part as being 

very informative and the majority of them also intend to 

attend the congress again in 2016. 

The accompanying exhibition offered the participants 

the opportunity to inform themselves in detail about the 

current product range and service offer of the companies 

present. At the same time, the overall event was an ideal 

platform in order to refresh industry contacts and to establish 

new ones. Above all, the international aspect of the 8 th 

International Congress Aluminium Brazing and Exhibition 

was of particular importance for many visitors and exhibitors. 

For instance, one exhibitor commented that the congress 

kept getting more and more international interest, 

something that is important from her perspective. 

From April 19 to 21, 2016, the 9 th International Congress 

Aluminium Brazing and Exhibition intends to continue with 

this year’s successful event. 

For further information please visit: www.dvs-ev.de/ 

aluminium-brazing 

The perfect recipe for success. 

ceramitec 2015 is the surefire way to 

give your business the competitive edge. 

Exhibit at this leading international exhibition 

and enjoy the benefits of a truly 

professional forum: 

∙ Full coverage of the ceramics sector. 

∙ High-caliber trade audience from 

around the world. 

∙ Professional services for exhibitors. 

Don’t delay. Sign up today! 

To register: 

www.ceramitec.de/application 


27

NEWS 

Events 

DIARY 

11-13 Sep. 

16-19 Sep. 

16-19 Sep. 

17-19 Sep. 

21-24. Sep. 

24-25 Sep. 

24-27 Sep. 

30 Sep. - 

1 Oct. 

6-8 Oct. 

7-9 Oct. 

7-9 Oct. 

22-24 Oct. 

27-28 Oct. 

28-30. Oct. 

Ankiros / Annofer / Turkcast 

in Istanbul, Turkey 

www.hmankiros.com 

7 th MEP – Modelling for Electromagnetic Processing 

in Hanover, Germany 

www.mep2014.uni-hannover.de 

Metalurgia 2014 

in Joinville, Brazil 

www.metalurgia.com.br 

KazMet 2014 

in Almaty, Kazakhstan 

www.kazmet.iteca.kz 

Euro PM2014 

in Salzburg, Austria 

www.epma.com/pm2014 

57 th International Colloquium on Refractories 

in Aachen, Germany 

www.feuerfest-kolloquium.de 

wire + Tube China 

in Shanghai, China 

www.wirechina.net 

www.tubechina.net 

CWIEME 

in Chicago (IL), United States 

www.coilwindingexpo.com 

Furnaces North America 

In Nashville (TN), United States 

www.furnacesnorthamerica.com 

Aluminium 2014 

in Düsseldorf, Germany 


Composites Europe 

in Düsseldorf, Germany 

www.composites-europe.com 

70 th Heat Treatment Congress 

in Cologne, Germany 

www.hk-awt.de 

ITPS Asia – 2 nd International Thermprocess Summit 

in Mumbai, India 

www.itps-asia.com 

5 th Metallurgy India / 6 th Tube India / 5 th Wire & Cable India / 

6 th Welding & Cutting India 

in Mumbai, India 

www.metallurgy-india.com / www.tube-india.com / 

www.wire-india.com / www.i-ewc.com 

Expansion of 

Metalurgia 2014 

T 

he metal-mechanic industry in Brazil is 

coming out of a retraction phase and is 

already showing signs of recovery, with a forecast 

for expansion in the coming years. In the 

truck industry alone, six new factories have 

begun their activities in the country: DAF, JAC, 

Foton Aumark, Sinotruck, Metro-Schacman and 

International. While those already installed are 

expanding their lines with heavier models, 

showing that there will be strong demand 

growth in the sector. The northern region of 

Santa Catarina is one of Brazil’s most developed 

in this sector, and is attracting large companies 

to install new plants, like GM with its two units 

and BMW; adding to those already based here 

such as Tupy, Docol, Whirlpool , Embraco, Weg, 

Tuper, ArcelorMittal, Marcegaglia, Schulz, Zen, 

Wetzel, Altona and others. 

At the centre of all this expansion is the 

Metalurgia fair, which attracts exhibitors and 

visitors from Brazil and abroad. For over 15 years 

it has integrated and developed the sector’s 

supply chain by presenting innovative products 

with technological advances. By participating 

in Metalurgia 2014, visitors have access 

to the entire national market in its moment of 

recovery. 

The Metalurgia – International Fair and 

Congress of Technology for Casting, Forging, 

Aluminum and Services is the sector’s largest 

fair held in Brazil. It always takes place in even 

years and, in 2014, will be held from 16 to 19 

September 2014. 

In the 2012 edition, in an area of 20,000 m 2 , 

the fair brought together 24,000 visitors, who 

conferred the latest news brought by 450 

exhibiting companies from Brazil, Germany, 

USA, China, Italy and Spain. The trade show 

generated approximately R$ 450 million in business 

during the fair itself and within the following 

six months, due to contacts initiated at the 

event. Metalurgia is a realization of Brazilian 

Foundry Association (Abifa), with organization 

by Messe Brasil. 


www.metalurgia.com.br 


Events 

NEWS 

Coming up of 6 th wire & Tube China 

This year the All China International 

Tube and Pipe Industry Trade Fair (Tube 

China 2014) and the All China International 

Wire & Cable Industry Trade Fair (Wire China 

2014) are to be held concurrently for the 

sixth time at Shanghai New International 

Expo Centre (SNIEC). Organized by Messe 

Düsseldorf (Shanghai) Co., Ltd. (MDS) the 

two trade fairs will take place from 24 to 

27 September 2014. 

As an international trade fair the Wire 

China provides exhibitors and suppliers 

of wires and cables in addition to the latest 

technology, specialty products and 

innovative machines around the wire and 

cable manufacturing, a unique communication 

platform. Experts from all over 

the world use the trade fair not only as 

an information centre for the developments 

and trends in wire, cable and wireprocessing 

industries: This key fair is the 

international forum for the purpose of 

setting up closer business contacts and 

for intensifying existing relations with 

customers. 

The Tube China is one of the world’s 

largest trade fairs for tube and pipe technologies. 

It has long been recognized as 

a forum for cutting edge technologies 

and provides one of the best platforms 

for trade and exchange. The fair provides 

novel materials and 

products, innovative 

machinery and 

production processes. 

The visitors can 

inform themselves 

about all these 

themes comprehensively. 

Given the glorious 

success of the 

previous four editions, 

the era of 

strong demand in 

tube & pipe, and 

great opportunities along with the fast growing 

tube & pipe industry in East China, Tube 

China 2014 will continue to lead the latest 

trend in China’s tube and pipe industry and 

establish a trade and exchange platform. 


www.wirechina.net or 

www.tubechina.net 

Ankiros/Annofer/Turkcast 2014 fairs in Istanbul 

This year’s Ankiros/Annofer/Turkcast will 

be organized by Hannover-Messe Ankiros 

A.S. from 11 to 13 September at Tuyap Fair 

and Congress Center in Istanbul, Turkey. The 

visiting hours are 9:30 to 19:00 daily. These 

fairs have become the largest and most prestigious 

metallurgy events of Eurasia aiming to 

bring together all the key players of foundry, 

iron & steel and non-ferrous metals industries 

under one roof. Taking place every two years 

since 1991, the exhibition size and scale has 

expended each year, establishing a reputation 

as one of the most significant exhibitions 

for industry suppliers. The fairs will form 

a chain of foundries, iron & steel and nonferrous 

metals industries which will bring a 

great convenience to exhibitors and visitors. 

The 2012 edition of this exhibition trio 

was a great success as 850 exhibitors from 

39 countries, more than 15,000 industry professionals 

from all around the world gathered 

in the 20,141 m 2 stand area. The 2014 

event will have 22,000 m 2 of net stand area 

to accommodate the expected more than 

950 exhibitors and more than 16,000 visitors. 

The fairs will play an important role in the 

metallurgy industry and bring great business 

opportunities again. 

By visiting Ankiros/Annofer 2014, one 

will have access to latest products including 

furnaces, refractory materials, molding 

lines, dust preparatories, foundry machines, 

laboratory and analysis machines, turnkey 

metallurgical facilities, rolling equipment and 

all kinds of heat processing products and 

materials in halls 2, 3, 5 and 6. The exhibitions 

will present a full range of business 

opportunities and smart solutions. In halls 

8 and 9 steel producers, steel service centres 

and global steel suppliers will exhibit 

together. Some of the leading suppliers of 

global metallurgy industry such as Germany, 

Italy, Spain, China, United Kingdom and Iran 

will be showcasing in the country pavilions 

which are supported by their governments. 

Turkcast 2014 is a unique platform where 

the leading Turkish foundries will exhibit their 

latest products and technologies for global 

castings buyers across various industries in 

hall 7. The fair will provide a wide ranging 

selection of castings for automotive, heavy 

equipment, construction, cement, heavy 

machinery, shipment, agricultural machinery, 

white good, energy, defence, glass and 

ceramic industries. 


www.ankiros.com 


29

NEWS 

Events 

11 th Furnaces North America 

This year will mark the 11 th Furnaces 

North America (FNA) produced by 

the Metal Treating Institute and its media 

Partner Industrial Heating Magazine. 

Established in 1995, FNA has become 

synonymous with bringing top suppliers 

and heat treaters, both captive and commercial, 

from around the world to one location 

for technical education, networking 

and the latest developments in furnace 

equipment, accessories and services. 

The Furnaces North America (FNA 

2012) will take place in Nashville, Tennessee 

from 6 to 8 October and it is full of 

technical information, trends, business and 

networking opportunities. The trade fair is 

truly a worldwide event with heat treaters 

and suppliers attending from nearly 40+ 

states and over 15 countries to experience 

this 2-day event. 

FNA 2014 will be the largest heat treat 

show of the year in North America, offering 

over 30 technical sessions with the 

information to energize your business, 

2-day trade show to network with 150+ 

top suppliers to see the latest trends and 

technology. 

Bottom line, everywhere the visitors 

turn, there are people who are experiencing 

the same challenges and successes as 

they do. Attending FNA gives participants 

a wealth of information to help create new 

ideas and energize their company back to 

record productivity. 


www.furnacesnorthamerica.com 

Euro PM2014 in Austria 

Europe’s annual powder metallurgy 

congress and exhibition organised 

and sponsored by the European Powder 

Metallurgy Association, will make its return 

to Austria in 2014. This will be the first time 

the Euro PM event has visited Austria since 

the World PM2004 in Vienna. 

The Euro PM2014 Congress and 

Exhibition will be held at the Messezentrum 

Salzburg in Salzburg, a UNESCO World Heritage 

Site, from 21 to 24 September 2014. 

The combination of a world class technical 

programme and state-of-the-art exhibition 

will provide the ideal networking opportunity 

for suppliers, producers and end-users. 

The congress is an all topic powder metallurgy 

event featuring: 

■■ 

Additive manufacturing, 

■■ 

Hard materials and diamond tools, 

■■ 

Hot isostatic pressing, 

■■ 

New materials and applications, 

■■ 

PM structural parts, 

■■ 

Powder injection moulding. 

Following the great success of Euro PM2013 

in Gothenburg, the organizers are expecting 

a considerable attendance from all over 

Europe and beyond, with what will surely 

be an outstanding level of technical presentations 

and key note speeches to share 

and promote the latest developments in 

PM technologies and markets. 

Salzburg is the perfect location to hold 

the next Euro PM event as Austria plays 

a great role in powder metallurgy with a 

number of companies involved in this field 

having had a leading role in the development 

of cemented carbide, hardmetals, 

the tungsten industry, powder metallurgy 

refractory metals, and also technologies like 

gas powder atomization processes. 

To improve the onsite experience 

EPMA will be launching a web app. 


www.epma.com/pm 2014 

Visit us at the HK 2014 

Vulkan-Verlag 

Hall 4.1 / Booth G 018 

22 - 24 October 2014 

Koelnmesse, Cologne 

Germany 


Personal 

NEWS 

The future — your future — is on full display at FABTECH. From 1,400+ exhibits with end-to-end 

solutions in metal forming, fabricating, welding and finishing, to the industry’s leading education 

and peer-to-peer networking, this is your opportunity to capitalize on the future. 

The answers and know-how you need for the challenges of tomorrow can be found at FABTECH. 

Visit fabtechexpo.com for complete event details. REGISTER TODAY! 


31

NEWS 

Personal 

Nucor Executive Vice President 

Keith Grass to retire 

Nucor Corporation announced that 

Keith Grass, Nucor’s Executive Vice 

President of Raw Materials and Chief 

Executive Officer of The David J. Joseph 

Company (DJJ), plans to retire effective 

12 September 2014. Grass joined DJJ in 

1978. He began his career as a brokerage 

representative and then as district 

manager of several DJJ trading offices. He 

was appointed Vice President of Trading 

in 1992. From 1996 to 1998, he served as 

President of DJJ’s International Division. 

He headed the Metals Recycling Division 

during 1999 and served as President of 

DJJ from 2000 until December 2012. Grass 

has served as CEO of DJJ since 2000 and 

was appointed Executive Vice President 

of Nucor Corporation when DJJ became 

part of Nucor in 2008. 

Upon the retirement of Keith Grass, 

Joe Stratman, who began his Nucor 

career in 1989 and has served as Executive 

Vice President since 2007, will 

assume EVP responsibilities for the raw 

materials group, which, in addition to 

DJJ, includes Nucor’s natural gas investments 

and logistics. 

Nucor and affiliates are manufacturers 

of steel products, with operating 

facilities primarily in the US and Canada. 

Products produced include: carbon and 

alloy steel – in bars, beams, sheet and 

plate; steel piling; steel joists and joist 

girders; steel deck; fabricated concrete 

reinforcing steel; cold finished steel; steel 

fasteners; metal building systems; steel 

grating and expanded metal; and wire 

and wire mesh. 

China names new 

General Manager 

for Baosteel Group 

China’s Baosteel Group, which owns the 

country’s biggest listed steelmaker, 

has named Chen Derong as its General 

Manager, replacing He Wenbo. Chen (53) 

used to be the Vice General Manager of 

Zhejiang Metallurgical Group and the 

vice governor of eastern Zhejiang province. 

Furthermore Chen once worked in 

Hangzhou Iron & Steel Group Company 

for many years. 

The 59-year-old He Wenbo also resigned 

as the chairman of Baoshan Iron and Steel 

Co Ltd. He, who has been working for Baosteel 

since 1982, will be assigned a new job, 

the company announced without elaborating. 

The official Xinhua news agency cited 

unidentified sources as saying He could be 

made the general manager of mining giant 

China Minmetals Corp. 

Michael Majerus new CFO of SGL Carbon 

The Supervisory Board of SGL Carbon 

SE has appointed Dr. Michael Majerus 

(photo) as CFO effective 1 July 2014 for a 

three year term until 30 June 2017. By mutual 

agreement, Jürgen Muth stepped down 

from the Board of Management as of 30 

June 2014. 

Dr. Michael Majerus was born on 6 February 

1961 in Cologne and studied business 

administration at the University of 

Cologne. Following his doctorate at the 

University of Siegen, he commenced his 

professional career in 1989 in the financial 

controlling department at Mannesmann 

AG. In the following years he held various 

executive functions in finance-related areas 

within the Mannesmann Group. From 1999 

to 2000, as Central Divisional Director, he 

had responsibility for financial controlling 

and accounting at the Mannesmann 

Group. Following the acquisition by Vodafone, 

he held the same position for the 

industrial activities under the umbrella of 

ATECS Mannesmann AG. From the end of 

2000 until 2006, he was a member of the 

divisional management board and CFO of 

the Memory Products Division at Infineon 

Technologies AG. After the division became 

a legally independent entity incorporated 

as Qimonda AG, he was appointed CFO and 

Labor Director of the company in 2006 and 

subsequently prepared the company’s IPO 

on the New York Stock Exchange. Following 

his departure from Qimonda AG, he 

became a member of the management 

board (CFO) of PHOENIX Pharmahandel 

GmbH & Co KG from 2009 to 2013. 


Personal 

NEWS 

Robrecht Himpe elected new Eurofer President 

Robrecht Himpe (photo), executive 

vice president at ArcelorMittal Europe, 

has been appointed as new president of 

Eurofer, the European Steel Association. At 

European Steel Day he addressed hundreds 

of delegates in his new function. He identified 

three targets for his presidency, to 

ensure the future of the steel industry in 

Europe: market demand, trade, and energy 

and climate. With steel demand in Europe 

still 25 % below pre-crisis levels – despite 

positive signs of a moderate recovery in the 

EU economy – Himpe reminded delegates 

that rising steel consumption of European 

steel, together with support from policymakers, 

is needed to create an internationally 

competitive environment for the industry: 

“We are all aware that industry is the 

backbone of the European economy. Being 

at the beginning of the supply chain, the 

steel industry has a special position in the 

manufacturing industry in Europe, accounting 

for more than 350,000 direct jobs and 

1.5 million indirect jobs through the supply 

chain.” As such a major employer in the 

region, Himpe called on the European 

Commission (EC) to take the steel industry 

into account, as a strategic sector for the 

EU economy. 

Eurofer was founded in 1976 and 

has 59 direct member companies and 

national associations, representing 528 

production facilities in 24 EU member 

states. voestalpine CEO Wolfgang Eder 

was the previous Eurofer president, serving 

for four years. 


33

NEWS 

Personal 

Peter Schwab new member of the voestalpine 

Management Board 

In its meeting, the Supervisory Board 

of voestalpine AG has appointed former 

Head of Group Research, DI Dr. Peter 

Schwab, to become a member of the Management 

Board of voestalpine AG, with 

effect from 1 October 2014. Consequently, 

from October 2014 the Management Board 

will consist of six, rather than five members. 

DI Dr. Peter Schwab will become the 

Head of the Metal Forming Division. The 

former Head of this Division, DI Herbert 

Eibensteiner, will become Head of the Steel 

Division from October 2014. In future, Dr. 

Wolfgang Eder, Chairman of the Management 

Board, and Head of the Steel Division 

since 1999, will be exclusively responsible 

for group activities and increasingly focus 

on the group’s strategic development. 

These changes to the Management Board 

and the allocation of responsibilities reflect 

the growth of the voestalpine Group over 

the past years. The term of office for each 

Management Board member ends on 31 

March 2019. 

Change in Management Board of Trumpf 

As of the end of the 2013/14 financial 

year, Harald Völker stepped down from 

the Group Management Board of Trumpf 

GmbH + Co. KG. Dr. Lars Grünert (photo), 

who was already a member of the Management 

Board of the machine tool and laser 

manufacturer in Ditzingen, took over his 

duties as CFO. 

Harald Völker (59) worked for Trumpf 

since 1990 and held the position as CFO of 

Trumpf GmbH + Co. KG and at the same 

time as Chairman of the Medical Technology 

Division since 2001. According to Dr. Nicola 

Leibinger-Kammüller, Chairwoman of the 

Trumpf Management Board, Harald Völker 

played a decisive role in shaping the success 

of the company in the past two decades. He 

made the Medical Technology Division a 

highly regarded player in the market. Moreover, 

it is largely thanks to him that Trumpf as 

a company was able to cope with the great 

crisis so well after 2008, she added. 

Dr. rer. pol. Lars Grünert (46), who has 

been working for Trumpf since 2002, is 

the new CFO. Dr. Grünert has been Executive 

Vice President of Trumpf GmbH + Co. 

KG since 2010 and was up to now CFO of 

the Laser Technology/Electronics Division. 

Within the Group Management Board he 

remains responsible for organizational 

development and information technology, 

among other things. 

IHEA announces 2014-15 Board of Directors and Officers 

At IHEA’s 85 th Annual Meeting at the 

Westin Verasa in Napa, California, the 

Industrial Heating Equipment Association 

announced its 2014-15 Board of Directors 

and Officers. Serving a second term 

as president is Tim Lee of Maxon, a div. of 

Honeywell. B.J. Bernard of Surface Combustion 

was elected IHEA Vice-President 

and Daniel Llaguno of Nutec Bickley was 

elected Treasurer. Past president, Mike Shay 

of Elster Kromschröder remains in that role 

and continues to serve on the Board of 

Directors. 

Furthermore IHEA announced the 

addition of three new board members 

to serve three-year terms; Francis Liebens 

of Solo Swiss; Michael Stowe of Advanced 

Energy and Aaron Zoeller of SCC Combustion 

Inc. Appointed to the IHEA Board 

of Directors to serve unexpired terms of 

open board seats are Scott Schindlbeck 

of Eclipse, Inc. and Jonathan Markley of 

Seco/Warwick. Continuing their service 

on the Board of Directors for 2014-2015; 

David Bovenizer, Selas Heat Technology 

Co.; Mike Chapman, Vulcan Catalytic 

Systems; Jay Cherry, Wellman Furnaces; 

John Podach, Fostoria Process Equip. – 

a Division of TPI; and John Stanley, Karl 

Dungs, Inc. 


Handbook of 

Aluminium Recycling 


Personal NEWS 

Order now! 

Mechanical Preparation | Metallurgical Processing | 


The Handbook has proven to be helpful to plant designers and operators 

for engineering and production of aluminium recycling plants. The 

book deals with aluminium as material and its recovery from bauxite, 

the various process steps and procedures, melting and casting plants, 

metal treatment facilities, provisions and equipment for environmental 

control and workforce safety, cold and hot recycling of aluminium including 

scrap preparation and remelting, operation and plant management. 

Due to more and more stringent regulations for environmental control 

and fuel efficiency as well as quality requirements sections about salt 

slag recycling, oxy-fuel heating and heat treatment processes are now incorporated 

in the new edition. The reader is thus provided with a detailed 

overview of the technology of aluminium recycling. 

Editor: Christoph Schmitz 

2 nd edition 2014, 556 pages, hardcover, 

with interactive e-book (read-online access) 

ISBN: 978-3-8027-2970-6 

Price: € 130,- 

Vulkan-Verlag GmbH, Friedrich-Ebert-Straße 55, 45127 Essen, Germany 


FUTURE 




— copies of Handbook of Aluminium Recycling 

2 nd edition 2014 (ISBN: 978-3-8027-2970-6 ) 

at the price of € 130,- (plus postage and packing) 

Company/institution 








45039 Essen 

GERMANY 

Phone 

E-mail 


Fax 


to Vulkan Verlag GmbH, Versandbuchhandlung, Friedrich-Ebert-Str. 55, 45127 Essen, Germany. 


It is approved 3-2014 that heat this data processing may also be used in commercial ways by mail, by phone, by fax, by email, none. 


✘ 


PAHBAR2014 

35

t induction technology. 

nd easy maintenance. 

erformance. 

23.05.2013 15:27:32 

2 nd Edition 

NEWS 

Media 

INFO 

by K.S.K. Weranga, Sisil 

Kumarawadu, 

D.P. Chandima 

1 st edition 2014 

141 pages, softcover 

€ 53.49 

ISBN: 978-981-4451-81-9 

www.springer.com 

Smart metering design and applications 

Taking into account the present day trends 

and the requirements, this brief focuses 

on smart metering of electricity for next 

generation energy efficiency and conservation. 

The contents include discussions on the 

smart metering concepts and existing technologies 

and systems as well as design and 

implementation of smart metering schemes 

together with detailed examples. 

The table of contents includes: smart 

grid and smart metering, evolution of 

electricity meters, basic functionalities 

inside an energy measurement chip, 

smart meter prototype design, shortterm 

demand forecasting and warning 

signal generation as well as smart metering 

applications. 

UT 

ION 

m 

Erwin Dötsch Inductive Melting and Holding 

2 nd Edition 

Erwin Dötsch 

Inductive Melting 

and Holding 

Fundamentals | Plants and Furnaces | Process Engineering 

INFO 

by Erwin Dötsch 

2 nd edition 2013 

306 pages, hardcover 

incl. ebook, 

€ 75.00 

ISBN: 978-3-8027-2386-5 


Inductive melting and holding 

The second, revised edition of this standard 

work for engineers, technicians 

and other practitioners working in melting 

shops and foundries appeared in mid-2013. 

This new version of the title on inductive 

melting and temperature maintenance 

originally published in 2009 is the result of 

the great demand generated at that time, 

and includes coverage of the plant- and 

process-engineering advances achieved 

during the intervening four years. These 

relate, in particular, to the use of the induction 

furnace in electric-steel production, 

a field in which this environmentally and 

mains-friendly melting system has evolved 

into a genuine and advantageous alternative 

to the electric arc furnace. Characteristic 

of this is the recent increase in inverter 

supply power from its maximum of 18 MW 

at the time of publication of the first edition 

of the book to its present 42 MW to permit 

supply of 65 t crucible furnaces. 

INFO 

by Cecil L. Smith 

1 st edition June 2014 

336 pages, hardcover 

€ 88.20 

ISBN: 978-0-470-38199-1 

www.wiley.com 

Control of batch processes 

This book gives a real world explanation 

of how to analyze and troubleshoot a 

process control system in a batch process 

plant. This is important since batch 

processing is used extensively in the 

pharma ceutical, biotechnology, coatings, 

electronic materials etc. industries, where 

new jobs are being created. 

In batch processes the product is made 

in discrete batches sequentially performing 

a number of processing steps on raw 

materials and intermediate products. For 

example, fixed amounts of reactants may 

be charged to a vessel, mixed and heated 

to a reaction temperature, reacted for a 

fixed period of time, drained from the vessel, 

separated, dried and packaged. In a 

batch process, the path followed is state 

space is often important. Consequently, 

compared to continuous process, batch 

process control requires a greater percentage 

of discrete logic and sequential control 

than regulatory control loops. Batch 

Control applications must control the timing 

and sequencing of the process steps 

based on discrete inputs and outputs as 

well as analog outputs. Batch processing 

is often used when more precise higher 

quality products have to be made therefore 

batch processing is used in pharmaceutical 

formulations, biotech products, electronic 

materials, coatings, food products. It is also 

used in beverage processing, dairy processing 

and soap manufacturing. 




03 I 2014 

ISSN 1611-616X 

Vulkan-Verlag 


Halle 4.1/Stand E-040 

Hall 4.1/Booth E-040 

Energieberater! 

Ipsen optimiert die Effizienz seiner Öfen und Anlagen. EcoFire, HybridCarb und Endo- 

Save sind nur drei unserer Verfahren, die mit diesem Ziel entwickelt wurden. Die mittels 

EcoFire optimierte Verbrennung sorgt für eine hocheffiziente Energienutzung während 

HybridCarb und EndoSave den Prozessgasverbrauch in signifikante Weise reduzieren. 

Energy Consultant! 

Ipsen is optimizing the efficiency of its furnaces and systems. EcoFire, HybridCarb 

and EndoSave are just three of our processes that have been developed with this goal 

in mind. Combustion optimized using the EcoFire system ensures highly efficient energy 

use while HybridCarb and EndoSave significantly reduce process gas consumption. 

www.ipsen.de 

INFORMATION 

All about the HK 2014 in 

Cologne (Germany) 

BASIC DATA 

Details and site plan of the 

new venue 

PRODUCT PREVIEW 

The latest product highlights 

from the HK-Exhibitors



The best of 10 years 


heat processing – 

10 years – anniversary edition 

The anniversary issue celebrating ten years of the “heat processing“ technical journal 

showcases the best articles published during the past decade in this, the international 

journal for thermoprocess technology. This edition opens with prefaces 

from Dr. Timo Würz, of the VDMA (German Engineering Association) and Dr. Hermann 

Stumpp. The editorial team has selected two articles from each year of publication. 

Burners & Combustion, Induction Technology, Heat Treatment – the range of topics 

encompasses the entire thermoprocessing field. 

The expert articles track, in a retrospective, the technological and economic developments 

in the thermo-process industry. Numerous well-known industry figures from 

the business, management and academic worlds have also contributed. Technical articles 

with up-to-date contemporary content and an industry perspective for the future 

round off heat processing‘s anniversary issue. The final, essential, feature: the Hot Shots 

– selected series of high-impact images focussing on fascinating technological topics. 

Edition hp, 1st edition 2014, approx. 180 pages, in full colour, 

Brochure, DIN A4 

ISBN: 978-3-8027-2975-1 

Price: € 40.-- 

Publication: late August 2014 

Hot-Hot-Heat 

Pre-order now! 



FUTURE 




— copies of heat processing – 10 years – anniversary edition 

1 st edition 2014 (ISBN: 978-3-8027-2975-1) 

at the price of € 40.-- (plus postage and packing) 

Company / institution 








45039 Essen 

GERMANY 

Phone 

E-mail 


Fax 


to Vulkan Verlag GmbH, Versandbuchhandlung, Postfach 10 39 62, 45039 Essen, Germany. 


38 

It is approved that this data may also be used in commercial ways by mail, by phone, by fax, by email, none. 


✘ 


heat processing 3-2014 

PAHPAE2014

GENERAL INFORMATION 

Heat Treatment Congress 2014 

The Heat Treatment Congress’ move to Cologne is in full 

swing. Once again, this year’s lineup of high caliber presentations 

will include several that are guaranteed to be the icing 

on the cake. As the plenary speaker visitors will be able to listen 

to Prof. Harry Bhadeshia from Cambridge University who will 

hold lecture on “Extraordinary bainitic steels”. To report on the 

successful evaluation of the pre-competitive collective 

research program, the organizers have invited Burkhard 

Schmidt, Managing Director of the research division of the 

German Federation of Industrial Research Associations (AiF). 

Detlef Dauke from the Federal Ministry for Economic Affairs 

and Energy will make a short welcoming speech in the name 

of the Ministry. 

The organizers are especially happy to welcome Dr. Joachim 

Wüst, Vice-President and Counsel of the festival committee of 

the Cologne Carnival and President of the “Große Kölner” as a 

guest speaker. He will introduce participants to the “kölsche” 

way of life with the motto: “Hey Kölle do bes e Jeföhl” (Cologne 

dialect: Cologne, you are a feeling). 

Besides hosting the Heat Treatment Congress 2014, the city 

of Cologne has much more to see. The Cologne Cathedral, built 

between 1248 and 1880, is always worth a visit and its towers 

offer a fantastic view over one of the oldest cities in Germany. 

Whether visiting the Romano-Germanic Museum, looking 

around the Roman Praetorium or taking a walk past the medieval 

city gates – Cologne’s 2,000-year history can be felt everywhere. 

Situated directly on the Rhine and marked by narrow 

gables and high slated roofs, the Old City of Cologne stands out 

with its unmistakable, historically appearing character. 

Visitors who arrive by car have to note that effective 1 January 

2008, Cologne’s downtown area was declared a “low emission 

zone”. This means that only vehicles with one of the stickers 

for Emission Groups 2 to 4 are allowed to enter this area. The 

Koelnmesse exhibition centre will remain accessible for all types 

of vehicles, even if they do not bear one of the aforementioned 

stickers. All of the routes for driving to and from the exhibition 

centre can be found at: www.koelnmesse.de 

However, only vehicles that bear the pertinent sticker will be 

allowed to drive outside of these routes. Trade fair visitors can 

apply for a sticker that allows them to drive into the environmental 

zone at: www.umwelt-plakette.de 

Starting now it is possible to register for the congress and the 

exhibition via the new HK ticket shop. The ticket shop provides 

all visitors with the opportunity to administer their address data 

and print or download onto their phones their own personal 

admission code for the event. The congress will be simultaneously 

translated German/English vice versa. In this way the organizer 

AWT (Association for Heat Treatment and Materials Technology) 

creates a forum for international knowledge transfer. This 

also addresses a significantly increased demand on the part of 

foreign visitors. 

Starting now you can find the final program of events for the 

2014 Heat Treatment Congress and all information on the exhibition 

on the individual HK website: www.hk-awt.de 



39

BASIC DATA 


Heat Treatment Congress 2014 

Basic Data 

Location 

Koelmesse 

Messeplatz 1 

50679 Köln, Germany 

Entrance West 

Organiser 

Arbeitsgemeinschaft Wärmebehandlung und Werkstofftechnik 

e.V. (AWT) 

Paul-Feller-Straße 1 

28199 Bremen, Germany 

Tel.: +49 (0) 421 / 5229339 

Fax: +49 (0) 421 / 5229041 

E-Mail: info@awt-online.org 

Internet: www.awt-online.org 

Entdecken Sie die Koelnmesse 

Discover the Koelnmesse 

A57 Zoobrücke 

Opening hours 

Wednesday, 22 October 2014, 9.00 - 18.00 h 

Thursday, 23 October 2014, 9.00 - 18.00 h 

Friday, 24 October 2014, 9.00 - 14.00 h 

Fees 

Complete program: 690 € 

Speakers and university employees: 385 € 

1-day-ticket: 460 € 

2-day-ticket: 575 € 

Transferrable ticket for exhibitors: 320 € 

Practitioner’s seminar (only in German language) 

- One seminar: 150 € 

- Both seminars: 290 € 

All prices incl. 7 % VAT. 

Rheinpark 

CC Nord 

Messeallee Nord 

Messeplatz 

Eingang Nord 

Entrance North 

Congress-Centrum Nord 

Congress Centre North 

Boulevard 

Messehochhaus 

Tanzbrunnen 

Rheinterrassen 

Theater am 

Tanzbrunnen 

Eingang West 

Entrance West 

Staatenhaus 

am Rheinpark 

Auenweg 

Messeallee West 

CC Ost 

Messe-Kreisel 

3, 4 

Pfälzischer Ring 

A3 /A4 

Autobahnkreuz Köln-Ost 

A3 Frankfurt/Oberhausen 

A4 Olpe 

Hauptbahnhof 

Central Station 

City 

Hohenzollernbrücke 

Eingang Süd 

Entrance South 

Messeallee Süd 

Barmer Straße 

1, 9 

Deutz-Mülheimer Straße 

Eingang Ost 

Entrance East 

Congress-Centrum Ost 

Congress Centre East 

Bahnhof Köln Messe / Deutz – Sonderhalte ICE- und IC-Züge 

Train Station Köln Messe / Deutz – Special stops rapid trains 

LANXESS arena 

40 

Dom 

Cathedral 

Opladener Straße 

3, 4 

City 


aße 

raße 

A4, Aachen


Focus on Innovation. 

HeatTreatmentCongress Cologne / AICHELIN Group booth E-060. 

www.aichelin.com 


41

PROGRAM 



Congress 2014 

Program 

Wednesday, 22 October 2014 

PRACTITIONERS’ SEMINAR (only in German language) 

9:00 - 10:30 h 

Nitrieren im Gas und im Plasma – Bauteilbezogene 

Verfahrensauswahl unter wirtschaftlichen Gesichtspunkten 

Marco Jost 

10:30 - 10:45 h 

Coffee break 

10:45 - 12:15 h 

Wärmebehandlung – Fehler, Schäden und Ursachen 

Peter Sommer 

13:50 - 14:30 h 

Plenary lecture 

Hey Kölle, do bes e Jeföhl 

Joachim Wüst 

INTEGRATION OF HEAT TREATMENT INTO 

THE PRODUCTION 

Chairmen: Michael Lohrmann, Berthold Scholtes 

14:30 - 15:05 h 

Survey lecture 

Integration of heat treatment into the production line 

Wilfried Goy 

15:05 - 15:30 h 

Integration of heat treatment into mechanical large 

scale production – based on the example of modern 

gear production 

Karl Ritter 

15:30 - 15:55 h 

Direct integration of plasma nitriding into manufacturing 

Uwe Huchel 

15:55 - 16:15 h 


LEIGHTWEIGHT 

Chairmen: Dieter Liedtke, Marco Jost 

or 

9:00 - 10:30 h 

Wärmebehandlung – Fehler, Schäden und Ursachen 

Peter Sommer 

10:30 - 10:45 h 


10:45 - 12:15 h 

Nitrieren im Gas und im Plasma – Bauteilbezogene 

Verfahrensauswahl unter wirtschaftlichen Gesichtspunkten 

Marco Jost 

13:30 - 13:40 h 

Opening 

Michael Lohrmann 

16:15 - 16:40 h 

Lightweight forging initiative 

Hans-Willi Raedt 

THERMOCHEMICAL PROCESSES 

Chairmen: Dieter Liedtke, Marco Jost 

16:40 - 17:05 h 

Recent development on the microstructure and the 

mechanical properties of carbonitrided parts, part 1: 

Heat treatment and microstructure 

Matthias Steinbacher 

17:05 - 17:30 h 

Recent development on the microstructure and the 

mechanical properties of carbonitrided parts, part 2: 

Load capacity of spur wheels 

Simone Lombardo 

13:40 - 13:50 h 

Welcome speech of the city of Cologne 

18:00 h 

General meeting of AWT members 

42 

heat processing 3-2014

PROGRAM 

Thursday, 23 October 2014 

THERMOCHEMICAL PROCESSES 

Chairmen: Michael Jung, Hans Werner Zoch 

9:00 - 9:25 h 

Research on low pressure carbonitriding with amines 

David Koch 

9:25 - 9:50 h 

Ammonia based closed loop control for defined 

plasma nitriding and nitrocarburizing – first results 

Sebastian Bischoff 

9:50 - 10:15 h 


10:15 - 10:30 h 

Welcoming speech from the Federal Ministry for 

Economic Affairs and Energy 

Detlef Dauke 

10:30 - 10:50 h 


Perfect link between science and industry – Results 

from the accompanying evaluation of the pre-competitive 

collective research program 

Burkhard Schmidt 

10:50 - 11:00 h 

Granting of the Paul-Riebensahm-Award 2013 to 

Martin Beck 

11:00 - 12:00 h 


Extraordinary bainitic steels 

Harry Bhadeshia 

12:00 - 13:20 h 

Lunch hour 

13:55 - 14:20 h 

Simulation of heat treatment processes also for “nonsimulation 

experts” 

Stefan Braun 

14:20 - 14:45 h 

From current to structure: FE-simulation of induction 

hardening of a calendar roll 

Jörg Neumeyer 

14:45 - 15:10 h 

New applications of numerical simulation in induction 

surface hardening processes 

Dirk Schlesselmann 

15:10 - 15:30 h 


15:30 - 15:55 h 

Adaptive finite element simulation for multifrequency 

induction hardening in 3D 

Thomas Petzold 

15:55 - 16:20 h 

Numerical optimization of the carburizing process 

for function-related construction details of steel 

components 

Andreas Diemar 

HIGH ENERGY HEAT TREATMENT 

Chairmen: Rainer Braun, Olaf Irretier 

16:20 - 16:55 h 


High-energy heat treatment – What energy beams 

can achieve in the field of surface treatment today? 

Rolf Zenker 

16:55 - 17:20 h 

A new combined surface treatment technology for 

tribological-loaded Al alloys 

Erik Zaulig 


SIMULATION OF HEAT TREATMENT PROCESSES 

Chairmen: Jörg Kleff, Klaus Löser 

13:20 - 13:55 h 


Simulation of case hardening processes – state of 

the art 

Matthias Steinbacher 

17:20 - 17:45 h 

Electron-beam cladding of wear-resistant coatings on 

corrosion-resistant steels 

Anne Jung 

18:00 h 

Reception – Bestowal of the 

Karl-Wilhelm-Burgdorf-Award 


43

PROGRAM 


Friday, 24 October 2014 

MANUFACTURING AND RESIDUAL STRESSES 

Chairmen: Brigitte Haase, Peter Krug 

9:00 - 9:35 h 


Manufacturing and residual stresses 

Volker Schulze 

9:35 - 10:00 h 

Mechanical surface treatment by micro peening 

Regina Weingärtner 

10:00 - 10:25 h 

Residual-stress fields as a consequence of turning 

operations of differently heat treated shafts made of 

steel SAE 6150 

Wolfgang Zinn 

10:25 - 10:50 h 

Shell hardening by high speed quenching 

Friedhelm Frerichs 

10:50 - 11:15 h 

Internal intensive quenching 

Jürgen Hofmeister 

11:15 - 11:35 h 


QUALITY CONTROL 

Chairmen: Winfried Gräfen, Hansjürg Stiele 

12:00 - 12:25 h 

Report from the AWT expert-committee 20 “Sensors 

in heat treatment”: Test bench for qualifying oxygen 

probes – first results 

Heinrich Klümper-Westkamp 

12:25 - 12:50 h 

Heat treatment and nondestructive testing: finding 

surface cracks using laser-thermography 

Matthias Ziegler 

LEGISLATION 

12:50 - 13:15 h 

Brussels: News for our industry 

Franz Beneke 

13:15 h 

Publication of Paul-Riebensahm-Laureate 2014 

Peter Krug 

13:20 h 

Summary 

Michael Lohrmann 

13:30 h 

End of the event 

11:35 - 12:00 h 

Simulation of the time-dependent evolution of the 

hardness and residual stresses in inductive heat 

treatment procedures 

Frank Schweizer 


Vulkan-Verlag 


22 - 24 October 2014 


Germany 

44 


Boost PRODUCT PREVIEW productivity. 

Cut costs. 


Modernizations for quality and reliability 

Excellent engineering services stand out from the crowd … 

especially when it comes to intelligent revamps. It’s about 

nothing less than upgrading existing plants to meet future 

market demands – one of today’s central challenges. 

That’s where our whole wealth of experience comes in. 

After all, our job is to help you increase your productivity 

while improving quality. Equally significant here is smart 

planning, for instance taking advantage of scheduled maintenance 

stoppages and minimizing production losses. 

Your bottom line: You save time and money. 

Countless completed projects prove our quality and 

reliability as a global specialist in metallurgical plant and 

rolling mill technology. 

SMS SIEMAG AG 

Eduard-Schloemann-Strasse 4 Phone: +49 211 881-0 E-mail: communications@sms-siemag.com 

40237 Düsseldorf, Germany 


Fax: +49 211 881-4902 Internet: www.sms-siemag.com 

45



Hardening centre for crankshafts 

Efficient 4-cylinder engines form the basis for the passenger 

car drive concepts of the future. This calls for innovative 

approaches to the hardening process which can be ideally 

implemented with Alfing’s BAZ KW600 hardening centre. 

The hardening centre is a new addition to the existing product 

range and was developed specially for 4-cylinder 

crankshafts. It is designed on the principle of machining centres 

and is suitable for crankshafts of up to 600 mm in length. 

Emphasis was also placed on good energy efficiency, a high 

throughput, low operating costs and ease of operation. The 

pin bearings are hardened in module 1 and the main bearings 

in module 2 of the two-module system. An optional 

extension can also be integrated for the hardening of flanges, 

journals and gear wheels. The full encapsulation of the working 

areas permits complete extraction of quenching fumes. 

Efficient drive systems and assemblies as well as optimized 

inductors guarantee low energy consumption, good process 

reliability and maximum availability. Minimum space requirement, 

full accessibility on one level and a standard height of 

only 2.3 m are all revolutionary features of this type of hardening 

machine. Preceding and subsequent processes can 

easily be integrated. Connection to portal systems can be 

performed in the same way as for existing technologies for 

machining centres. 

Maschinenfabrik Alfing Kessler GmbH 

www.alfing.de 

Hall 4.1 / Booth B-021 

ATEX Certificate for steel degassing vacuum systems 

Degassing, especially those with oxygen insufflation, as in 

VOD and RH-OB methods, produce potentially explosive 

gases. Vacuum components and equipment with ATEX 

approval enable safe and cost-efficient solutions for mechanical 

vacuum solutions. Today, the standard mechanical 

vacuum pumps already fulfil high requirement for safety. 

Nevertheless, in case there are uncertainties regarding the 

flammability of gas mixtures which need to be handled by 

the pump sets, the user will have to conduct a risk analysis of 

the various plant parts to define the relevant explosion protection 

zones. The result will most probably be the definition 

of an explosion Zone 1 for the inner part of the vacuum system. 

For this assessment, components with an ATEX-certificate 

Category 2 (inside) for gases can be the easy solution. 

Thus way the user can reach the highest safety standard for 

his employees with relatively low investment expenditure. 

ATEX vacuum solutions from Oerlikon Leybold Vacuum 

consist of pumps and components that meet the specification 

of ATEX Cat 2 (i) G IIC T2. This equipment can be combined into 

ATEX certified vacuum systems. To meet the requirements, an 

additional gas cooling and temperature control between the 

pumps is provided to prevent gas temperatures from exceeding 

the defined limits. Furthermore, all pumps are controlled 

and monitored by a specially programmed frequency converter. 

Regarding the vacuum pump set, potential ignition 

sources such as overheating or electrostatic charging must be 

considered, which will be achieved with the usual attention 

during design and manufacturing of ATEX-certified pumps. In 

particular, the pumps must be protected efficiently against 

overload by too high pressure differences in order to avoid 

excessive temperatures. This is valid for all possible operating 

point starting with high suction pressures, passing to medium 

operating pressures, that are to be hold over a longer time as 

for example during delayed pump down in the VD-process or 

during the oxygen blow phase in the VOD-process, down to 

lowest end pressures with its high compression ratios. The 

vacuum solutions of Oerlikon Leybold Vacuum consist of two 

different standard pump models only, combined into threestage 

vacuum systems. Such three-stage designs allow highest 

suction speed combined with lowest power consumption. 

Oerlikon Leybold Vacuum GmbH 

www.oerlikon.de 

Hall 4.1 / Booth F-058 - G-059 

46 



Digital pyrometry reinvented 

Sensortherm introduces another Metis sensor to its Metis 

series product line. Known as the Metis M3, it has an 

advanced design, customization, and adaptability. The sensor 

has the ability to be used in ambient temperatures up to 

80 °C, with fibre optic versions on the optical head rated up to 

250 °C. The integrated keypad and 10-digit display enable all 

settings to be easily manipulated by the user for a variety of 

applications. 

The device offers manually adjustable focus optics, fixed 

focus optics, or remote motorized focus options. The precise 

alignment of the target is accomplished by laser, through lens 

sighting, or real-time colour video. It is available in either single 

wavelength or two colour pyrometer versions. Superior to 

analogue technology and based on the latest electronic and 

digital signal processing, the M3 provides convenient universal 

configuring. Equipped with many new features, such as 

digital inputs and outputs as well as an increased accuracy of 

0.25 %, it meets the highest industry demands. The sensor’s 

built-in video chip offers the ability to view in real time a 

colour composite video that can be displayed on a video 

monitor or PC using a standard off-the-shelf video to USB 

frame grabber. 

The high-speed serial digital interface and two high-resolution 

16-bit analogue current outputs are adjustable and 

configurable for a precise output of temperature measured 

values. Optionally, a PID controller can be integrated or the 

pyrometer can be equipped with Profinet, Profibus or Ethernet 

to couple to a master controller. 

Sensortherm GmbH 

www.sensortherm.de 

Hall 4.1 / Booth A-002 

AFC-Holcroft: 

Strength and Innovation since 1916. 

Powerful Solutions for the Future. 

As a privately owned company with thousands of installations worldwide, 

AFC-Holcroft is a worldwide leader in the heat treat equipment industry. 

One of the most diverse product lines in the heat treat equipment 

industry: Pusher Furnaces, Continuous Belt Furnaces, 

Rotary Hearth Furnaces, Universal Batch Quench (UBQ) 

Furnaces and Endothermic Generators. 

Robust construction and long service life, 

designed for ease of maintenance. 

Various global facilities in North America, Europe 

and Asia for fastest local delivery, service and support. 

HK 2014 Cologne 

October 22–24, 2014 

UBQ: Universal Batch Quench Furnace. 

Ultimate in flexibility and versatility. 

Modularly constructed universal batch system 

with state-of-the-art technology. 

Delivers consistently high quality with predicable 

and repeatable results. 

Hall 4.1, Stand E-038 

Get in touch with us today to learn more about how 

we can improve your production processes and 

how we can give you the edge over the competition. 

For further information please visit 

www.afc-holcroft.com 

AFC-Holcroft USA · Wixom, Michigan AFC-Holcroft Europe · Boncourt, Switzerland AFC-Holcroft Asia · Shanghai, China 


Phone: +1-248-624-8191 Phone: +41 32 475 56 16 Phone: +86-21-58999100 

47



Hybrid charging stick for thermal treatments 

The GTD Graphit Technologie GmbH offers patent-registered 

hybrid-systems for thermal treatments. The latest 

product development is the GTD hybrid charging stick for all 

charges, that are hardened in a hanging or upright way. The 

stick has an inlay made of C/C (Carbon-fibre-reinforced Carbon) 

which is surrounded by steel. C/C as a high-strength 

composite material consisting of carbon-fibre provides a 

heat-resistance of the charging stick in inert gas or vacuum 

Boron-free and copper-free stop-off paints 

new labelling requirement for stop-off paints will take 

A effect on 15 June 2015. Stop-off paints will then be subject 

to the GHS, the Globally Harmonised System of Classification 

and Labelling of Chemicals. Stop-off paints containing 

boron can easily be removed by washing and are made of the 

raw materials boron trioxide, borax and boric acid. Copperbased 

stop-off paints can mostly be removed by sandblasting 

and contain copper, copper(I) oxide or copper(II) oxide. 

While the first version will, in future, be labelled as toxic for 

reproduction within this classification, the version containing 

copper will be classified as environmentally dangerous. That 

means that the new labelling will clarify one thing: All stop-off 

pastes currently used in the industry or in the market pose a 

risk not only to the environment in general but also to the 

individual person. 

For more than 20 years, DAM Härtetechnik GmbH has 

been a worldwide active and leading company which specialises 

in the development and manufacturing of stop-off paints 

for the heat treatment of steel. 

The company reacted to the new GHS regulation with 

new developments. These products are used like traditional 

stop-off paints for gas carburising and vacuum carburising, 

nitriding and nitrocarburising, for plasmanitriding, annealing 

and oxidation, for induction hardening and brazing. The 

furnaces at temperatures up to more than 1,200 °C. In that 

way it prevents any deformations of the stick long-term. The 

steel cover saves the inlay from abrasion of sharp-edged 

components and covers the charge against carbon contamination. 

Individual braces prevent equable charging of the 

components, for example rings. 

The new hybrid charging stick is part of the patent-registered 

GTD hybrid system, which also includes a hybrid grid 

that employs a combination of C/C and ceramic parts. Decisive 

arguments for the use of carbon materials are the high 

load capacity combined with tensile and flectional resistance 

especially when used in automated processes. The low density 

and the light weight of C/C makes handling much easier 

and also ensures an excellent energy balance 

GTD Graphit Technologie GmbH 

www.gtd-graphit.de 

Hall 4.1. / Booth D-079 

name of these new stop-off products is Luiso®. What is new is 

the fact that these products are both boron-free and copperfree 

and ensure optimal protection properties. They have, in 

addition, a neutral odour and do not contain any solvents. 

Any residues remaining after the heat treatment can be 

removed easily by washing with water. Even their viscosity 

and flow can be controlled by water. The objective behind 

the development of these new stop-off pastes was to 

strongly improve their environmental performance. 

Three additional products (Luiso W30, W34 und W36) are 

offered for gas carburising for case depths of up to 6 mm. And 

the new product line also includes two products for nitriding 

and nitrocarburising: Luiso W21 which is ceramic-based and 

the Luiso W25 paste which can be used both for nitriding and 

nitrocarburising. The product portfolio contains, in addition, 

two hardness protection paints each for vacuum carburising 

(W44 and W45) and annealing (W61) as well as two pastes 

which cover the field of plasmanitriding (W51 and W53). The 

product offer is rounded off by a kneadable protection mass 

(W63) to seal off hardening boxes, small or large holes. 

DAM Härtetechnik GmbH 

www.dam-gmbh.de 


48 



A modular approach to production 

global rise in component production has increased demand 

A for heat treatment systems capable of meeting production 

needs today, yet scalable for future production. AFC-Holcroft 

offers many thermal processing solutions, and highlights one of 

the most flexible heat treating furnace designs available – the 

UBQ (Universal Batch Quench) system. The UBQ is capable of 

running a variety of metallurgical processes, and can be delivered 

as a single unit or as a complete, fully automated cell integrated 

with companion equipment such as tempering furnaces, 

pre-heat furnaces, spray-dunk washers, forced air cool stations 

and more. With its modular design, additional cells can be 

added for maximum productivity with consistent, repeatable 

metallurgical results. 

Another modular, flexible product featured is AFC-Holcroft’s 

EZ-Series endothermic gas generator, offering a maintenance- 

and operator-friendly design. A 5:1 turn down ratio 

provides substantial savings in operating costs vs. nitrogen 

methanol; often with return on investment less than one year. 

Units can be provided individually, or up to three units 

grouped into an array; each unit having standalone plug-andplay 

type control. 

When consistent high volume production is needed, the 

company offers its classic pusher-style furnace for continuous 

throughput under protective gas atmosphere. The pusher-style 

furnace design allows the furnace chambers to be combined 

into one, or separated into multiple chambers for independent 

control over temperature and atmosphere. 

AFC-Holcroft 

www.afc-holcroft.com 

Hall 4.1 / Booth E-038 

Innovative Heat Treatment Systems 

Visit us at HK 2014: 

Hall 4.1, Stand E 078 

For hot-form hardening, 

hardening, annealing, 

sintering and brazing etc. 

Also under protective and 

reactive atmospheres 

schwartz GmbH 

Edisonstrasse 5 

D-52152 Simmerath 

Germany 

schwartz Heat Treatment Systems 

Asia (Kunshan) Co. Ltd. 

278 JuJin Road 

Zhangpu Town Kunshan City 

Jiangsu Province 

215321, P.R. China 

For more information visit: www.schwartz-wba.com 


schwartz, Inc. 

2015 J. Route 34 

Oswego IL 60543 

USA 

49



Industrial furnaces made in Germany 

Nolzen Industrieofenbau produces in the fourth generation 

“made in Germany” – since 1919 – industrial furnaces 

and heat treatment plants for annealing and hardening of 

metals. With own casing and insulating construction, retorts 

manufacturing as well as switchgear production, the company 

located in Wuppertal offers competence in consultation, 

construction and manufacturing solutions for economically 

and individually designed heat treatment processes. 

Nolzen delivers energy-efficient standard furnaces and 

customised solutions in electric- and gas-heated version for 

temperatures up to 1,300 °C. Pit type furnaces, boogie hearth 

and chamber furnaces belong to the core business for largevolume 

components and heavy load weights. Pit type 

furnaces for nitriding, case hardening and annealing have 

already been realised up to a diameter of 4,500 mm or a 

depth of 11,000 mm. Boogie hearth and chamber furnaces 

Precision temperature control to increase efficiency 

and profitability 

Invensys Eurotherm, a global supplier of measurement and 

instrumentation for process and machine control applications, 

has launched a family of new precision PLC products 

aimed at significantly increasing the profitability and efficiency 

of heat treatment and thermal processing. The new 

E+PLC series combines precision measurement and control, 

secure data recording, and a variety of visualisation solutions. 

Previously to obtain optimum performance and meet 

accurate pyrometry specifications (e.g. AMS2750E), companies 

needed to separate products for temperature control, 

data recording and visualisation. This was costly and inefficient. 

Combining all these products into one easy to use, flexible 

and highly functioning precision PLC platform simplifies 

commissioning and reduces engineering time. The E+PLC 

also targets operational efficiency and makes regulatory compliance 

much easier. 

The high precision temperature control ensures the correct 

temperature is obtained quicker and stays at the optimum 

level required without deviation, ensuring high quality results 

first time without wasting time waiting for operating temperature 

to be reached. This increases throughput of a furnace or 

thermal treating machine in comparison with traditional PLC 

based control. Fast acting PID with overshoot inhibition can 

enable an extra furnace batch cycle to be completed within 

any 24 hour period. By eliminating damping of PID sets and 

relying on Eurotherm’s overshoot inhibition customers can 

are designed in all dimensions, up to 50 m 3 volumes and load 

weights of more than 100 t. 

The company offers “everything out of one hand”. Beside 

the development of new furnace design its special main focus is 

on engaged after sales service which encloses the servicing and 

maintenance as well as modernisation and the process optimisation 

of furnaces. On account of the nearly 100-year-old experience 

in industrial furnace design, the high manufacturing depth 

in production as well as the robust construction method of the 

furnaces Nolzen stands for efficiency of specially developed 

and produced furnaces. Today the company grants a guarantee 

from up to 5 years on industrial furnaces to its customers. 

Artur Nolzen Industrieofenbau GmbH + Co. KG 

www.nolzen.de 

Hall 10 / Booth A-005 

heat aggressively up to temperature with the confidence of 

keeping within the required set point temperature tolerances. 

The E+PLC range also includes secure data logging designed 

to meet the requirements of thermal treatment standards such 

as CQI-9 and AMS2750E. The precision measurement circuitry 

also assures compliance with accuracy specifications, aids conformance 

to System Accuracy Tests (SAT) and improves the output 

from Temperature Uniformity Surveys (TUS). 

Key features and benefits of E+PLC include: 

■■ 

Easy to commission precision PID control blocks with 

auto tuning. 

■■ 

Set point programmer. 

■■ 

Precision measurement of process variables to give accurate, 

repeatable results which translates to minimum 

energy usage. 

■■ 

Total data integrity and secure recording, keeping valuable 

process records safe by using highly robust file storage 

strategies to protect against power and network failures. 

■■ 

An open Codesys platform, a de facto industry standard. 

■■ 

Integrated HMI software platform with a variety of visualisation 

options. 

Invensys Systems GmbH Eurotherm 

www.eurotherm.de 


50 



c\aaa\anzeigen\vulkan\EW HP 13.qxd 

Elektrowärme; Heat processing 2014 

182 x 31 1/8 4c 

Tube 

furnaces 

Heat processing 3 /14 

Induction hardening systems 

Rohröfen 

Induktions-Härteanlagen 

Schutzgasöfen 

Team solutions from a single source 

The KompetenzTeam, a materials engineering division of 

MWS Dr. Schreiner VDI at Munich, is preoccupied with the 

formation of working groups for project implementation, 

accumulate knowledge, researches, developing and organizes 

symposia, seminars and workshops. An annual symposium 

in Munich, for over 30 years, provides professionals a 

Elektrowärme 3 /14 

platform for exchange among colleagues, access to expertise 

and specific information from the work areas. The next meeting 

of “Härterei 2015” takes place between 19 and 20 March 

2015 in Munich instead. 

In addition to the focus on the German speaking countries 

(D, A, CH), the team of experts, in materials technology, also 

maintains contacts throughout Europe and demonstrated 

experience in China and overseas. Together with partners 

they offer analysis, systems engineering and heat treatment 

Protective gas furnaces 

as a service, which expands on the workpiece- and partscleaning. 

The Central Association of Surface Technology (ZVO) and 

the Association of Industrial Parts Cleaning e.V. (FIT) will host 

together with the KompetenzTeam, Induktionserwärmung 

the 24 th Fachtagung 

Industrielle Teilereinigung on 12 and 13 March 2015 in Munich. 

On the HeatTreatment Congress 2014 in Cologne provides 

the KomptetenzTeam the companies Ahotec eK, Graphite 

Materials GmbH, Spectro Analytical Instruments GmbH, TAZ 

GmbH and Uttis srl. Here, interested visitors can meet the 

booth makers of these companies and get information about 

news, facts and scope. 

Universal-Induktions- 

Härteanlage. 

MWS Dr. Schreiner VDI 

www.kompetenzteam.com 


Induction heating 

www.linn.de 

www.linn.de 


New controller generation 

Based on the successful carbon, nitriding, dew point 

and temperature controllers Mesa Electronic GmbH is 

introducing a new family of MCon controllers to the market. 

The new generation of controllers provides controllers 

for any application. MCon type Carbo is the new C-level 

controller with a total of three different control loops enabling 

the customer to regulate the C-level, furnace temperature 

and oil bath temperature. MCon type Nitro regulates 

the nitriding factor Kn and furnace temperature. MCon 

type TP is used for dew point control of an endogas generator, 

MCon type Uni is a universal controller used to control 

up to three different process factors. All controllers are 

equipped with the latest technologies such as touchscreen 

colour display, multiple analogue inputs and outputs 

as well as a wide variety of communication protocols. 

Complex processes can be carried out with the program 

controller option. By means of control tracks all MCon controllers 

can control the process without SPS and thus 

reduce costs. MCon controllers provide the ability to communicate 

with different automation systems via communication 

protocols such as Modbus RTU, TCP, Ethernet and 

Profibus. An integrated data logger allows the recording of 

process data during the entire process. To be flexible, the 

customer can order and configure each controller with a 

desired number of analogue or digital inputs and outputs. 

Mesa Electronic GmbH 

www.mesa-international.de 

Hall 4.1 / Booth D-029 


51



Chamber furnace heat treatment plant for big size rings 

Recently a customer in Mexico expanded his production 

facility with the IOB chamber heat treatment furnace 

plant system consisting out of four chamber furnaces, one 

charging machine and two quenching baths. In this furnace 

plant system it is possible to heat treat rings up to a diameter 

of 4,300 mm. Following processes can be executed: hardening, 

tempering and normalizing. For the quenching baths the 

choice is between water or polymer quenching. 

The properties after heat treatment to be achieved are: 

homogeneous hardness at 90° of 300-330 HBN, distortion 

(oval) less than 6 mm, charpy impact above 30-35 lbft at ¼" 

thickness and Ferrite at the core < 5 %. To guarantee the temperature 

uniformity and operating the furnace plant economically 

the furnaces were equipped with natural gas operated 

high velocity recuperator burners. The uniformity inside 

the furnaces: 530-950 °C = ± 5 °C; 450-529 °C = ± 7.5 °C. 

The quenching baths are equipped with rotating, lifting 

and lowering lifting tables. In addition to the installed agitation 

and cooling pumps IOB also installed stationary inside 

the bath and on to the movable lifting table so-called liquid 

jet mixing nozzles for intense agitation. The loading/unloading 

of the furnaces, baths and deposit tables is done using 

the charging machine. In automatic mode the plant here 

achieves transit times of approx. 25-30 s between furnace and 

bath. A modern measuring and control system with material 

tracing and connection to further processing line equipment 

will complete the furnace plant system. 

IOB Industrie-Ofen-Bau GmbH 

www.industrial-furnaces.com 

Hall 4.1 / Booth F-091 

Heat treatment specialist invests in state-of-the-art 

plant technology 

For the last 78 years, the Hauck Group has been active as a 

powerful system supplier to customers throughout 

Europe in key sectors such as the automobile industry, 

mechanical engineering, electrical engineering, medical 

technology, jointing and fastening technology and many 

others. At seven locations in Germany, a wide variety of components 

are processed with almost all the heat treatment 

processes in common use (thermal and thermo-chemical), 

different surface treatments and galvanic processes. All company 

locations combine experience and precise production 

processes with consistent quality management, quality assurance 

through in-house inspection procedures, state-of-theart 

plant technology with backup options, certification in 

accordance with all relevant international quality, environment 

and energy standards and a close relationship with our 

customers in the regions. 

This year, Hauck has further extended its service and has 

invested even more than usual in new plant technology. The 

highlight is the new semi-automatic charging system at the 

Remscheid site, which is unique in its construction and 

design. Significant investments have also been made in the 

expansion of nitriding facilities. Fifteen large furnaces are currently 

in operation, functionally treating more than 40 t of 

products per day. 

Härterei Hauck GmbH 

www.haerterei-hauck.de 


52 



Simultaneous crack and structure testing 

with eddy current 

Since its founding in the year 1977, Rohmann GmbH has 

specialised in non-destructive testing by means of eddy 

current. The comprehensive product range extends from 

sensors to coils, rotors and universal hand-held devices, to 

tailor-made testing systems. Customers from the most varied 

branches such as aviation, automotive industry, rail transport 

and the steel industry value the work of this family-managed 

company. 

The basis for successful eddy current testing lies in the 

interaction between highly sensitive sensors and the latest 

equipment technology. Here, and in addition to a wide range 

of standard sensors, Rohmann GmbH offers a wide range of 

customized sensors for the most varied testing tasks, supported 

by a flexibly configurable, fully digital equipment 

platform. One component of this equipment platform is the 

Elotest IS500 family. It is available as a 19” module or as a separate 

box-variant for integration into the production line. The 

series has a wide range of configuration possibilities up to a 

maximum of two test channels. This enables combined crack 

testing, with simultaneous structure and material identification 

testing. In the case of structure testing, the user can 

choose between simple 1-frequency sorting, fast sorting at 

several hundred parts per second, or multi-frequency testing 

as a solution for complex sorting tasks. The product series can 

optionally also be equipped with a multiplex option for the 

connection of up to eight sensors per test channel, and can 

therefore cover a broad range of testing applications in the 

course of the production process. If the Elotest IS500 family is 

not enough, a universal multi-channel equipment family is 

available as an alternative in the form of the Elotest PL500 line. 

Rohmann GmbH 

www.rohmann.de 


Visit us 

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ALD Vacuum Technologies latest development SyncroTherm ® offers the highest flexibility for heat 

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63450 Hanau, GERMANY 

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Internet www.ald-vt.com


Protective system control with bus communication 

With the protective system control FCU 500, Elster Kromschröder 

is offering a comprehensive all-round 

package for the implementation of current safety standards. 

The unit performs the essential functions of a central protective 

system pursuant to EN 746-2:2010 in multiple burner 

applications. 

The protective system control monitors various safety 

conditions (such as minimum and maximum gas pressure 

and air pressure) and carries out a standard-compliant prepurge. 

The main valves undergo an extended tightness test 

in parallel to purge. This tightness test function checks the 

system for leaks during system start. A special algorithm saves 

time in the case of large test volumes. As an option and in 

conjunction with Kromschröder burner control units, an internal 

safety temperature limiter (STL) or a safety temperature 

monitor (STM) for monitoring the maximum furnace/flue gas 

temperature or for high temperature monitoring guarantee 

increased operational safety. 

The functions combined in the FCU 500 can be precisely 

adapted to the requirements of the respective heating equipment 

using parameters. For this, the FCU features an optical 

interface via which the parameters can be adjusted using the 

PC software BCSoft and data for diagnosis can be read. 

The system has been developed for installation in control 

cabinets. It features tried-and-tested operating controls on 

the front of the unit or can be controlled directly from the 

control cabinet door using the external operator-control unit 

OCU. Thanks to the Profinet bus module BCM 500, the 

FCU 500 can be easily integrated in the process automation 

system. This opens up a wide range of options as regards 

process control and visualization. The automation system 

(controller) and the connected units of the FCU 500 series 

(device) communicate via the bus module BCM 500 on two 

levels. 

The acyclic communication allows information on the 

parameters and statistics of the FCU 500 as controlled by the 

program to be read. The device master data required for system 

engineering of the bus module BCM 500 can be read 

from the GSD file of the FCU 500. The Internet-based knowledge 

platform KST (Kromschröder System Technology) is 

available as planning support for the protective system as 

well as for the design of the entire heating equipment. KST 

offers many tools for the effective and safe project planning 

of heating equipment. 

Elster GmbH 

www.kromschroeder.com 

Hall 4.1 / Booth C-089 

Hardware and software solution for more efficiency 

The Ipsen EcoFire system burns natural gas 

and protective gas for highly efficient 

energy usage – with almost no loss. The system 

is an intelligent solution, which allows the gas 

fired heating system already installed 

in your furnace to burn 

protective gas. It increases 

the efficiency of industrial 

furnace systems 

through intelligent 

hardware and software, 

saving money and protecting 

the environment 

sustainably. 

Normally, the protective 

gas used in a 

furnace must be burnt off safely. But with the EcoFire system 

the protective gas needed in atmospheric heat treatment 

furnaces is used for the gas fired heating system. In this way, 

the energy content of the protective gas is available for the 

heating system. In addition, it’s used to heat the halls in winter 

– this saves money and protects the environment at the same 

time! 

With EcoFire, one not only can use the energy content of 

the otherwise useless burnt protective gas, increasing plant 

efficiency, but also lower the cost of the natural gas consumption 

and lower the CO 2 emissions. 

Ipsen International GmbH 

www.ipsen.de 


54 


Heat treatment using ceramic matrix composites 

The WPX Faserkeramik GmbH develops and manufactures 

heat treatment components made of innovative Whipox® 

oxide ceramic matrix composite (OCMC). Whipox® OCMC 

consists of pure aluminium oxide fibre ceramic Nextel® 

embedded in a pure aluminium oxide matrix. Due to its excellent 

properties like extreme stability against thermal and 

mechanical shocks, thermal insulation, low thermal load, 

minimal warping, and good tensile and bending strength, the 

material is well suited for charge carriers and furnace lining for 

heat treatment processes in the temperature range from 750- 

1,300 °C (1,380-2,370 °F). As it is oxidation- and corrosionresistant, 

it can be used in atmospheric processes. 

In particular, its open grid structures can be used as systems, 

components and parts for fast temperature change and 

homogeneous temperature distribution. Whipox® allows 

improved energy efficiency by significant reduction of carrier 

weight, improved product properties by precise temperature 

control, increased furnace equipment uptime through noncatastrophic 

failure, and less rejects due to Carbon contamination. 

USPs are documented through industrial applications. 

WPX Faserkeramik GmbH 

www.whipox.com 

Hall 4.1 / Booth C-101 


55



“One heat processing world – with 

But only one, heat processing, covers 

from a truly unique international 

Congratulations on 10 years and 

all the best for the future.” 

Paweł Wyrzykowski 

CEO of Seco Warwick Group


so many magazines. 

the whole industry 

perspective.


Thermoprocessing 

Technologies 


Order now! 

Volume 1: Fundamentals | Processes | Calculations 

This Handbook provides a detailed overview of the entire thermoprocessing 

sector, structured on practical criteria, and will be of particular assistance 

to manufacturers and users of thermoprocessing equipment. 

In Europe thermoprocessing is the third largest energy consumption 

sector with a very diversified and complex structure. Therefore it is split 

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for the industrial economy. Accordingly we find the application knowhow 

for the design and the execution of respective equipment represented 

by a multitude of small but very specialized companies and their experts. 

So this second edition is based on the contribution of many highly 

experienced engineers working in this fi eld. The book’s main intention is 

the presentation of practical thermal processing for the improvement of 

materials and parts in industrial application. Additionally it offers a summary 

of respective thermal and material science fundamentals. Further it 

covers the basic fuel-related and electrical engineering knowledge and 

design aspects, components and safety requirements for the necessary 

heating installations. 

Editors: Franz Beneke, Bernhard Nacke, Herbert Pfeifer 

2 nd edition 2012, 674 pages with additional media files 

and e-book on DVD, hardcover 



FUTURE 




— copies of Handbook of Thermoprocessing Technologies 2nd edition 2012 

(ISBN: 978-3-8027-2966-9) at the price of € 200,- (plus postage and packing) 


(ISBN: 978-3-8027-2966-9) at the special price of € 180,- (plus postage and packing) 

for subscribers of heat processing 









45039 Essen 

GERMANY 

Phone 

E-mail 


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to Vulkan Verlag GmbH, Versandbuchhandlung, Friedrich-Ebert-Str.11, 45127 Essen, Germany. 


PAHBTT2014 


It is 

58 

approved that this data may also be used in commercial ways by mail, by phone, by fax, by email, none. 



✘


REPORTS 

Low pressure carburizing and 

nitriding of fuel injection nozzles 

by Maciej Korecki, Piotr Kula, Emilia Wołowiec, Michał Bazel, Michał Sut 

The article describes the newest achievements in heat treatment of fuel injection nozzles made of hot working tool steel 

applied in diesel engines. Different methods of improving surface properties have been applied by means of vacuum 

carburizing and vacuum nitriding, especially suitable for elements characterized by difficult shape geometry such as 

blind holes. Variable process parameters have been considered in terms of sequence and temperature as well as their 

influence on surface microstructure, hardness and case layer uniformity. A complex technology was invented involving 

thermo-chemical process supplemented by high pressure gas quenching (HPGQ), deep freezing and tempering. All 

technological steps were performed in a single chamber vacuum furnace equipped with LPC, LPN and HPGQ. 

Fuel injection nozzles (Fig. 1) are a key element of 

a diesel engine which influences its performance 

properties, including fuel consumption and reliability. 

Furthermore, they play a major role in emission of harmful 

substances. In the course of cyclic operation they withstand 

various loads, they work at raised temperatures under high 

pressures (1,500-3,000 bar) and withstand intense streams 

of liquids (above 100 m/s) [1]. Due to these factors, nozzles 

are prone to accelerated wear and defects (Fig. 2) [2]. The 

design of fuel injection nozzles must ensure appropriate 

strength, impact as well as fatigue resistance and abrasion 

of passage channels. 

Nozzles are made of medium and high alloy steels featuring 

additionally hardened surface. Typically, the tensile 

strength of the core remains within the range of 1,000- 

1,500 MPa for steel grades 20MnCr5, 17CrNiMo6, EN39B, 

18CrNi8, while extended surface hardness (above 60 HRC) is 

obtained through the hardening which follows carburizing. 

Adequate heat treatment is performed in vacuum furnaces 

featuring vacuum carburizing (LPC) and high pressure 

gas quenching (15 bar and above). Vacuum carburizing 

enables obtaining case uniformity in the thin nozzle channels 

of complicated shapes, inaccessible to conventional 

carburizing atmospheres. On the other hand, gas quench 

eliminates the inconvenience of cleaning after quenching 

in oil. In some solutions, nitriding is applied in place of 

carburizing to harden the surface. 

For certain applications, injection nozzles are made 

of even more durable steels, e.g. hot working tool steels. 

In such events, the strength increases decidedly (over 

2,000 MPa), although the surface still requires additional 

reinforcement. This article presents the complex processes 

and results of thermal and thermo-chemical treatment 

of fuel injection nozzles made of hot working tool steel 

carried out in a vacuum furnace. The processes applied 

included vacuum carburizing and nitriding (LPC and LPN), 

gas quenching, deep freezing and tempering. 

Fig. 1: Fuel injection nozzle (Bosch) 

Fig. 2: Typical nozzle defects: cracking (left) and abrasive wear (right) 


59

REPORTS 


Fig. 3: Fuel injection nozzle used 

Fig. 4: Standard single chamber vacuum furnace Seco/Warwick 

model 15.0VPT-4035/36IQCN Vector – Vacuum Furnaces Line 

Fig. 5: Uniformly carburized case layer in a nozzle crosssection 

following LPC 920 process 

THE OBJECT AND OBJECTIVE 

OF TESTS AND RESEARCH 

The object of testing were injection nozzles made of X37Cr- 

MoV5-1 (1.2343, H11) steel shaped as presented in Fig. 3. 

The objective of testing was to create upon the nozzle surfaces 

(in particular upon the internal surfaces) a uniformly 

hardened case layer while maintaining appropriate core 

hardness. The required case layers were created through 

vacuum carburizing and nitriding. 

TESTING EQUIPMENT 

Applied for the tests was a standard Seco/Warwick single 

chamber vacuum furnace model 15.0VPT-4035/36IQCN 

(Fig. 4) of working area 600/600/900 mm, equipped with 

a vacuum carburizing (LPC) and nitriding (LPN) systems 

and high pressure gas quench system (15 bar). 

Carburizing was performed with a gas mixture of acetylene 

(C 2 H 2 ), ethylene (C 2 H 4 ) and hydrogen (H 2 ), while 

ammonia (NH 3 ) was used for nitriding. The 250 kg workload 

consisted of ballast rods among which the tested injection 

nozzles were placed. The workload reflected typical conditions 

found in industrial heat treatment. 

Fig. 6: Hardness profiles obtained at selected points M1-5 in LPC 

processes 

LPC PROCESSES 

Four heat treating series based on vacuum carburizing were 

conducted. Carburizing was preceded with pre-nitriding 

using the PreNitLPC® [3] technology in order to restrict 

the growth of austenite grain at high temperature. The 

entire process sequence consisted of: pre-nitriding, vacuum 

carburizing (using the FineCarb® [4] technology) at various 

temperatures, which was followed by the repeated for all 

sequence of (direct) quenching in 5 bar nitrogen, deep 

freezing at -75 °C for 2 h and tempering for 2 h at the temperature 

of 200 °C. Carburizing treatments were performed 

at four temperatures: 860, 920, 950 and 1,020 °C, in each 



REPORTS 

case targeted at the surface concentration of carbon in 

the range of 0.60 % and predefined case depth of approx. 

0.4 mm. 

Total times in the sequence of carburizing and diffusion 

for individual treatments were as follows: 

LPC 860 C = 10 min, D = 70 min 




Fig. 5 presents a longitudinal cross-section through a 

nozzle following LPC carburization at the temperature of 

920 °C. A uniform case was obtained both on the outer and 

in the inner channels of the nozzle, which is characteristic 

for vacuum carburizing. The uniformity of the case layers 

obtained at individual treatments was presented in Fig. 6 

as hardness profiles at selected M1-5 points. 

After the LPC 860 treatment a uniformly hardened 

case layer was obtained on the outer and inner surfaces 

of the nozzle. The surface hardness was approx. 850 HV (at 

0.05 mm) and the core hardness was 500 HV, at predefined 

case layer depth of 0.35 mm for core hardness +50 HV. The 

LPC 920 treatment yielded a uniform case layer of surface 

hardness 820 HV and case layer depth of 0.30 mm for core 

hardness of 590 HV. 

Also carburizing at 950 °C (LPC 950) resulted in appropriate 

uniformity and case layer parameters: depth 0.35 mm, 

surface harness 850 HV and core hardness 620 HV. 

It was only the LPC 1020 process that failed to provide 

satisfactory outcomes. The case layer appeared only on 

the outer surfaces of the nozzle while none of it appeared 

inside. Maximum hardness was 850 HV at the surface and 

680 HV at the core. The hardness profile in the outer layer 

indicates a drop right at the surface, which is suggestive 

of improper microstructure. 

Fig. 7 presents a comparison of the case layer microstructure 

after the individual treatments. Globular carbides 

are a characteristic feature in the matrix of martensite. Their 

size and number increases parallel to the increase of process 

temperature. At higher temperatures they tend to create 

distinct structures, a network at boundaries of austenite 

grains, as in the LPC 1020 process. 

LPN PROCESS 

The nitrided layer was created as a result of a complex 

process composed of the following phases: austenitization 

at 1,030 °C, quenching in 5 bar nitrogen, tempering 

at 580 °C for 2 h and vacuum nitriding at the temperature 

of 560 °C for 4 h. The results of the process are presented 

in Fig. 8 as hardness profiles measured at selected spots 

on the inside and outside surfaces of the nozzle (M1-5). 

In the course of nitriding a very uniform hardened case 

was obtained of surface hardness in excess of 900 HV at 

the depth of 0.05 mm and case depth of nearly 0.2 mm 

at core hardness of 530 HV. The results shown in Table 1 

were obtained in the processes performed: 

LPC 1,580 °F (860 °C) 

LPC 1,688 °F (920 °C) 

LPC 1,742 °F (950 °C) 

LPC 1,868 °F (1,020 °C) 

Fig. 7: Surface microstructure after LPC processing at various 

temperatures 

Fig. 8: Hardness profile and case layer microstructure following 

LPN treatment 


61

REPORTS 


Table 1: Results of the performed processes 

Process 

Surface 

hardness 

[HV/HRC] 

CONCLUSION 

The processes of vacuum carburizing and nitriding enable 

to obtain uniformly hardened case layers on hardly accessible 

surfaces of fuel injection nozzles made of X37CrMoV5-1 

tool steel. In the event of vacuum carburizing the surface 

hardness accessible exceeds 800 HV for tempering 

temperature of 200 °C (hardness decreases as tempering 

temperature rises). The core hardness depends on the 

quenching temperature and is the higher parallel to the 

rise in temperature; in the tests from 49 to 59 HRC and also 

depends on tempering temperature. 

Carburizing at 1,020 °C failed to create proper uniformity 

and microstructure (carbides network) due to high intensity 

of treatment (incontrollable) and the tendency to create 

carbides in the steel at higher temperature. LPC processes 

at that temperature need to be refined. 

Promising results were attained for the vacuum nitriding 

process: case layer uniformity and the highest surface 

hardness in excess of 900 HV as well as stability of case layer 

parameters at high temperatures exceeding 500 °C. In the 

light of the study it should be claimed that the case hardening 

technology of the fuel injection nozzles made of tool steel by 

vacuum carburizing and nitriding has been developed, tested 

and is ready for industrial implementation. Further research 

will focus on improvement of LPC processes at high temperatures 

and on using hybrid: carburized and nitrided case layers. 

LITERATURE 

Core 

hardness 

[HV/ 

HRC] 

[1] Blau, P.J.; Yang, N.: Materials for high pressure fuel injection 

systems, US Dept. of Energy, poster presentation May 10, 2011 

[2] http://www.dieselpowermag.com/tech/1211dp_why_diesel_ 

fuel_injectors_fail/viewall.html 

Case depth 

[mm] 

LPC 860 850/66 500/49 0.35 good 

Case uniformity 

LPC 920 820/65 590/55 0.30 very good 

LPC 950 850/66 620/56 0.35 good 

LPC 1020 850/66 680/59 0-0.40 insufficient 

LPN >900/67 530/51 0.18 very good 

[3] Kula, P.; Pietrasik, R.; Dybowski, K.; Korecki, M.; Olejnik, J.: 

Prenit LPC – the modern technology for automotive, New 

Challenges. In: Heat Treatment and Surface Engineering, 

Dubrownik-Cavtat, Croatia, 2009, pp. 165-170 

[4] Kula, P.; Korecki, M.; Pietrasik, R.; Wołowiec, E.; Dybowski, K.; 

Kołodziejczyk, Ł.; Atraszkiewicz, R.; Krasowski, M. FineCarb ® 

– the flexible system for low pressure carburizing. New 

options and performance, The Japan Society for Heat Treatment 

2009, 49 (1), pp. 133-136 

AUTHORS 

Ph. D. Eng. Maciej Korecki 

Seco/Warwick 

Swiebodzin, Poland 

Tel.: +48 (0) 683820506 

maciej.korecki@secowarwick.com 

Prof. Piotr Kula Ph. D. 

Technical University of Lodz 

Institute of Materials, 

Science and Engineering 

Lodz, Poland 

Tel.: +48 (0) 426312279 

piokula@p.lodz.pl 

Ph. D. Emilia Wołowiec 

Technical University of Lodz 

Institute of Materials, 

Science and Engineering 

Lodz, Poland 

Tel.: +48 (0) 426312269 

emilia.wolowiec@p.lodz.pl 

Michał Bazel 

Seco/Warwick 


Tel.: +48 (0) 68-4111632 

Michal.sut@secowarwick.com 

Michał Sut 

Seco/Warwick 


Tel.: +48 (0) 68-4111632 

michal.bazel@secowarwick.com 



REPORTS 

Knowledge management in 

the maintenance of thermal 

process plants 

by Hartmut Steck-Winter, Axel Filounek 

Knowledge management in maintenance has become a critical success factor. System availability requirements, cost pressures, 

increasing complexity of systems and, especially, knowledge-intensive maintenance strategies are just some of the 

reasons why the systematic management of knowledge is becoming increasingly important. The knowledge management 

solutions mainly used in practice today are – like a library – focused on the archiving and retrieval of information. Meanwhile, 

the progressive transformation of maintenance into an engineering discipline receives rather less attention. Using the example 

of condition-based maintenance of thermal process plants, this article will describe how knowledge management and 

maintenance methods can complement each other, without neglecting practical maintenance, with knowledge managers 

forming the link to operational practice. Document management continues to play an important role, but even more emphasis 

is given to the use and creation of knowledge. After all, what good is a great library if no one reads the books? 

If our company only knew how much it knew, then… 

Who hasn’t heard this sentence 1 ? For the maintenance of 

industrial thermal process plants (ITP), we could complete 

the sentence as follows: If our maintenance department only 

knew how much it knew, then the availability, reliability and 

safety of our thermal process plants would be better than the 

competition, then our cost-efficiency would be better, and 

we would make fewer mistakes and never repeat them [1]. 

So why don’t we invest more in knowledge management? 

The answer, which will be demonstrated in this article, 

is that knowledge management in maintenance is a complex 

matter that imposes considerable organisational requirements, 

demonstrating once again the transformation of 

maintenance into an engineering discipline. 

WHAT IS KNOWLEDGE? 

In this introductory chapter we will first define a few key 

terms in knowledge management. 

Knowledge as production factor and company asset 

Fig. 1 shows how the most important resources of almost any 

1 This saying is attributed to Siemens CEO Heinrich von Pierer. At a press conference, 

von Pierer lamented the fact that Siemens was always „reinventing 

the wheel“ and wasting a lot of resources in the process. However, the saying 

was already in use internally much earlier than this. 

company – labour, capital and knowledge – have changed 

over the years. Even in agrarian societies, people tried to 

acquire, keep and re-apply knowledge. Early techniques 

included storytelling or picture stories. With the progress of 

industrialisation, knowledge became increasingly important, 

overtaking the production factors of labour and capital. More 

and more specialised knowledge was needed, for example to 

build new machinery or provide special services. 

In a knowledge society, the value of knowledge as a production 

factor increases further still. Knowledge became the 

most important resource in production and services. Today, 

Importance 

Labor 

Agrarian 

society 

Capital 

Industrial 

society 

Knowledge 


society 

Fig. 1: Importance of the production factor knowledge 


63

REPORTS 


knowledge management is of existential importance in many 

sectors of industry. Today, knowledge as an independent 

production factor is so important that it must be actively managed 

– which is why we talk about ‘knowledge management’. 

Data, information, knowledge – 

the knowledge pyramid 

Data, information and knowledge form a pyramid. Knowledge 

is the tip of the pyramid and data forms the base. Data refers 

to facts about events or processes, for example vibration 

measurements. When data is placed in context and given 

meaning, it becomes information – for example the permissible 

vibration limit values for a specific part. P. Drucker, a 

pioneer of modern management theory, said, “Information 

is data with relevance and an intended purpose.” 

Knowledge, on the other hand, is goal-oriented, networked 

information that includes expert opinions and experience, 

for example how a vibration will probably develop 

into a problem. Knowledge is always personal and usually 

problem-oriented. The difference between knowledge and 

information is not ultimately the most important question, 

but rather which data, information and knowledge is useful 

for an organisation and which is not. 

Explicit vs. tacit knowledge 

In literature, a distinction is made between explicit and tacit 

knowledge. The metaphor often used to explain this is that 

of an iceberg. The part of the iceberg above water is explicit 

knowledge, and the part below water is tacit knowledge. 

Explicit knowledge is found in documents, books, forms, 

photos or drawings, for example. It can be stored, processed 

and transmitted using any type of media. It can be logically 

explained and practically applied. It would probably be more 

accurate to speak of ‘explicit information’, because it exists 

independently of a person. 

Tacit knowledge, on the other hand, has a personal quality. 

It is always linked to personal experience and personal skills. 

Core competencies are contained within tacit knowledge. 

On average, 80-90 % of the knowledge in a company is tacit. 

One of the main functions of knowledge management is 

the transformation of tacit knowledge into explicit knowledge 

[2]. However, this is easier said than done. Michael Polanyi, 

known for his work in theory of knowledge, said in 1985, 

“We know more than we can tell.” Tacit knowledge can be 

internalised in such a way that it is no longer (consciously) 

accessible. For example, service technicians may be able to 

intuitively assess the condition of a gas circulation fan and 

the repairs required by the running noise, but be unable to 

explain exactly how they do it. There are many publications 

dealing with this problem, including methods for storing 

and transmitting knowledge, and especially for safeguarding 

knowledge using storytelling, mind mapping, competence 

matrices and so on. 

Relevant knowledge 

Obviously, knowledge is only relevant to a company if it allows 

the company to solve problems or create something new. It 

doesn’t matter whether this knowledge is tacit or explicit. 

The question of relevance is the most important one. Only 

when this question has been answered can we proceed to 

ask what knowledge is relevant. 

Probst et al. [3] define knowledge as the entirety of insights 

and skills that individuals use to solve problems. This definition 

includes both theoretical knowledge and practical everyday 

rules and instructions. 

According to another, equally popular, definition, there is 

knowledge about why you do something (know why), what 

you do (know what) and how to do it correctly (know how). 

Two additional factors are often added: knowing where to find 

information for a specific purpose (know where) and when 

what information is needed (know when). So knowledge is 

more than what is often referred to as ‘know-how’. 

Maintenance knowledge 

Maintenance demands specialised knowledge. It needs to be 

embedded in practical activity without neglecting the transformation 

to an engineering discipline. A good maintenance 

department used to be one that fixed problems quickly, but 

now it is measured by its ability to prevent problems (breakdowns 

or faults) occurring in the first place. So a modern 

maintenance department must have an understanding of 

damage mechanisms and scientific methods relating to the 

changes caused by wear and tear. In other words, in addition 

to practical knowledge, it is increasingly important to know 

why something is done in the way it is done. 

The role of the experts 

Experts are the main knowledge holders in a company. They 

have specialist knowledge and technical authority. They have 

experience and the ability to apply their knowledge to new 

situations. In other words, they are not just knowledge holders, 

but knowledge developers. This characteristic cannot 

necessarily be attributed to other knowledge holders, for 

example pure practitioners. 

When experts leave a company, their tacit individual knowledge 

is lost to the organisation. Some of their explicit knowledge 

remains, for example in the form of records, but as the 

metaphor of the iceberg shows, this is only the smaller part. 

The volatility of knowledge 

Knowledge is tied to people. There is always the risk that a 

knowledge holder will leave the company, for example due 

to retirement. Demographic change therefore plays an important 

role in maintenance professions, where experience and 

knowledge are so important. We also shouldn’t forget that 

knowledge, too, becomes obsolete. The average half-life of 

professional technical knowledge is approximately five years, 



REPORTS 

and considerably less for automation engineers and computer 

scientists. As paradoxical as this may sound, it is because our 

knowledge is currently exploding – and therefore loses its 

value ever more quickly as a result of technological change. 

So sometimes it is important to forget what you know, get 

rid of ballast and be open to new ideas. 

WHAT IS KNOWLEDGE MANAGEMENT? 

Albert Einstein is credited with saying, “Knowledge means 

knowing where it’s written down.” He was probably thinking 

along similar lines to the problem outlined at the start, “If 

my company only knew how much it knew”. For this reason, 

knowledge management is commonly discussed in the context 

of locating information or creating databases, and is often 

reduced to simply that. But merely building a database isn’t 

knowledge management. Databases are tools for information 

processing; sometimes data graveyards. At the beginning a 

database is like a library without books – empty. 

The most familiar example of an external database is the 

Internet. To someone looking for knowledge, the Internet is 

like a vast unsorted library without librarians to impose any 

kind of order. Information stored on the web can be found 

with the help of search engines. A search turns up a huge 

amount of irrelevant and unverified information, to name just 

the two biggest problems, and the user must decide for themselves 

what is relevant and what is not, which information can 

be trusted and which cannot. There is no librarian to help. 

By contrast, document management systems represent 

an attempt to reproduce a more or less structured company 

memory. One of the main purposes of a document management 

system is to store text documents (such as installation 

instructions, troubleshooting guides or criteria lists), drawings, 

pictures and so on in a central place and make them accessible 

to employees. Information is generally made available 

on a company intranet. However, the documents must first 

be classified in order for the knowledge they contain to be 

located quickly and in context. This sometimes involves a lot 

of work and is only worth it if the ‘keyworded’ knowledge is 

of permanent relevance. This is rarely the case. 

Elements of knowledge management 

We have seen so far that knowledge management is much 

more than just knowing where it’s written down. Probst et al. 

[3] go considerably further by defining knowledge management 

as a systematic process of organisational knowledge 

use and creation within a company. In the authors’ view, the 

process proposed by Probst et al., shown in Fig. 2, is a good 

theoretical basis for knowledge management in maintenance. 

The individual elements are briefly explained below. 

Knowledge goals 

Corporate knowledge management begins with the definition 

of knowledge goals as part of the company strategy. 

Strategic 

level 

Operational 

level 


acquisition 


goals 


identification 


development 


assessment 


preservation 


distribution 

Fig. 2: Building blocks of knowledge management 

These goals can be used both for planning and as a basis 

for implementation and performance monitoring. This 

includes, for example, the direction in which the company 

wants to develop its knowledge and the fields in which it 

wants to achieve superior knowledge over competitors. 

Knowledge identification 

Knowledge identification creates transparency as to internally 

and externally available knowledge. This includes an 

analysis of the state of knowledge in the accessible environment 

(customers, suppliers, industry associations, etc.). A 

deficient analysis may result in inefficiency, inadequately 

justified decisions and duplications. Knowledge identification 

also entails the systematic evaluation of customer 

complaints, error analyses and customer surveys and the 

identification of employees with specific competencies. 

Not all knowledge needs to be within the company itself, 

as long as it is accessible in some way. 

Knowledge acquisition 

Much of the knowledge a company needs is imported from 

external sources. External training courses and seminars 

are the traditional sources, as well as internal training and 

development programmes. There is also considerable and 

often untapped potential for knowledge acquisition in links 

with customers, suppliers, competitors and cooperation 

partners. 

Knowledge development 

Knowledge development is complementary to knowledge 

acquisition. It revolves around developing new skills, products, 

new and better ideas and more effective processes. 

Much internal knowledge is tacit (remember the iceberg) 

and consists of experience and special skills not accessible 

to other employees. The essential aim is to pass this 

knowledge on to colleagues. 


utilization 


65

REPORTS 


Knowledge distribution 

Knowledge must be shared and distributed within a company 

so that the entire organisation can use it. The distribution of 

existing knowledge within the company must be put into 

practice and upheld. Sharing information with colleagues 

and supervisors, as well as people outside the company at 

meetings, conferences and forums such as the Aichelin Maintenance 

Forum, is very important. Even a very good technical 

infrastructure cannot by itself satisfy the requirements of 

knowledge sharing and distribution. This is an opportunity 

for knowledge managers to play a key role. 

Knowledge utilisation 

The ultimate aim of knowledge management is to make 

productive use of knowledge for the benefit of the company. 

However, the successful identification and sharing/distribution 

of knowledge will not by themselves ensure that knowledge 

is used effectively in everyday operations. The utilisation of 

available knowledge must be accompanied and ensured by 

organisational measures, such as service plans. 

Knowledge preservation 

Once it has been acquired and developed, perhaps with great 

effort, knowledge must be retained and kept up to date. 

Both the technical infrastructure (databases or document 

management systems) and the retention of experts within 

the company play the most important roles in this respect. 

There are plenty of ways in which available knowledge can 

be quickly lost again, for example when employees leave 

the company. 

Knowledge assessment 

Finally, the measures taken must be assessed. Have the investments 

in knowledge management paid off? Are they moving 

in the right direction? Have the defined objectives been 

achieved? This evaluation is not at all easy because there are 

no standard measurements for knowledge. 

Continuous improvement process 

The connecting lines between the various elements in Fig. 2 

show the interdependencies at work. It is not sufficient to 

focus on one particular element to the exclusion of the rest. 

Knowledge management is a process without an explicit start 

and end, a process of continuous improvement. However, this 

wider definition of knowledge management is not yet evident 

in many organisations. Existing knowledge is not utilised, for 

example because internal knowledge is not valued enough 

and knowledge is acquired externally at high cost. Employees 

are sent on pointless training courses, the content of which 

they cannot apply in their jobs. Expensive document management 

systems are often useless because the system does not 

contain any relevant information. So there are many reasons 

to continually re-implement the elements of knowledge management 

and take appropriate corrective action. 

KNOWLEDGE MANAGEMENT 

IN MAINTENANCE 

Knowledge management in maintenance is associated with 

very specific requirements and problems. When it comes to 

the maintenance of complex machines and plants, maintenance 

knowledge has always been shared between a number 

of different professions. Designers, operators, maintenance 

departments and external service teams need to pool their 

specific experience to come up with solutions to problems. 

Maintenance demands multidisciplinary knowledge – a 

combination of mechanics, automation and process engineering. 

The breadth and depth of knowledge required today can 

no longer be held by a single individual. A modern maintenance 

department will carry out key processes cooperatively, 

i.e. in close collaboration with relevant specialists [4]. 

The maintenance of complex thermal process plants can 

only be achieved through a close interlinking of theoretical 

knowledge, experience and practical activity. The extent to 

which maintenance has already developed into an engineering 

discipline will be described using the example of knowledge 

management at Aichelin Service GmbH. 

Data base 

• Wear process 

symptoms e.g. 

vibration, etc. 

• Wear process marks 

e.g. abrasion, etc. 

• Characteristic life-time 

data (MTBF) 

• Running times or 

cycles 

• Repair times (MTTR) 

• Failure statistics 

• Limit values 

• … 

Knowledge goals 

• Service plans with 

ideal maintenance 

strategies 

• Functional wear 

models 

• Best practice guides 

• Lifetime data 

• Weak-points 

• Hazards 

• Failure probabilities 

• FMEA, PFMEA 

• … 

Key processes 

• Inspection 

• Maintenance 

• Repair 

• CIP e.g. on energy, 

efficiency 

• Spare parts 

management 

• Change management 

• Remote services 

utilization 

• Cooperation 

• … 

Knowledge objectives in maintenance 

As a general rule, every maintenance key process requires 

several knowledge objectives. As shown in Fig. 3, knowledge 

objectives must be defined and the data basis or knowledge 

status must be assessed at a strategic level on the basis of 

the key processes. 

The most important knowledge objectives in maintenance 

include a plant-specific service plan and an optimum 

maintenance strategy 2 for critical parts (for example 

a condition-based maintenance strategy). This requires the 

procurement of a lot of knowledge about the parts used, for 

Fig. 3: Knowledge management in maintenance – Strategic level 

2 Ultimately, the maintenance strategy defines what kind of measure is carried 

out on defined maintenance objects and how often. [DIN EN 13306: 

Maintenance terms] 



REPORTS 

example characteristic lifetime data. Other 

important knowledge objectives include 

best practice procedures, the identification 

of weak points, failure mode and effects 

analyses and guides. 

Key maintenance processes 

Though, before the definition of knowledge 

objectives comes the question of relevance: 

we are talking primarily about maintenance 

key processes. This refers to the four basic 

measures named in DIN 31051 [5]: maintenance, 

inspection, repair and improvement. 

However, an optimum maintenance plan is 

not limited to these activities but includes 

further key processes such as efficiency 

enhancement, cost-optimised parts procurement 

and change management. 

Service 

plan 

Definition of 

plant 

structure 

and maintenance 

strategies 

Functional wear 

model 

(1) (2.1) (2.3) (3.1) 

(7) 

Create a 

functional 

model of 

wear 

process 

conditions 

(2.2) (2.4) 

Determine 

wear 


limits 


wear 


marks or 

symptoms 

Select a 

measurement 

technique 

Inspection, wear prediction 

and maintenance measures 

Definition of 

specified 

conditions 

& detection 

of actual 

conditions 

(3.2) 

Readjust 

marks or 

symptoms 

of wear 

(4.1) 

(4.2) 

Documenting and archiving 

Evaluation 

and failure 

prediction 

Lifetime 

data 

statistics, 

e.g. MTBF 

(5.1) 


maintenance 

measures 

(5.2) 

Adjust 

operating 

instructions 

CIP 

Weak point 

analysis 

(6.2) 

(6.1) 

Optimisation 

Data basis and knowledge evaluation 

In order to achieve the strategic knowledge 

objectives, the data basis and the 

attained knowledge status must be regularly 

evaluated. A potential sticking point 

is feedback from maintenance employees, 

for example after a condition assessment. 

Maintenance technicians are not writers, 

and if information is conveyed at all, it 

tends to be verbal. If data and information are not documented, 

they are not available for evaluation purposes etc. 

– either now or in the future. Not documented is like not 

been done! 

Knowledge managers are a critical success factor 

In the authors’ experience, a knowledge manager must 

be someone who holds the reins for a particular knowledge 

area, an expert who proactively manages their own 

knowledge area. Knowledge managers ensure through 

effective personal communication that colleagues share 

their knowledge with one another. They motivate people 

to cooperate and make clear that it is the knowledge 

inside their heads that keeps the company competitive. 

They create organisationally embedded (explicit) action 

routines and rules, for example service plans or condition 

assessment checklists. 

Knowledge managers also form a link between those 

who possess knowledge and those who are trying to find 

it. To return to the library metaphor, they are the librarians. 

They make sure that knowledge reaches the maintenance 

technician’s workplace and therefore produces a benefit. 

Hence, knowledge managers are much more than just 

administrators of knowledge. They must have knowledge 

of their own and act as role models. Their success is also 

Knowledge goals Knowledge acquisition 

Knowledge identification Knowledge utilization 

Knowledge preservation 

dependent on their personal credibility and honesty, especially 

in the handling of other people’s intellectual property. 

Practical example at operational level: knowledge 

management in condition-based maintenance 

Few maintenance strategies are so frequently misinterpreted, 

or not fully interpreted, as condition-based maintenance. 

Condition-based maintenance depends on recognisable 

wear of a unit detected during an inspection 3 . The wear 

must be measurable and closely linked with the failure of the 

unit. For many components this is not the case, or cannot 

be formulated in a practically relevant way. Strictly speaking, 

condition-based maintenance is not possible in this case. 

The basic idea of condition-based maintenance is to 

predict the remaining lifetime of a part by comparing a 

theoretical wear model and an inspection, as described 

in VDI guideline 2888 [6]. For reasons of economy, worn 

parts should continue to be used for as long as possible 

before the part is replaced. Both, knowledge management 

and practical maintenance activities within this key process 

are based on the process shown in Fig. 4, which in turn is 

based on VDI guideline 2888. 

3 According to DIN 31051, a unit is “any part, element, device, subsystem, 

functional unit, piece of equipment or system that can be considered on its 

own”. 

Knowledge development 

Knowledge assessment 

Fig. 4: Knowledge management in condition-based maintenance – Operational level 


67

REPORTS 


100 % 

± 5 mm 

Wear margin 

Bulging of tube 

Wear margin limit 

(maximum bulging of tube) 

+ 15 mm 

0 % 

Characteristic wear marks in the wear process model 

3 4 

5 Years 

Fig. 5: Example of a multi-purpose chamber furnace 

Fig. 6: Wear characteristic mark: Bulging of a radiant tube 

Maintenance tasks and knowledge management elements 

cannot be simply matched up because they usually 

overlap. Instead, the technical processes of maintenance and 

the organisational processes of knowledge management 

are interlinked in a matrix. For clarity, in Fig. 4 the numbers 

in round brackets are referenced in the description below. 

Service plan 

To start with, for every plant there is an individual service plan 

(1), agreed with the customer, for example a service plan for 

a multi-purpose chamber furnace (Fig. 5). All elements of 

knowledge management are incorporated in the service 

plan. For example, the knowledge objectives and knowledge 

identification are defined by the maintenance strategies. A 

well-designed service plan includes a list of system parts or 

sections requiring maintenance and the associated maintenance 

activities. The allocation of maintenance activities 

includes the chosen maintenance strategy for the section or 

part (event-oriented, time-oriented or condition-oriented), 

inspection findings, and if necessary possible improvements. 

A service plan also includes the maintenance cycle and 

planned duration of activities. The intervals for maintenance 

jobs are continually reviewed and must be empirically 

adjusted to avoid too little or too much maintenance. 

Providing scheduled times for maintenance activities allows 

the required capacity to be predicted for both, staff planning 

and maintenance duration. 

All measures carried out are documented in the service 

plan. The proper documentation of maintenance is not only 

a legal requirement but also an important element of knowledge 

management, both for the maintenance department 

and even more for the operator. 

Defining a wear model 

When it comes to producing a theoretical wear model, 

the biggest knowledge management problem is probably 

knowledge acquisition, because for furnace parts there are 

typically only a few examples to provide orientation. To 

produce the wear model we can avail ourselves of the wear 

margin defined in DIN 31051 [5]. In this model a part has a 

limited wear margin, which is reduced continually through 

normal use and abruptly by extreme stress until it reaches 

the end of its useful life. Wear behaviour is described by 

the wear curve (2.1). The difficulty arises firstly from the 

determination of the wear curve and secondly from the 

definition of the wear limit or optimum time at which the 

piece of equipment is preventatively replaced (2.2), which 

should be just before the time of failure. The closer the optimum 

date is to the time of failure, the greater the potential 

savings compared with periodic, non-condition-based 


As a further difficulty, wear is usually a combination of 

very different chemical and/or physical processes caused 

by various types of stress, such as friction, corrosion, fatigue, 

ageing, cavitation, fracture and temperature. Maintenance 

therefore tends to concentrate on the symptoms of wear, 

for example vibration. The symptoms of wear are different 

from wear per se. The best way to explain the difference is 

by using an analogy. A viral infection is caused by a virus, 

but because viruses themselves are very difficult to detect, 

we focus on the symptoms, such as fever, which are more 

easily measurable. 

As can be seen in Fig. 6, it is by no means straightforward 

to define measurable condition-based features or 

symptoms (2.3) for furnace parts, such as a radiant tube. 

However, without them it is impossible to define measurement 

variables and a measurement method for inspection 

purposes (2.4). Usually, a solution can be found. For 

example, the bulging of a radiant tube may appear to be 

‘only’ a qualitative wear characteristic, but it can be made 

measurable with relatively little effort – in this example 

using hole templates of different diameters. The measur- 



REPORTS 

able characteristic wear marks can then be assigned a limit 

(the wear margin limit). Most parts will have more than one 

wear characteristic, each with its own wear limit. 

Inspection 

In accordance with DIN 31051 [5], the inspection includes 

all measures designed to establish and evaluate the current 

condition, including the identification of causes 

of wear and the definition of necessary consequences 

for future use. With condition-based maintenance the 

inspected condition must be correlated with the theoretical 

wear curve and wear characteristics defined in the 

wear model (3.1). This is the key characteristic of conditionbased 

maintenance. Because wear (friction, corrosion, 

fatigue, ageing etc.) is often very difficult to measure 

directly if at all, maintenance and inspection criteria are 

primarily concerned with the symptoms of wear, such 

as unbalance, increased temperature or noise, which are 

more easily measurable. 

Sometimes more suitable wear characteristics or symptoms 

only become apparent through experience. In this 

case the defined target and actual characteristics may 

have to be adjusted (3.2). Only a very few furnace parts 

can be constantly monitored with a condition monitoring 

system (CMS), for example to measure the unbalance of a 

gas circulation fan. All other parts, particularly inside the 

furnace, require inspection by a suitably qualified person. 

The possibilities of CMS in thermal process plants are 

often seriously overestimated. During the inspection it 

is essential to utilise and develop existing knowledge. In 

other words, the condition assessment should always be 

carried out with reference to a checklist of criteria – otherwise 

the results of an inspection are just the personal 

opinion of the inspector. 

Forecast 

If we assume that the unit is still intact at the present time, 

then the forecast concerns the remaining time until probable 

failure. Based on a comparison of the theoretical wear 

model and the practical inspection, the task is to predict 

whether a part can continue to be used until the next 

maintenance, needs to be repaired, or needs to be replaced 

immediately (4.1). 

If the wear is approximately proportional to the service 

life in the relevant time period of the wear model, the 

forecast is very straightforward. The probable time of 

failure can then be mentally extrapolated using the rule 

of proportion. Although in many cases the wear margin 

cannot be assumed to be linear, it is usually possible, on 

the basis of experience, to estimate the failure risk of a 

part before the next maintenance. Failure rates and the 

characteristic lifetime of a unit of this kind are also taken 

into account (4.2). 

Reliability forecasts based on failure rates 

If condition-based maintenance is not possible because 

no measurements or qualitative wear characteristics can 

be noted, we can revert to (time-based) predictive maintenance 

with MTBF values, or the technical failure rate. For 

this purpose it is assumed that identical parts always wear 

in the same way every time. The failure rate (often shown 

as a bathtub curve) can be mathematically calculated very 

easily using a Weibull distribution 4 . To calculate a reliability 

forecast using the Weibull distribution, we simply need 

to know the characteristic lifetime and the form factor 

that characterises the failure behaviour [7, 8]. However, this 

alternative will not be discussed further here; the quoted 

sources should be consulted for more information. 

Measures (maintenance and repairs) 

The necessary maintenance or repairs are then carried 

out in accordance with the forecast (5.1). These measures 

typically include cleaning, lubrication and the replacement 

or repair of parts. The operating instructions may also be 

updated if necessary (5.2). 

Continuous improvement 

The aim of continuous improvement in condition-based 

maintenance is to continually improve the quality of maintenance 

processes through small incremental changes. 

Continuous improvement is a central process in both 

knowledge management and condition-based maintenance, 

requiring errors and weak points to be continually 

re-analysed (6.1) and optimised (6.2). 

Documentation 

Documentation is a central process within knowledge 

management (7). Protecting acquired knowledge is vital 

to the success of a company. Useful improvement cannot 

be achieved without documentation. Only once a relevant 

volume of data has been evaluated can weak points be 

clearly identified and probability statements be made as 

to the failure behaviour of particular parts. 

In day-to-day operations, however, maintenance documentation 

is often given secondary importance or neglected 

altogether. As a result, the results of inspections and 

measures carried out often go unrecorded, and no record 

remains of the quantitative or qualitative measurements of 

the actual condition or the forecasts and measures based 

on them. If something is not documented, it is like not been 

done. Quite apart from the requirements of knowledge 

management, it should be borne in mind that the testing, 

maintenance and upkeep of safety equipment is required 

by law, and records must be kept for this reason alone. The 

4 The supplementary use of mathematical methods is characteristic of predictive 



69

REPORTS 


crucial importance of documentation cannot therefore be 

over-emphasised. 

CONCLUSION 

A few years ago knowledge management in maintenance 

was still the exception, but it has now become an essential 

component of forward-looking strategies in professional 

maintenance organisations. Good knowledge management 

enables these organisations to exploit the full potential 

of maintenance. Condition-based maintenance is an 

organisationally and technically complex task. In few areas 

of maintenance theory and practice are so closely linked. 

Condition-based maintenance is not possible without 

knowledge management, because the prediction of service 

life always requires a comparison of the inspection 

(practice) with the previously defined wear characteristics 

(theory). Knowledge managers play a central role in this 

process, particularly as they represent the link between 

theory and practice. 

Knowledge management is an ongoing process that 

depends on the team performance of the organisation as 

a whole. When it comes to knowledge development and 

application in the key process of condition-based maintenance, 

manufacturers’ service teams can contribute their 

additional knowledge (e.g. design knowledge, process 

engineering, possession of the technical documentation or 

information during the warranty period). This has enormous 

benefits for the customer, too. 

LITERATURE 

[1] Filounek, A.: Knowledge Management in the Maintenance of 

Thermal Process Plants. Presentation at Aichelin Maintenance 

Forum 2013. Korntal-Münchingen, 2013 

[2] Nonaka, I.; Takeuchi, H.: Die Organisation des Wissens: Wie 

japanische Unternehmen eine brachliegende Ressource 

nutzbar machen. Frankfurt am Main, 1997 

[3] Probst, G.; Raub, S.; Romhardt, K.: Wissen managen: wie 

Unternehmen ihre wertvollste Ressource optimal nutzen. 

Gabler, Wiesbaden, 2006 

[4] Hiller, M.; Steck-Winter, H.: Kooperative Instandhaltung von 

Thermoprozessanlagen. gwi – gaswärme international 

3-2013, Vulkan-Verlag, Essen, 2013 

[5] DIN 31051:2012-09. Grundlagen der Instandhaltung. Beuth 

Verlag Berlin, 2012 

[6] VDI: Richtlinie 2888, Zustandsorientierte Instandhaltung. 

Beuth Verlag, Berlin, 1999 

[7] Steck-Winter, H.: Instandhaltungskennzahlen. Gaswärme 

International Nr. 3/2012, Vulkan Verlag Essen, 2012 

[8] Steck-Winter, H.: Vorausschauende Instandhaltung von 

Thermoprozessanlagen. Gaswärme International Nr. 3/2011, 

Vulkan Verlag Essen, 2011 

AUTHORS 

Dr. Hartmut Steck-Winter 

Aichelin Service GmbH 

Ludwigsburg, Germany 

Tel.: +49 (0) 7141 / 6437 106 

hartmut.steck-winter@aichelin.com 

Dr.-Ing. Axel Filounek 

Aichelin Service GmbH 

Ludwigsburg, Germany 

Tel.: +49 (0) 7141 / 6437 528 

axel.filounek@aichelin.com 


Vulkan-Verlag 


22 - 24 October 2014 


Germany 



REPORTS 

Impacts of allowed tolerances in 

temperature on nitriding results 

by Karl-Michael Winter 

In recent years, nitriding and nitrocarburizing have gained more and more importance in the heat treatment of components. 

While only a few years ago, it has been common to perform these processes with fixed set temperatures and gas 

flows, today so-called potential control became state of the art. Consequently, besides appropriate temperature uniformity 

nowadays also permissible tolerances in atmosphere potential control are required. The article uses the example of 

the American aerospace specifications SAE AMS2759/10 and 2750D on the extent to how the therein required tolerance 

bands allow for staying within the specified tolerances of given compound layer thickness. Intensive experiments were 

conducted using pure iron, carbon steels AISI 1018 and 1070 , the high-tensile steel AISI 4140 and the hot work tool steel 

AISI H13, where potentials and temperatures have been varied over a wide range in order to make qualified conclusions. 

As a follow up on an article about the impact of measurement errors on nitriding and nitrocarburizing results (Gaswärme 

International (60) No. 3/2011 and Heat Processing (9) No. 3/2011) requirements for measurement instruments and furnace 

equipment are additionally considered. In a second series of experiments, process setup has been varied, in order to 

quantify the influence of heating and cooling with inert gas or process gas and nitrogen diluted atmospheres. 

Goal of a classical nitriding / nitrocarburizing treatment 

is to induce nitrogen / nitrogen and carbon 

into the surface of a part in order to enhance its 

mechanical and chemical properties. The treatment is 

typically performed in a temperature range between 490 

and 590 °C. At this temperature nitrogen / nitrogen and 

carbon will diffuse into the ferritic structure of the material. 

Because of the comparably low temperature (below 

A C1 in the iron – nitrogen system of ferritic steels) there 

will be no phase change forced in the base material and 

the hardness increase is given by lattice distortion created 

by interstitially placed nitrogen / nitrogen and carbon 

but mostly by formation of nitrides / carbonitrides with 

nitride forming alloying elements such as chromium, 

aluminum, titanium etc. In addition, nitrogen also has a 

high affinity to iron which may also evolve into the formation 

of a so-called compound layer (CL), also known 

as white layer. This very hard ceramic layer offers very 

low friction and high resistivity to chemical aggression 

and may consist of Fe 4 N γ‘-nitrides, Fe 2-3 N[C] ε-(carbo)- 

nitrides or a mixture of both. Depending on material and 

the planned for stress scenario once the parts are in use, 

either the nitrogen diffusion depth and with it the effective 

hardness depth or the dimension and composition 

of the compound layer will be in the focus of the treatment. 

The temperature and atmosphere dependence of 

the formation of such iron (carbo)-nitrides for pure iron 

is shown in the Lehrer Diagram (Fig. 1). 

Fig. 1: Fe-N Lehrer Diagram with iso-concentration-lines 

for Nitrogen in the Epsilon phase [1, 2], nitriding 

potential K N in bar -0.5 


71

REPORTS 


Fig. 2: K N ranges for AISI 4140 versus temperature for white layer thickness 

classes 0, 1 and 2 

Specified parameters for nitrided and nitrocarburized 

parts are [3]: 

■■ 

Surface hardness, 

■■ 

Core hardness, 

■■ 

Case depth (NHD for nitriding hardness depth), either 

effective (in relation to a given reference hardness) or 

core hardness plus 50 HV, 

■■ 

Compound layer thickness (CLT). 

Often, there might be additional requirements such as: 

■■ 

Compound layer composition, 

■■ 

Thickness of allowed for porous layer respectively percentage 

of porosity. 

The nitriding processes discussed in the article will mainly 

focus on a comparably deep diffusion depth to increase 

load resistance. In this process the formation of a compound 

layer is rather unwanted as this layer is very brittle 

and tends to break out; consequently the thickness of the 

compound layer should not exceed a given limit. 

SPECIFICATIONS 

As early as in 1987, the SAE International, an internationally 

active U.S. American organization for standardization of 

automotive and aerospace part manufacturing introduced 

a specification for nitriding of aerospace parts, giving a classification 

of the treated parts in relation to the maximum 

allowed for compound layer thickness. In the document, 

nitriding parameters temperature and dissociation degree 

are specified [4]. Classified are: nitriding to a maximum 

compound layer thickness of either 12.7 microns (Class 1) 

or 23 microns (Class 2). In order to achieve the given classes, 

the specification also requires good temperature uniformity 

(+/- 8 °C) and a tight control of the dissociation (+/- 5 % of 

setpoint). The process may be performed in one or two 

stages, the stages differing in temperature, dissociation 

or both. Typically the first stage starts at low temperature 

and low dissociation followed by a second stage at 

higher temperature and high dissociation. The first stage 

(nucleation) is aiming for a very little closed compound 

layer, later used as a diffusion reservoir, while the second 

stage uses the higher temperature to produce the desired 

case depth without excessively increasing the compound 

layer thickness. 

The dissociation degree is given by the thermal dissociation 

of ammonia (1) into nitrogen and hydrogen and 

describes the percentage in the exhaust gas no longer 

being ammonia. Dissociation can easily be measured using 

a water burette. 

(1) Thermal dissociation 

Unfortunately, this specification is not applicable to nitrogen 

diluted atmospheres as the ratio between ammonia 

and dissociated ammonia cannot be determined correctly. 

Partially out of this reason, the requirements have been 

modified in 1999 by launching the AMS2759/10 [5]. In this 

specification the atmosphere control parameter dissociation 

has been replaced by the nitriding potential K N , better 

describing nitriding phenomena and not affected by 

nitrogen dilution. In addition to the two classes specified 

in AMS2759/6 a new class has been added aiming for no 

compound layer at all (Class 0). The limits for classes one 

and two have been slightly changed to 13 microns and 

25 microns. 

From the nitriding reaction (2) can be observed that the 

nitrogen uptake is proportional to the partial pressure ratio 

of ammonia to hydrogen; establishing equilibrium between 

atmosphere and nitrogen percentage in the very surface 

of the material which can be described by the nitriding 

potential (3) and the actual process conditions, given by 

temperature and percentages of alloying elements. 

(2) Nitriding reaction 

(3) Nitriding potential 

In atmosphere consisting exclusively of ammonia and dissociated 

ammonia both atmosphere parameters can easily 

be converted into each other (4). 

(4) with D = Dissociation / 

100 % 

Like the older specification, the newer AMS2759/10 is giving 

tolerances for the process parameters. 



REPORTS 

Table 1: Recommended ranges of nitriding potential in AMS2759/10A (Excerpt) 

Steel Class 0 (no CL) Class 1 (max. 13 μm) Class 2 (max. 25 μm) 

Stage 1 Stage 2 Stage 1 Stage 2 Stage 1 Stage 2 

AISI 4140 4-12 0.25-0.7 4-15 0.6-2.6 4-15 1.2-4.5 

Carbon Steel N/A N/A 5-12 0.8-2.6 1.2-4.0 N/A 

PROCESS PARAMETERS AND TOLERANCES 

AMS2759/10 is defining setpoints for the controlled nitriding 

potential depending on compound layer class and steel 

grade, for one and two stage processes (see Table 1). As 

the allowed for temperature range is set between 490 and 

590 °C, the table is interpreted in such a way that at 490 °C 

the higher nitriding potential has to be applied and at 

590 °C the lower. In between the two extremes the potential 

is determined by linear interpolation. If, for example, an 

AISI 4140 shall be nitrided without formation of a compound 

layer at 548 °C, in the first stage a nitriding potential of 7.3 

(range 4-12) has to be applied. In the second stage, at the 

same temperature, the nitriding potential has to be reduced 

to 0.44 (range 0.25-0.7). Fig. 2 displays K N ranges versus 

temperature for this particular steel and all three classes. The 

black dashed lines represent the phase boundaries towards 

Fe4N and Fe2-3N in the Lehrer Diagram. 

The atmosphere controller has to be able to maintain 

an actual nitriding potential staying within +/- 10 % of the 

setpoint. The maximum allowed for tolerances in our example 

come to 7.3 +/- 0.73 in stage one and 0.44 +/- 0.044 in 

stage two. 

REQUIREMENTS ON MEASUREMENT 

EQUIPMENT 

Assuming the process gas is consisting of ammonia and 

dissociated ammonia only, the setpoints for nitriding 

potential can be converted into volume percentages of 

ammonia and hydrogen in exhaust. During stage one, 

residual ammonia has to be maintained between 70.2 

and 73.0 %, the according hydrogen percentage range 

comes to 20.2 to 22.4 %. For stage two, the ammonia 

percentage comes to 19.1 and 21.9 % and the hydrogen 

percentage comes to 60.7 and 58.6 %. Consequently, the 

measurement of ammonia requires a minimum accuracy 

of 1.8 %, the measurement of hydrogen requires an accuracy 

of 2.1 %; both numbers related to a full scale (FS) of 

100 %. These requirements, per se, should not cause any 

problems for commercially available measurement technique 

but the conditions will change over a range from 

zero to full scale and behave reciprocal for ammonia and 

hydrogen. If only one instrument is used to determine the 

nitriding potential and the corresponding partial pressure 

is calculated, this will result in non-negligible errors. Fig. 3 

illustrates the relative error in calculated nitriding potential 

determined by a 

hydrogen measurement 

and allowing 

for varying allowed 

for tolerances on 

the full scale error. 

The deviations in 

the hydrogen measurement 

are given 

in absolute volume 

percentages. 

Table 2: Furnace classes according 

to AMS2750 D [7] 

(Excerpt) 

Furnace class 

Temperature 

uniformity 

1 +/- 3 °C 

2 +/- 6 °C 

3 +/- 8 °C 

4 +/- 10 °C 

REQUIREMENTS ON 

TEMPERATURE UNIFORMITY 

Nitriding equipment respectively heat treating furnaces 

are classified according to their temperature uniformity. 

E.g. AMS2750D [7], originally serving as basis for CQI-9, differentiates 

furnaces in an order shown in Table 2. 

Allowing for a tolerance in temperature throughout the 

load automatically results in a variation in nitriding potential, 

as this number is a function of temperature according 

to AMS2759/10. Consequently this raises the question at 

what allowed for temperature deviation the derived nitrid- 

Fig. 3: Relative error in the calculated nitriding potential 

of Ammonia – dissociated Ammonia atmosphere 

when using a Hydrogen analyzer [6] 


73

REPORTS 


In addition, it is possible to set a higher surface nitrogen 

content (8), also increasing the growth rate. 

(6) Influence of diffusion coefficient on 

layer growth 

(7) Influence of temperature on diffusion 

coefficient 

(8) Influence of surface nitrogen 

content (cs) on layer growth 

referenced to specified 

nitrogen content (cx) 

Fig. 4: K N ranges for AISI 4140 versus temperature for white layer thickness 

classes 0, 1 and 2 

ing number will stay within the given tolerances. Fig. 4 

shows a part of Fig. 2 at a temperature setpoint of 548 °C 

and a maximum deviation of +/- 8 °C (furnace class 3). It 

can be seen that up to this furnace class the graph of the 

temperature dependent nitriding number is still within the 

allowed for tolerance at set temperature. If a process would 

be performed in a higher furnace class, the process would 

not be longer complying with the specification. Based on 

a temperature setpoint of 548 °C, the diagram displays a 

temperature range representing furnaces classes 1 through 

3. Nitriding potentials are shown within the allowed for 

tolerances. The black dashed lines represent the phase 

boundaries towards Fe 4 N and Fe 2-3 N in the Lehrer Diagram. 

PARAMETERS INFLUENCING 

COMPOUND LAYER GROWTH 

Having a look on the allowed for tolerances presented up 

to this point in the article raises the question on how these 

deviations in temperature and potential will influence the 

growth of the compound layer and if it will still be possible 

to reach the required results. First of all, the growth of the 

compound layer is following a square root of time law (5). 

(5) Diffusion controlled growth rate 

But this is only valid if a) the temperature and with it the 

diffusion coefficient and b) the expected percentage of 

nitrogen in the surface in equilibrium with the atmosphere 

are constant. As an analogy, Fig. 5 is displaying the growth 

of a carbon profile depending on time, temperature and 

carbon potential, achieved in a carburizing process. With 

increasing temperature the diffusion speed is increasing 

and consequently the growth of the layer is increased (6, 7). 

NITRIDING TESTS 

A series of heat treatments has been performed on various 

steels in order to validate the influence of process parameters 

temperature and nitriding potential. Samples made 

from iron, carbon steels AISI 1018 and 1070, low alloy steel 

AISI 4140 and hot working steel AISI H13 were nitrided for 

4.5, 5 and 5.5 hours soak time at temperatures of 550 °C 

+/- 10 °C and a nitriding potential of K N = 3.5. Parts have 

been loaded into the cold furnace, heated to 360 °C in 

air and held for 5 minutes. Afterwards the furnace was 

purged with nitrogen, filled with process gas and heated to 

process temperature in about 30 minutes. After soak time, 

parts were cooled down to about 100 °C with nitrogen 

flow, within approximately one hour. Test results including 

expected (calculated) results are listed in Table 3. 

It is clearly to observe that the measured results for the 

lower tolerance limit of temperature (550 °C - 10 °C) show 

good agreement with the calculated values, except for the 

hot working steel H13. However, at the upper tolerance limit 

(550 °C + 10 °C) measured compound layer thicknesses 

were significantly higher than expected. Fig. 6 illustrates 

this effect with the example of iron. A possible explanation 

for these differences is the higher effective nitriding 

potential in the phase diagram at the higher temperature 

and a longer heating time. Both effects have not been 

considered in the calculation. 

Table 3: Average measured and [expected] CL thicknesses 

for 550 °C, K N = 3.5, 5.5 hrs. 

Material 

Temperature 

540 °C 550 °C 560 °C 

Iron 12.5 [13.5] 15 23 [16.7] 

1018 8.5 [7.7] 10 20 [11.1] 

1070 13 [12.6] 14 18 [15.1] 

4140 9 [7.2] 8 15 [8.9] 

H13 2 [6.3] 7 7.5 [7.8] 



REPORTS 

Fig. 5: Parameters time (left), temperature (center) and temperature and carbon potential (right) 

INFLUENCE OF NITRIDING POTENTIAL ON 

THE GROWTH OF THE COMPOUND LAYER 

In a second series of tests performed at 550 °C, the nitriding 

potential was raised to K N = 10. The expected results were 

estimated using data from an extensive study conducted 

by the Stiftung Institut für Werkstofftechnik (IWT) in Bremen 

[8] several years ago. Fig. 7 is based on data from this 

study, which was presented by Dr. Klümper-Westkamp 

during a nitriding conference in Canada. The black dashed 

lines show the phase boundaries towards Fe 4 N (left) and 

Fe 2-3 N (right) for iron. The red dashed line represents the 

phase boundary towards Fe 2-3 N[C] corrected for the carbon 

content of the steel. 

Using the square root of time relation and taking the 

change in diffusion speed and the temperature dependent 

displacement of the phase boundaries into account, it is possible 

to transfer the diagram shown in Fig. 7 to the actual test 

conditions (550 °C, 5.5 hours soak time). The calculation for 

the Ck15 performed with HT-Tools Nitriding Simulation results 

in a compound layer thickness of 9 microns at K N = 3.5 and 

12 microns at K N = 10. The measured values for the AISI 1018, 

with very similar chemical composition, showed an average 

of 10 microns at K N = 3.5 and 12 microns for K N = 10. 

INFLUENCE OF TOLERANCE LIMITS ON THE 

ABILITY TO REACH THE SPECIFIED CLT 

In the same manner the expected variations were also estimated 

for the other steels and compared with the experimental 

results. From the results summarized in Table 4 can 

be seen that it is possible to meet the specification given 

for class 2 (13-25 microns CLT) for all the steels tested, with 

the exception of AISI 4140, and allowing for a tolerance 

of +/- 10 °C in temperature and +/- 10 % variation in the 

nitriding potential. 

INFLUENCE OF PROCESS SETUP ON THE 

ABILITY TO REACH THE SPECIFIED CLT 

In another series of experiments, changes were made in the 

process setup. The aim was to determine the role played by 

heating with nitrogen as opposed to heating with process 

Fig. 6: Calculated (red) und measured (blue) white layer 

thickness at constant K N and soak time for temperature 

deviation of +/- 10 °C 

Fig. 7: Measured white layer thickness for a Ck15, nitrided at 570 °C, 

10 hours soak time with varying nitriding potentials 


75

REPORTS 


Table 4: Achievable tolerances in CLT when treated to class 2 

(13-25 μm WL) with allowed for +/- 10 % in nitriding 

potential in furnaces of classes 1 through 4 

Furnace class 

Material 

1: +/- 3 °C 2: +/- 6 °C 3: +/- 8 °C 4: +/- 10 °C 

Iron 17-21 16-22 16-22 15-23 

1018 18-20 17-21 17-21 16-22 

1070 17-20 16-20 16-21 16-21 

4140 10-21 10-22 10-23 10-23 

H13 16-20 15-21 15-21 15-22 

Table 5: White layer thickness μm after 5 hours at 550 °C and K N = 10 

Material Iron 1018 1070 4140 H13 

Nitrogen 22-23 N/A 16-25 12-16 9-13 

Ammonia 23-25 10-15 15-20 17-24 7-12 

gas and the use of nitrogen diluted atmospheres on layer 

formation and composition. 

For the heating experiments a process at 550 °C and 

K N = 10 was performed for 5 hours soak time, then cooled 

under nitrogen within about one hour to 100 °C. The heating 

was carried out in a time span of about 1.5 hours, first with 

ammonia, next with nitrogen. Table 5 shows the achieved 

compound layer thicknesses. As might be expected, the 

compound layer thicknesses reached for heating with 

ammonia where slightly above the ones reached for heating 

with nitrogen. Heating was performed during 1.5 hours with 

ammonia and with nitrogen. The parts have been cooled 

down with nitrogen for about one hour. Interesting at this 

point is that for the AISI H13 little difference in the compound 

layer thickness was found, but the diffusion zone 

was significantly affected. While for heating under ammonia 

100 microns diffusion layer was achieved, for heating under 

nitrogen this was reduced to only 90 microns. 

Theoretically, AMS2759/10 should allow for diluted atmospheres, 

since in this process the nitriding potential is controlled. 

However, in the past already Zimdars [9] proved that 

the results are strongly influenced with increasing dilution 

and the concomitant decrease in residual ammonia, despite 

constant nitriding potential, when reaching a certain dilution. 

From Table 6 it can be seen that a nitrogen dilution results 

in lower CLT. This is especially true for the higher alloyed H13, 

where no compound layer was observed at 90 % dilution. In 

addition, starting with 70 % dilution the diffusion zone was 

not provided with sufficient nitrogen flow. This is explained 

by the fact that no perfect nucleation on the surface has 

taken place, which results in an insufficient and very irregular 

nitriding by itself. 

CONCLUSION 

The test results have shown that both, variations in temperature 

(+/- 10 °C) and variations in nitriding potential (+/- 10 %) 

have a non-negligible influence on the growth of the compound 

layer. The resulting too low nitriding potentials at the 

lower end of the temperature band as well as the too high 

nitriding potentials at the upper end of the temperature 

band, assuming constant gas conditions, lead to a greater 

difference in CLT than expected from temperature deviation 

affecting the diffusion speed only. 

Both allowed for tolerance bands require controlling the 

nitriding potential to a value far enough away from the phase 

boundaries; the distance also reflecting the capabilities of the 

measurement system and control deviations; this is taken into 

account in the AMS2759/10. A treatment to class 1 and class 2 

(≤ 13 microns / ≤ 25 microns) can theoretically be performed 

in a furnace of class 3 (+/- 8 °C) and class 4 (+/- 10 °C). 

The steel AISI 4140 showed unexpected deviations for 

all tests performed and this will be investigated into in a 

separate study. A treatment to class 0 (no compact layer 

permitted) requires the use of measurement devices with 

a maximum FS error of 0.5 % or better due to the very little 

distance to the phase boundaries. 

Process setup also has a tremendous influence on the 

nitriding result; e.g. heating with nitrogen requires longer 

nitriding times compared to heating in ammonia. As a consequence, 

parts with geometrical variations, such as a solid 

block with attached fins, where the fins will be heated faster 

Table 6: White layer thickness in μm after performed with varying nitrogen dilution 

Material 

N 2 Dilution 

Iron 1018 1070 4140 H13 

0 % 23-25 10-15 15-20 17-24 7-12 100 

20 % 19-21 26-32 14-25 13-16 8-9 100 

45 % 20-21 10-12 23 15-25 8-10 100 

70 % 17-19 16-19 20-27 12-17 7-9 95 

90 % 13-14 8-10 14-20 8-15 0 10-60 

H13 Diffusion 

Zone 



REPORTS 

compared to the solid block, should be heated in nitrogen 

and temperature stabilized prior to start injecting the nitriding 

atmosphere, in order not to risk non-uniform nitriding. 

Nitrogen dilution eventually will result in non-uniformly 

nitrided layers even if the nitriding potential is controlled 

perfectly to the setpoint. 

ACKNOWLEDGEMENTS 

I would like to thank my colleagues Dimitri Koshel and Paulo 

Abrantes from Nitrex Montreal who performed the tests and 

evaluated the samples. 

[5] S.A.E. Aerospace: AMS2759/10A, Automated Gaseous Nitriding 

Controlled by Nitriding Potential 

[6] Winter, K.-M.: Auswirkungen von Messfehlern auf das Behandlungsergebnis 

beim Nitrieren und Nitrocarburieren. Gaswärme 

International (60) Nr. 3/2011 and Heat Processing (9) Nr. 3/2011 

[7] S.A.E. Aerospace: AMS2750D, Pyrometry 

[8] Klümper-Westkamp, H.: Multi Sensor Controlled Gas Nitrocarburizing 

for Optimized Properties of Component Parts and 

Tools, Vortrag auf dem Nitrierseminar in Montreal, 2005 

[9] Zimdars, H.: Technologische Grundlagen für die Erzeugung 

nitridhaltiger Schichten in stickstoffangereicherten Nitrieratmosphären, 

Dissertation, TU Freiberg 1987 

LITERATURE 

[1] Lehrer, E.: Über das Eisen-Wasserstoff-Ammoniak-Gleichgewicht. 

Zeitschrift für Elektrochemie 36, 1930, p. 383-392 

[2] Spies, H.-J.; Berg, H.-J.; Zimdars, H.: Fortschritte beim sensorkontrollierten 

Gasnitrieren und -nitrocarburieren. Zeitschrift für 

Werkstoffe, Wärmebehandlung, Fertigung - HTM, 58, 4/2003, p. 

189-197 

[3] DIN ISO 15787: Technische Produktdokumentation - Wärmebehandelte 

Teile aus Eisenwerkstoffen - Darstellung und Angaben 

[4] S.A.E. Aerospace: AMS2759/6A, Gas Nitriding and Heat Treatment 

of Low-Alloy Steel Parts 

AUTHOR 

Dipl.-Ing. (FH) Karl-Michael Winter 

Process-Electronic GmbH 

Heiningen, Germany 

Tel.: +49 (0) 7161 / 94888-0 

km.winter@process-electronic.com 


77

6th All Indian Exhibition 

& Conference for the 

Tube and Pipe Industries 

www.tube-india.com 

28 – 30 October 2014 

5th International Exhibition 

& Conference on Metallurgical 

Technology, Material Handling 

and Services 

www.metallurgy-india.com 

Bombay Convention & Exhibition Centre, Mumbai, India 

Held in conjunction with: 

WELDING 

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CUTTING 

P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany 

& 

Phone +49 (0) 2 11/45 60-77 62 _ Fax +49 (0) 2 11/45 60-77 40 

SchreiberG@messe-duesseldorf.de 

78 heat processing 3-2014 

www.messe-duesseldorf.de


REPORTS 

Magnetic flux control in 

induction systems 

by Valentin Nemkov 

Magnetic flux controllers are widely used in induction heating systems for concentration, shielding or redistribution of 

the magnetic field which generates power in the part to be heated. Controllers, made of Soft Magnetic Composites 

(SMC), provide accurate heat pattern control, improve parameters of inductors and performance of the entire installation. 

In melting systems, especially in the case of vacuum furnaces, cold crucible and other specialty furnaces, the magnetic 

control can provide large energy savings, magnetic field shielding, shorter melting cycles and optimized field distribution 

for enhancement of the metallurgical processes. Due to the diversity of applications, service conditions of controllers 

are very different including very severe cases. Mechanical, magnetic, electrical, thermal and other properties must be 

considered in design and application of SMC. This article describes properties and performance of SMC typically used 

in induction heating technology. Several presented case stories are based on more than 20 years of R&D and practical 

experience of scientists and practitioners at Fluxtrol, Inc. Presented material may be interesting not only for induction 

heating community but also for all people using AC magnetic fields in technological processes. 

Magnetic flux control, i.e. modification of the 

magnetic field distribution and intensity may 

be accomplished by variation of shape and 

positioning of the induction coil turns, by insertion of 

the non-magnetic shields or the magnetic templates 

that may be all called the magnetic controllers. Each 

method of magnetic control has its own advantages, 

drawbacks and limitations. 

Induction coil designers pay main attention to optimisation 

of active conductors, their size, number and 

position. They try to avoid using additional components 

for the magnetic flux control in order to simplify 

design, reduce cost and possibility of the potential coil 

life time reduction. This approach is understandable 

but it is only partially correct. In today’s competitive 

market with new materials and technologies, more 

strict demands to the product quality and ergonomic 

requirements force us to review the existing guidelines 

and make corrections to the design procedure. The 

main tool for that is computer simulation which can 

predict not only the process parameters but also life 

time of tooling (inductors) and service properties of 

the final products [1]. Different methods of magnetic 

flux control must be considered in the process of new 

system development and modification of the existing 

equipment. 

Non-magnetic controllers (shields), typically made 

in the form of copper rings (Faraday rings), sheets or 

massive copper blocks, are often called “Robber Rings”. 

Their use leads to increase in the coil current, reduction 

in the induction coil power factor and efficiency. However 

they may be less expensive and give good results 

in the case of shielding. Magnetic flux concentration 

and accurate control of the power distribution by using 

Faraday rings are very problematic and require significant 

power adjustment. 

Use of magnetic flux controllers, made of soft magnetic 

materials (steel laminations, ferrites and magnetic composites), 

is addressed in this paper. Application of magnetic 

controllers can increase field intensity in required areas 

(field concentration), change field distribution, shield certain 

areas from unintended heating and strongly reduce 

magnetic field in external space. Typically several effects 

are being achieved simultaneously and a reasonable 

compromise must be found in the process of design. 

In some cases it is difficult or even impossible to meet 

specifications of heating without application of magnetic 

controllers. Effects of using magnetic controllers, design 

guidelines and results prediction with the help of computer 

simulation are described in multiple publications [1-3]. 

This presentation is focused on performance of materials 

used for magnetic flux control in different applications. 


79

REPORTS 


MATERIALS FOR MAGNETIC FLUX CONTROL 

Ferrites 

Use of ferrites for magnetic flux control in induction systems 

is limited to high frequency applications (typically 

above 100 kHz) such as impeders for HF tube welding, 

inductors for sealing and plastic welding, small brazing 

coils, etc. Advantages of ferrites are: possibility to work at 

high frequencies (up to 13.56 MHz in some cases of induction 

heating), high permeability in weak fields, high electrical 

resistivity (not for all grades of ferrites) and chemical 

resistance. However they have low saturation flux density 

(below 0.3-0.4 T), low Curie point (typically below 200- 

250 °C with up to 350 °C for some types). Ferrites are sensitive 

to thermal shocks, brittle and very hard, which makes 

manufacturing the complex geometries by machining very 

challenging. Variety of induction coil designs is very big but 

quantity of the coils of any particular type is usually rather 

small and it isn’t economical to make “net shape” concentrators 

of optimal size and geometry. Designers of induction 

tooling try to use the standard shapes (plates, rods, 

C and E forms, etc.) and “adapt” the coil design to these 

limits. Of course there are some cases when a required 

number of controllers may be very big and it is effective 

to manufacture special net shape ferrites, e.g. ferrite rods 

for the impeders for high frequency tube welding. In traditional 

induction heating applications the use of ferrites is 

limited to relatively simple shape controllers for small high 

frequency induction coils. 

Laminations 

Laminations are the main material for low and middle frequencies 

(up to 30 kHz and even up to 50 kHz in some 

special cases). They are used for matching transformers (up 

to 20 kHz), shunts and cores for induction melting furnaces, 

forge heating furnaces, large heat treating coils. Advantages 

of laminations: very large components of simple geometry 

may be made (such as big furnace shunts which may reach 

a length of several meters), high saturation flux density 

(1.7 T), high permeability, low losses at low frequencies, 

high Curie point and good temperature resistance. The 

drawbacks of laminations are: bad performance in 3D magnetic 

fields, limited machinability, laborious assembling, 

frequency limits and complicated thermal management 

(cooling). Stamping and laser cutting simplify manufacturing 

of sheets but some manual cleaning of burr and other 

defects is still required. 

SMC 

SMC is a class of materials that was significantly improved 

during the last two decades [2, 3]. SMCs are made from 

ferrous particles (iron or its alloys), covered with a thin insulation 

layer, mixed with organic or inorganic binder, pressed 

at high pressure (up to 720 MPa and even higher) and 

cured or sintered. Majority of SMC that are being used in 

induction industry has organic binder, which provides good 

machinability. Long term experience in induction business 

shows that mechanical properties are very important for 

the magnetic flux controlling materials. Possibility to work 

in 3D fields and good machinability are highly valued by 

the induction coil manufacturers. 

Different types of SMC can work in the whole range of 

frequencies used in induction heating (50 Hz-13.56 MHz). 

Losses of SMC at low frequency may be comparable to 

losses in laminations and at high frequencies – to losses 

in ferrites. Temperature resistance is lower than for laminations 

but usually sufficient for induction applications. High 

thermal conductivity (up to 0.2 W/cmK) and possibility of 

effective thermal management using external or internal 

cooling can keep the controllers safe in heavy loaded cases 

[3]. The drawbacks of SMC are limited dimensions (up to 

220 mm long plates at present time) and higher price than 

for laminations. However with account for labour cost and 

possible improvement in performance, use of SMC in many 

cases is cheaper than for laminations. Technical and economic 

analyses show that in some cases a combination of 

different materials will give excellent results. For example, 

laminations may be used for the regular part of controllers 

and SMC for areas with complex shape and 3D field, such 

as the end zones of seam annealing coils. 

PROPERTIES OF SELECTED SMC MATERIALS 

SMCs are very versatile materials. Wide and always growing 

variety of applications sets new demands to the material 

properties [2, 4]. These applications include biomedical 

treatment, food packaging, electronic clean room processing, 

crystal growth, traditional heat treating, metals and 

non-metals melting, and many others. Typically the following 

groups of properties must be considered: mechanical, 

magnetic, electrical, thermal and chemical. For special 

applications the magnetostriction and acoustic properties 

may be also important. A significant number of SMC types 

are being used in industry. Three materials: Fluxtrol 100, 

Ferrotron 559H and Alphaform MF are selected for further 

description as representatives of different groups of SMCs 

[2, 3]. The first two materials are manufactured by pressing 

technology and the third one is formable. Some magnetic, 

thermal and mechanical properties of these materials are 

presented in Table 1. 

All pressed materials have certain anisotropy with 

lower thermal conductivity and permeability in direction 

of pressing. Magnetic and thermal properties in the table 

correspond to the favourable direction, i.e. for a plane perpendicular 

to direction of pressing. Anisotropy must be 

taken into account in design of induction coils and stock 

material orientation in the process of magnetic controller 

manufacturing. In spite of anisotropy all pressed materials 



REPORTS 

Table 1: Main properties of selected soft magnetic composites 

Material 

Frequency 

Range, 

kHz 

Density, 

g/cm3 

Initial 

Permeability 

Max 

Permeability 

Saturation, 

Bs, T 

Thermal 

Cond-ty, 

W/cmK 

Flexural 

Strength, 

MPa 

Flexural 

Modulus, 

GPa 

Fluxtrol 100 Up to 50 6.8 80 130 1.8 0.22 75-80 9-10

REPORTS 


practical tests showed that for majority of induction systems 

permeability of 20-40 is sufficient for good performance 

of magnetic controllers [3]. It is because almost all 

induction systems have open magnetic circuit and above 

a certain limit the value of permeability ceases to influence 

the system parameters. Major improvements take 

place when permeability increases from 1 to approximately 

10. Further increase in permeability causes lower effects 

and improvements disappear at permeability higher than 

30-50 depending on particular case. Moreover, computer 

simulation shows that when permeability of C-shaped 

concentrator is too high, there is no improvement in the 

power concentration, coil efficiency and power factor, while 

power density concentration in the corners of the coil 

tubing grows. It leads to local overheating of copper and 

formation of cracks due to thermal stresses. This effect was 

confirmed in crankshaft hardening when switching from 

laminations to Fluxtrol material significantly extended the 

copper life time [6]. 

The above evaluations of the permeability influence 

were made for the service conditions. Under heavy loading 

conditions which are typical for example for surface 

hardening at low frequencies (up to 3-5 kHz) the concentrator 

permeability must be still high enough. It means that 

low frequency materials must have high saturation flux 

density and their maximum permeability must be much 

higher than 40. 

In high frequency applications flux density is much 

lower and high maximum permeability isn’t necessary. In 

some high frequency applications such as induction welding 

of small diameter tubes, flux density in the impeder 

may be high, the ferrite core saturates and the process 

efficiency drops. Use of SMCs with high Bs can improve 

the situation. It is important to underline that SMCs are 

quasi-linear materials. Permeability of Ferrotron is almost 

constant in a wide range of the magnetic field strengths 

with initial and maximum permeabilities equal to 16 and 

Fig. 2: Fluxtrol 100 with zirconia coating 

Fig. 3: CNC machined set of parts with thin walls 

18. Linear properties are favourable for some induction 

processes because the linear magnetic controller does not 

generate higher harmonics in the coil voltage and current. 

Electrical properties 

Electrical resistivity and strength are two parameters important 

for SMCs. Electrical strength may be measured for HF 

materials only. Ferrotron 559H has break strength of around 

100 V for a 1 mm thick plate at frequencies 100-400 kHz. 

For Alphaform MF it is app. 350-400 V. These values are very 

small for real dielectric materials but are sufficient for majority 

of induction heating applications and the live parts can 

touch the magnetic controllers. For example, Alphaform 

may be applied to bare turns of the coil without danger of 

short-circuiting. Fluxtrol 100 has much lower resistivity and 

there is a thermal, not electrical break in tests. Therefore 

the parts made of this material must not touch two live 

parts with a difference of potentials. Insulation coatings 

must be applied to the copper or insulation tape such as 

Kapton glued to the controller. 

Electrical resistivity of SMCs is a tricky parameter. In the 

process of material pressing or machining of the components 

there is always smearing of the surface, which creates 

an additional path for current to flow. Surface resistivity of 

smeared layer depends upon the material composition 

and structure, manufacturing process (grinding, milling, 

turning, saw cutting), tool quality and regime of operation. 

Its value can vary from several Ohms to several hundred 

Ohm. Removing of smeared layer by etching helps but 

does not give reliable results. Etching agent penetrates into 

the material pores and influences the electrical resistivity. 

Special technique for evaluation of volumetric resistivity 

has been developed and used for different materials. More 

information about resistivity of considered SMCs may be 

found in [3]. Alphaform samples for measuring resistivity 

may be made with no surface smearing and traditional 

4-point technique may be used. 

Ferrotron 559H and 

Alphaform have very 

high resistivity, exceeding 

1 MOhm·cm. In induction 

applications it may be 

considered as infinitely 

high. For low and middle 

frequency materials 

including Fluxtrol 100, 

the situation is more 

complicated. Fluxtrol 100 

has resistivity around 

12 kOhm·cm. This level of 

resistivity is sufficient for 

keeping the induced eddy 

currents in the controller 



REPORTS 

volume at a negligible level. However one 

needs to prevent application of external voltage 

to the concentrator body. 

(a) 

(b) 

Chemical resistance 

In Alphaform all the iron particles are encapsulated 

in epoxy and the material is resistant 

to the environmental conditions of induction 

processes. Fluxtrol 100 and Ferrotron 559H 

are resistant to traditionally used quenchants 

except of a smeared surface layer where the 

iron particles may be exposed to atmosphere 

and the surface rusting can happen. Additional 

treatment of machined controllers can 

eliminate the problem. For traditional heat 

treating and brazing application it is sufficient 

to etch the parts in CrysCoat or similar agents. 

Etching removes smeared layer and loose 

particles and prepares the parts for additional treatments 

if it’s necessary. 

Coating and other treatments 

Several treatment technologies may be used in order to 

meet special requirements. Some of them are described 

below: 

■■ 

■■ 

■■ 

■■ 

Teflon coating may be used to meet requirements of 

clean rooms, food packaging and other special applications. 

After etching the parts are coated by a thin layer of 

a special Teflon coating according to a patented DuPont 

technology. Coating penetrates into the porous material 

and forms a firm surface cohesion. Coating thickness 

may be 4-6 microns. This coating is FDA approved and 

is being used in packaging industry for many years. 

Alumina, zirconia or other ceramic coatings may be 

applied to both Fluxtrol 100 and Ferrotron 559H using 

traditional flame spray technique. Of course special 

attention must be paid to the process setup in order to 

prevent thermal damage of SMC. A consistent ceramic 

layer may be formed with excellent cohesion with the 

substrate (Fig. 2). Ceramic coating may be applied also 

to the whole assembly of induction coil. This coating 

can prevent wearing and electrical grounding of the 

coil in the case of occasional touch to the moving part 

in the process of heating. 

Other coatings such as electrostatic plastic powder 

coating may be used when required for less demanding 

applications. 

Impregnation may be successfully used to fill the material 

pores and prevent outgassing, improve chemical 

resistance and mechanical strength. Impregnation 

with anaerobic epoxy according to Henkel technology 

showed very good results. Depth of impregnation 

depends upon the material type. Impregnated pieces 

Fig. 4: Clamshell inductors for non-rotational hardening of crankshafts (a) 

and simulated temperature distribution (b) 

may be glued to each other or to copper. Thin impregnated 

parts of Ferrotron passed severe down-hole tests 

for oil and gas drilling application. 

Material machining 

Fluxtrol 100 and Ferrotron may be easily machined using 

sharp standard tools or coated carbide tools. Materials may 

be machined using various methods (drilling, milling, turning, 

grinding, saw cutting, etc.). It is recommended to use 

higher speed and slower feed than for machining soft steel. 

Multiple passes are recommended in machining of thinwall 

parts. With some experience parts with wall thickness 

less than 1 mm may be produced by turning or milling (Fig. 

3). Drilling must be made on a strong support (wooden or 

plastic block) to avoid chipping and pilot holes are required 

for making large bores. It is not necessary to use cooling 

or lubricating fluids. 

Threaded bores may be made directly in Fluxtrol or 

Ferrotron parts but for higher strength and multiple use it 

is better to install brass or stainless steel inserts. Ferrotron 

559H has low coefficient of friction and it is recommended 

to use a small droplet of epoxy when installing inserts Flat 

parts may be produced by water jet cutting from disks 

or plates. 

EXAMPLES OF USE OF SMC 

IN INDUCTION HEAT TREATING 

Crankshaft hardening 

Crankshafts were the first parts in mass production [5] 

hardened by induction using clam-shell inductors (1934-35). 

Heating was static, i.e. the crankshaft did not rotate in the 

process of heating. U-shaped induction coils have been 

introduced later (1940-42) by Elotherm company; in this 

case the crankshaft was rotating. Both types of inductors 

are still being used until today. In spite of almost 80 years of 


83

REPORTS 


Fig. 5: Inductor for rotational hardening of crankshaft 

Fig. 6: Inductor for simultaneous hardening of four cams 

production history, there are new tasks (more complicated 

geometry and hardness pattern, reliability, lifetime, etc.) 

that require technology improvement. Main improvements 

are connected with innovative applications of magnetic 

controllers [6]. 

In clam-shell inductors, thin plates of magnetic controllers 

made of SMC Fluxtrol 100 applied to the sides of the 

coil (Fig. 4). Magnetic plates are accurately positioned 

in place by pins and glued to the coil for effective heat 

transfer. They provide precise control of heat pattern and 

simultaneously improve the system parameters. Fig. 4b 

shows temperature distribution in the crankshaft at the 

end of heating cycle generated by program Flux2D. When 

there are no side plates (top half of picture), significant 

heating of the crankshaft web (side portions of the shaft) 

take place. This unintended heating results in energy waste 

and additional distortion of the part. Practical experience 

showed reliable performance of SMC shields. 

Flux controllers made of laminations are traditionally 

used on U-shaped crankshaft hardening coils in order to 

distribute power in such a way that results in required heat 

pattern, including the patterns that extend onto the fillet. 

U-shaped coils are much more loaded because the coils 

cover only a small part of the pin surface (Fig. 5). One of 

the drawbacks of such coils is insufficient lifetime due to 

copper cracking under the concentrators. It was found 

that replacement of laminations with SMC material led 

to a significant increase in the coil life and to a possibil- 

Fig. 7: a) Magnetic lines and temperature distribution in a tube heated by 4-turn inductor; b) ID coil with moldable Alphaform core; 

c) Machined inductor with SMC core for ID hardening of hub (courtesy of Eldec Induction) 



REPORTS 

ity of better heat pattern control. This application is very 

demanding and big attention must be paid to material 

selection and concentrator installation technique. High 

thermal conductivity of Fluxtrol 100 provides effective heat 

transfer between the coil copper and the concentrator. 

Fluxtrol concentrator is made of a set of blocks in order to 

minimize influence of difference in thermal expansion of 

the copper and concentrator. 

Another example of inductor with SMC controllers is 

presented in Fig. 6. This assembly contains 4 single-turn 

coils separated by Fluxtrol rings. These rings shield the coils, 

eliminating their mutual influence and improve treatment 

quality and efficiency. 

Internal inductors 

Internal Diameter (ID) inductors are widely used for brazing, 

curing, heat treating and other operations. Application of 

magnetic controllers is especially important for ID coils 

because magnetic flux must flow in closed loop around 

the turns through the narrow space inside the coil. For this 

reason the current demand for ID coils without core is high 

and their parameters (efficiency, power factor) are much 

lower than for the external coils. The core “magnetically” 

expands the area inside the inductor thus strongly reducing 

additional coil current required to push the magnetic flux 

around the turns (Fig. 7a). Results of computer simulation 

for one of typical ID heating cases are presented in 

Table 2. The part is a stainless steel tube with ID 55 mm 

and wall thickness 6.4 mm; inductor has ID 30 mm and, 

length 30 mm. Winding is made of 4 turns of square tubing 

6.4 x 6.4 mm. Frequency is 15 kHz and power transferred 

into the part 10 kW [7]. One can see that magnetic core 

reduced the coil current and reactive power more than 2 

times with approximately the same coil voltage. Efficiency 

increased from 70 to 84 %. For smaller parts effects will be 

even higher. 

Both machined and moldable SMC materials may be 

effectively used for ID coils. Small ID coils are often made by 

bending copper tubing (Fig. 7b). This case is very favorable 

for using Alphaform. Moldable material fills the whole space 

inside the winding in spite of some irregularities in dimensions 

and provides excellent thermal contact to the copper. 

Machined induction coils are used for hardening larger 

parts such as automotive hubs (Fig. 7c). In this coil quenching 

fluid is supplied onto the part surface through the 

orifices both in copper and in machined concentrator made 

of Fluxtrol material. 

TEMPERATURE PREDICTION AND CONTROL 

The main problem that can appear when SMC controller 

is not applied properly is its overheating. There might be 

three sources of heat: magnetic losses in the controller, 

convection and radiation from the heated part and, in 

Table 2: ID coil parameters with and without core 

Core Ui, V Ii, A Pi, kW Pw, kW Eff-cy, % Coil kVA 

Yes 46 875 12.0 10.0 84 40 

No 44 1,850 14.3 10.0 70 81 

some cases, heat transfer from the locally overheated coil 

copper. Temperature prediction of magnetic controllers 

is a complex task, which requires consideration of electromagnetic 

and thermal phenomena and material characteristics. 

When magnetic controllers are cooled by contact 

to the coil turns, coil temperature must be considered 

simultaneously with the concentrator. There are many cases 

when the concentrator fails due to too hot coil copper. 

Computer simulation is the most accurate way to study 

and predict temperature distribution. Flux 2D program is 

a proven tool for this task [8]. With some additional procedures 

the simulation can account for the magnetic losses 

and external heat sources, properties of material and glue 

as well as heat transfer from the copper wall to cooling 

water. An example of simulation is presented in Fig. 8. It 

shows a map of temperature in the coil copper and in the 

concentrator for a single-turn scanning inductor. Selection 

of the concentrator material and glue between the copper 

and concentrator plays a big role in temperature control. 

There are many methods of the concentrator temperature 

control. One of them is an internal cooling of material 

by means of water channels milled or drilled inside the 

concentrator. 

Fig. 8: Concentrator temperature prediction using computer simulation; 

temperature scales are different for the part and coil 


85


REPORTS 


CONCLUSION 

Theoretical studies and practical experience demonstrate 

that magnetic flux control is a very important component 

of optimal design of induction systems. Magnetic flux controllers 

can improve heat pattern, prevent unintended heating 

of the part, hardening machine or furnace structure, 

improve induction coil parameters and performance of the 

whole induction installation and shield the external space 

from strong magnetic fields. Soft magnetic composites can 

give new opportunities for induction system optimisation 

with account for magnetic flux control. They are very versatile 

materials and may be custom modified for special 

applications. Different types of SMC can cover the need 

in magnetic controllers for all range of frequencies used 

for induction heating (up to 13.56 MHz). 

One of the most valuable features of SMC with organic 

binder is their good machinability, which allows the users 

to make magnetic controllers of various shape and size. 

Additional treatment of SMC controllers (impregnation, 

coatings) expands their application to food packaging, electronic, 

etc. Computer simulation makes possible to forecast 

their effectiveness and optimize the heating process and 

coil design. It can predict also temperature distribution 

inside the controller and evaluate life time of the inductor. 

[1] Goldstein, R.; Nemkov, V.; Jackowski, J.: Virtual Prototyping of 

Induction Heat Treating, Proc. of the 25 th Conf. ASM Heat 

Treating Society, Indianapolis, September 2009 

[2] Ruffini, R.; Vyshinskaya, N.; Nemkov, V.; Goldstein, R.; Yakey, C.: 

Innovations in Soft Magnetic Composites and their Applications 

in Induction Systems, Proc. of the 25 th Conf. ASM Heat 

Treating Society, Indianapolis, September 2013 

[3] Website www.fluxtrol.com 

[4] Nemkov, V.: Magnetic Flux Control in Induction Installations, 

Proc. of the Int. Symp. HES13, Heating by Electromagnetic 

Sources, Padua, Italy, 2013 

[5] Muehlbauer, A.: History of Induction Heating and Melting, 

Vulkan-Verlag, 2008 

[6] Myers, C.; Osborn, J.; Tiell, C. et al.: Optimizing Performance of 

Crankshaft Hardening Inductors,” Industrial Heating, December, 

2006 

[7] Nemkov, V.; Goldstein, R.: Optimal Design of Internal Induction 

Coils, Proc. of the Int. Symp. HES04, Heating by Electromagnetic 

Sources, Padua, Italy, 2004 

[8] Nemkov, V.; Goldstein, R.; Jackowski, J.; Vyshinskaya, N.; Yakey, 

C.: Temperature Prediction and Thermal Management for 

Composite Magnetic Controllers of Induction Coils, Proc. of 

the Int. Symp. HES10, Heating by Electromagnetic Sources, 

Padua, Italy, 2010 

LITERATURE 

AUTHOR 

Prof. Dr.-Ing. Valentin Nemkov 

Fluxtrol, Inc. 

Auburn Hills, MI, USA 

Tel.: +1 248-393-2000 

vsnemkov@fluxtrol.com 

Get your copy of the 

anniversary issue now! 

10 

Anniversary Issue 

Years 

• 10 Ye 

0 Years Anniversary Issue • 10 Years Anniversary Issue • 10 Years Anniversary Issue 



REPORTS 

Modular induction solutions for 

drive and axle components 

by Dirk M. Schibisch, Jochen C. Huljus 

The automobile industry continuously roles out more models while simultaneously shortening new model launch 

intervals. Meanwhile, worldwide car sales are booming, particularly with the emerging demand from China and India. 

To drive over pot holes and rough roads at speed without damage, and yet give the driver a sensitive road feel would 

seem to be mutually exclusive goals. Powertrain and suspension components require toughness to handle the worst 

of everyday driving, and also high-precision mechanical characteristics to accurately transmit road conditions and driving 

dynamics to the driver. This paradox can be resolved with induction hardened modern automotive components. 

The manufacturing of these high-performance components is accomplished by a sophisticated induction hardening 

machine with the flexibility to harden a variety of disparate parts. 

Today’s induction hardening machines handle a 

dynamic and continuously growing product spectrum 

while setting new records for shorter cycle 

times and higher throughputs. Fast, reliable, and reproducible 

setup and change-over from one product run to 

the next is critical, particularly with today’s smaller lot sizes 

and flexible run scheduling. 

Essential machine performance requirements include: 

■■ 

■■ 

■■ 

■■ 

■■ 

A good price/performance ratio, 

Fast and reliable setup, 

Short machine delivery times, 

Simple and quick installation and commissioning on 

the production floor, 

Optimal, appropriate solutions for each application. 

with one or more workstations for hardening and tempering. 

These machines feature an elegant modern design that 

meets all the requirements regarding process visibility and 

maintenance access. Selected example configurations are 

described below. 

Elotherm has developed a manual machine with two 

double workstations for hardening drive shafts (Fig. 1) with 

a length of 1,000 mm. In each station, two shafts are hardened 

simultaneously, while the other station is unloaded 

and reloaded. Both stations are supplied by a single power 

supply. Thus, the time for loading and unloading does not 

MODULAR MACHINE DESIGN 

Induction hardening machines meet these diverse requirements 

by incorporating modular machine designs, where 

a base system can be configured with various modules 

for fast and easy adaptation to a variety of hardening jobs. 

Standard hardware and software interfaces (analogous to 

object oriented programming) facilitate a plug-and-play 

approach to the machine configuration process, streamlining 

the engineering, manufacturing, installation, and 

commissioning of these machines. 

BASIC MACHINE VARIANTS 

Depending on the requirements, machines are available 

both with manual and automated loading and unloading, 

Fig. 1: Examples of a few drive shafts in solid design 

and surface 


87

REPORTS 


Fig. 2: Hardening depths on a longitudinal cross section of induction-hardened 

drive shafts 

Fig. 3: Various ball hubs and joints 

Fig. 4: Hardening depth on a ball hub (right) and a joint part (left) 

increase the cycle time. Depending on customer requirements, 

hardening depths in a range from 3 to 8 mm can be 

achieved by adjusting the relevant parameters like power, 

feed rate, and frequency (Fig. 2). 

The EloFlex Inline is an automatically-chained machine 

with one workstation for hardening ball hubs, jointed parts 

(see Fig. 3 and 4) or similar workpieces with a hardening 

zone. The hardening can be performed in a single shot 

or alternatively in the scanning process. The workpieces 

go into the machine by way of a plate conveyor with a 

separating device. From there, the machine transports 

them to the hardening station and (if needed) to cooling 

and/or blow-off stations, before they are placed on a plate 

conveyor again at the machine outlet. 

The automatically-chained machine is also available 

with two workstations for hardening workpieces with two 

hardening zones, e.g. axle journals or tripods (see Fig. 5-7). 

For these workpieces, usually a shaft and the bearing races 

(contact surfaces) are hardened in the bell and/or in the 

tulip. These areas can be hardened with a single shot or 

a scanning process. Optionally, the two stations can be 

used for hardening and subsequent tempering. Here as 

well, the intermediate positions are available for cooling 

and/or blow-off. 

MODULAR STRUCTURE 

The hardening system is modular, meaning that the appropriate 

hardware for the customer’s special requirements 

can be selected for each individual machine module. 

With standardized interfaces, plug-and-play modules can 

be selected to make multiple configurations. This also 

applies to the individual workstations so, for example, 

during the hardening of axle journals or tripods, the hardening 

sequence for the shaft and bell/tulip can be freely 

selected. Also bells/tulips can be hardened from below or 

from above (with workpiece turning) in the single shot or 

scanning process. The transport direction of the workpieces 

through the hardening machine can be in either direction. 

Different options for transport systems within the 

machine offer solutions for short or long workpieces. With 

options for two different control systems and multiple 

converter sizes, the base machine is quickly adapted to a 

given application. Fig. 8 shows the individual modules in 

the machine, emphasized in color, which can be expanded 

with further modules and various option packages. 

Process know-how and energy efficiency 

Synergies are realized through a systems engineering 

approach to machine and process development. This starts 

with the converter technology for optimal and energyefficient 

heating of workpieces, selective application of 

the current exactly at the point in the workpiece to be 

heated by precisely adjusted inductors and not least, by 

exact parameter setting for the entire process. 

The current generation of the digitally-controlled frequency 

converter (power supply) features: 

■■ 

■■ 

■■ 

■■ 

Patented control algorithms for the converter for an 

automatic adaptation of the converter to various loads 

and for reducing losses in the converter [1], 

Fast reaction times for extremely short heating times 

< 1 s, 

The ability to run continuously at 100 % of rated power, 

A larger frequency range, 



REPORTS 

Fig. 6: Micrograph of a tripod 

Fig. 5: Various sizes and designs of axle journals 

Fig. 7: Micrograph of an axle journal 

■■ 

■■ 

Short-circuit-resistance due to integrated overcurrent 

and overvoltage protection, 

Robust monitoring and diagnostic capabilities. 

Energy efficiency has been improved by optimizing the medium-frequency 

equipment (better placement of individual 

components with respect to each other, better bus bar and 

cable connections to the capacitors, more precise matching 

of the transformer to the inductor). Optimized inductors are 

essential for a reproducible and energy-efficient hardening 

process. For further reduction of the energy consumption, if 

there are no workpieces at the loading position, the machines 

automatically switch to standby mode in which all pumps and 

auxiliary equipment are shut off. 

Accessibility and maintenance-friendliness 

Large doors in the front allow good observation of the 

process and also good access for maintenance work. A 

reduced work space depth improves component access. 

Another safety door permits access from the rear. 

Reduced floor space 

The complete machine, together with the control, the converter, 

the network transformer and the capacitor cabinet, 

is set up on a common base frame. The machine footprint 

is reduced, and complete, fully-assembled machines can 

be transported to the plant. 

Quality 

Patented net workpiece energy monitoring performs 100 % 

online quality control of the hardening process in these 

machines [2]. Power generated by the IGBT power supply 

is necessarily subject to heat losses in the converter, in the 

busbars, capacitors, transformers, and finally in the inductor. 

The net heating energy applied to the workpiece is less 

than the power supply output energy. Conventional energy 

monitoring schemes have monitored only to the power 

output by the converter and therefore do not account 

for system losses. The SMS Elotherm patent describes a 

method with which the frequency-dependent losses are 

measured and considered so ultimately the power actually 

applied to the workpiece is integrated over the complete 

heating time (energy) and recorded as a curve and 

monitored in real time. In this case, the energy applied to 

the workpiece is an absolutely reliable measurement for 

checking the quality of the heating. The smallest changes 

of the coupling gap between inductor and workpiece 

lead to clearly measurable changes in the energy values, 

and tolerance limits are user-adjustable. Changes of the 

coupling cap could, on one hand, be due to deformations 

of the inductor. On the other hand, these changes 

could be caused by tolerance deviations or cracks in the 

workpiece surface. 

In addition to the heating (austenitizing), the hardening 

process consists of quenching with cooling medium. 

During quenching, it is a matter of running through a fast 

cooling curve by using adequate cooling medium supply, 

which leads to the desired hardening microstructure in 

the material (martensitic microstructure). Monitoring of the 

quenching process occurs using measurement of the exact 


89

REPORTS 


frequently-changing hardening tasks and designed costeffectively 

according to this. Using net workpiece energy 

measurement and other systems for quality monitoring, 

out-of-spec parts recognized and rejected automatically, 

ensuring continuous operation without interruption. 

LITERATURE 

[1] SMS Elotherm Patent DE 101 15 326 B4, Method for actuating 

a resonant circuit converter and controller 

[2] SMS Elotherm Patent EP 0 427 879 B1, Device and method for 

inductive heating of workpieces 

Fig. 8: Modules of the EloFlex Inline 

AUTHORS 

spray flow quantity and an appropriate temperature control 

for the quenching medium. Together with the net workpiece 

energy monitor, the complete hardening process is 

therefore monitored and recorded for each and every part. 

CONCLUSION 

With modular induction systems for hardening automotive 

components, manufacturers are set up for both current 

and future product requirements. This is true for complex 

and also simple components, with high reproducibility 

and process control using patented process technologies. 

Modular system solutions are conceived for users with 

Dipl.-Wirtsch.-Ing. Dirk M. Schibisch 

SMS Elotherm GmbH 

Remscheid, Germany 

Tel.: +49 (0) 2191 / 891-300 

d.schibisch@sms-elotherm.de 

Dipl.-Ing. Jochen C. Huljus 

SMS Elotherm GmbH 

Remscheid, Germany 

Tel.: +49 (0) 2191 / 891-331 

j.huljus@sms-elotherm.de 

HOTLINE Meet the team 

Managing Editor: Dipl.-Ing. Stephan Schalm +49(0)201/82002-12 s.schalm@vulkan-verlag.de 

Editorial Office: Annamaria Frömgen +49(0)201/82002-91 a.froemgen@vulkan-verlag.de 

Editor: Thomas Schneidewind +49(0)201/82002-36 t.schneidewind@vulkan-verlag.de 

Editor (Trainee): Sabrina Finke +49(0)201/82002-15 s.finke@vulkan-verlag.de 

Advertising Sales: Ute Perkovic +49(0)201/82002-24 u.perkovic@vulkan-verlag.de 

Subscription: Marcus Zepmeisel +49(0)931/4170-459 leserservice@vulkan-verlag.de 



REPORTS 

Efficiency-enhancing maintenance 

of heating systems 

by Dirk Mäder, Octavio Schmiel Gamarra, Mario Schulze, René Lohr 

As a matter of fact, the heating system engenders a major part of current operating and servicing costs of a thermoprocessing 

installation. It is not rare that saving potentials are latent therein which cannot be immediately detected by 

the end user. As regards firing efficiency, the index for combustion efficiency, this is not only attributable to the burner 

but also to other central components of heating system; contrary to the widespread belief. The present article shows 

various maintenance concepts and describes, on the basis of examples, where and who optimisation potentials can be 

opened-up by simple measures, for instance, in terms of efficiency-enhancing maintenance. 

As to thermoprocessing equipment (TPE), the heating 

system is also of fundamental importance as the 

engine for a car. In both cases, optimal results and a 

long lifetime can be achieved only by good care or, in other 

words, by intelligent maintenance (IM). 

When purchasing a TPE, numerous options for potential 

energy savings usually recede into the background during 

price negotiations at the latest due to their extra price and 

are discarded again against all common sense due to the 

enormous cost pressure. As compared to the purchase costs, 

the costs for running operation of TPE are rather treated as 

something of secondary importance. Costs for maintenance 

only incurred in the third step are very often completely 

neglected at that moment. This carelessness may have negative 

impacts for the end user afterwards. If said carelessness 

is accompanied by a no longer up-to-date, exclusively reactive 

maintenance according to the motto “Rather wait than 

maintain”, increasingly occurring faults, in the worst case, 

even unplanned breakdowns and, thus, production failures 

are pre-programmed. The TPE performance is ever more 

reduced over the period of time in use, thus making the 

operation of equipment more and more inefficient. Predictive 

maintenance is also of particular importance which 

counteracts the decrease of equipment performance due 

to increased wear and tear and, in the ideal case, keeps it 

constant over the entire time of use, as shown in Fig. 1. The 

“free exercise” here is undoubtedly the efficiency-enhancing 

maintenance where weak points and/or reserve capacities 

are, for instance, systematically detected by a check of heating 

system [1]. Thanks to their elimination and/or activation, 

the production capacity of TPE can be noticeably increased 

by partially simple optimisation measures. On the other hand, 

the costs for running operation can be discernibly reduced 

to a similar extent. 

REACTIVE MAINTENANCE IS 

A THING OF THE PAST 

When designing TPEs, it was usual for a long time to provide 

higher reserve capacities and to operate such central 

components as, for instance, burners not continuously near 

their load limits. As a consequence thereof, the lifetimes 

of numerous components were accordingly high. Fig. 2 

shows a Noxmat burner of the first production series that 

was operated between 1991 and 1998 in continuous duty 

with almost no failures without the need to perform significant 

maintenance work thereon. 

Not least because of such high lifetimes, it was mostly 

common practice to perform purely reactive maintenance 

Fig. 1: Impacts of various maintenance concepts on equipment 

performance [1] 


91

REPORTS 


Fig. 2: Noxmat recuperator burner 

operated in continuous 

duty from 1991 

Fig. 3: Damage on a steel-jacket tube/ 

recuperator burner 

work restricted to repair and/or replacement of defective components. 

If, however, further consequential damages occur in 

such cases, the repair expenditure is generally much higher 

and damages on affected components are partially irreparable. 

Fig. 3 shows a typical damage on a steel-jacket tube/ 

recuperator burner to be attributed to overheating in the 

area of burner mouth. In this case, the flame gases were not 

led through the flame tube to the bottom of jacket tube, as 

provided, and redirected there. As a consequence thereof, 

they could not transmit their energy contained uniformly 

over the surface of jacket tube to the furnace atmosphere 

in the backdraught but were redirected into the waste-gas 

chamber without cooling directly after exiting the burner. 

The resultant partial overheating destroyed both the jacket 

radiant tube and the recuperator of burner. A typical reason 

for such a failure is the negligence of regular cleaning of 

steel-jacket tube. Unlike ceramic jacket tubes, scale will 

normally settle there in the bottom area which more and 

more obstructs the normal way of flame gases as described 

above. This damage became obvious by combustion gases 

exiting the jacket tube due to a steadily rising pollution of 

furnace atmosphere and associated quality deficits on the 

material to be heated. Other consequences for the end user 

included the replacement of destroyed components and 

unplanned furnace breakdown with production failure. 

PREVENTIVE MAINTENANCE MAINTAINS 

EQUIPMENT PERFORMANCE 

As to preventive maintenance, components are replaced 

in regular intervals the failure thereof may adversely affect 

flawless operation. This takes place irrespectively of their 

condition and represents the minimum level of basic maintenance 

further to some other actions to be performed. As to 

maintenance-friendly burners, as shown in Fig. 4, wear parts 

(W) cover only very few and cost-effective components. In 

this case, only some seals as well as the ignition and monitoring 

electrode are concerned. If this is equally done with other 

comparably cost-intensive components, the so-called spare 

parts (S), that are also subject to some wear and tear, it is quite 

obvious that unnecessary costs may incur to the end user as 

replacement would take place already well before reaching 

the maximum possible lifetime in many cases. Therefore, 

these components are renewed in terms of maintenance 

only when reaching a defined wear limit where the function is 

not yet necessarily affected. This is called “condition-oriented 

(preventive) maintenance”. A precondition therefore is that 

the wear of associated component is measurable. In case 

of a burner, this refers e.g. to the recuperator. The circular 

burner exit port in new condition is checked for roundness 

and diameter errors and the ribbed segments in the front 

thermally stressed area for wear and tear. If the wear limits 

to be defined by the manufacturer have been reached, the 

component is replaced and/or can be recovered in many 

cases to save costs. 

As to maintenance work performed in regular intervals, 

it is meanwhile possible to pre-define spare parts required 

in addition to wear parts with sufficiently high accuracy. In 

this way, time and cost expenditure can be estimated very 

precisely in advance, offering relevant planning reliability to 

the end user. The special benefits of recuperator burners 

designed maintenance-friendly will accordingly contribute 

thereto. However, not only the burner itself but also the 

design of upstream air-gas proportioning application plays 

a decisive part in whether a fault-resistant, energy-efficient 

and, thus, sustainably cost-efficient configuration is obtained 

for the end user or not. The superior design in the most 

cases includes separate feed of supply media through quickopening 

gas and air valves characterised by simplest and 

most precise mix adjustment due to the cease of combined 

air-gas control. However, it makes also special demands on 

the ignition behaviour of burner. Special advantages become 

evident in gas consumption, emissions, easy and, thus, timesaving 

burner adjustment as well as temperature uniformity 

in the combustion chamber of TPE but also in easily feasible 

monitoring of volumetric flow rates required by standard in 

any condition of operation as they are always constant [2]. It 

is mandatory to consider here that a recuperator burner must 

be set at operating temperature. The burner setting records 

will provide information thereof. In cold condition, increased 

volumetric flow rates are existent due to the absence of air 

preheating and, thus, completely different pressure conditions. 

If one considers this, optimal setting of such a burner 

can be normally performed without any problems. 



REPORTS 

Fig. 4: Overview of spare and wear parts of a Noxmat RHGB recuperator burner 

Each maintenance procedure should be finalised by a 

detailed service report on which the end user can clearly see 

and comprehend the actions and checks carried out such 

as, for instance, waste-gas measurement on the burners at 

different operating conditions, annual leak test of solenoid 

gas valves, of gas line belonging to the thermoprocessing 

equipment and, as far as provided, of jacket radiant tubes. 

COST PRESSURE CAUSES WEAK POINTS 

In order to withstand the enormous cost pressure, it is nowadays 

rather usual to choose central components such as, for 

instance, radiant tubes, combustion-air fans, valves, pipelines 

etc. as small as possible, however, to pressurise them with 

maximum possible loads just as the burners. Although the 

quality of many burner components has been continuously 

improved, much shorter lifetimes unlike the example shown 

in Fig. 1 are normally achieved. The failure to reach the optimal 

firing efficiency possible for the relevant burner type is 

another negative effect resulting therefrom. 

Many circumstances adversely affecting energy-efficient 

operation of a burner which remain undetected unless being 

visualised by the burner itself and/or by burner or furnace 

controls can be very often attributed to the periphery of heating 

system. Tightly dimensioned or unfavourably arranged 

components of the gas-pressure control and safety system 

may cause, for instance, undesired pressure fluctuations in 

the gas supply of burner so that the burner is operated with 

a too high air ratio [3]. Another consequence is the decrease 

of equipment performance, thus causing unnecessary costs 

to the end user in two respects. The same applies analogously 

to the combustion-air fan of a heating system. A too tightly 

dimensioned fan effects increased pressure drop in full-load 

operation. Understoichiometric combustion, inadmissible 

CO-concentrations in waste-gas and considerable excess 

consumptions come into question as potential consequences. 

MAINTENANCE AND HEATING CHECKS 

REVEAL OPTIMISING POTENTIALS 

As already mentioned before, efficiency-enhancing maintenance 

is, further to maintaining the installation, also focussed 

on the optimisation thereof, contrary to reactive and preventive 

maintenance. This may include increase of production, 

more efficient operation as well as enhancement of plant 

safety. On a more detailed analysis of the heating system of a 

TPE by accordingly skilled personnel, optimisation potentials 

can be revealed in astonishingly many cases. The demands 

made on the qualification level of maintenance personnel 

are accordingly high and reach meanwhile far beyond purely 


93

REPORTS 


purposefully searched for. This applies both to the thermoprocessing 

equipment as a whole and the section of heating 

system which naturally causes the major part of operating 

costs incurred. However, potentials of this kind cannot be 

exclusively found on old systems but are frequently tacitly 

tolerated on new systems due to the increased cost pressure 

as the costs for running operation and maintenance mostly 

recede into the background as compared to the purchase 

price. Heating checks and up-to-date maintenance concepts 

demonstrate to the end user weak points of his system thanks 

to the elimination thereof potential reserve capacities can be 

activated to increase safety and to enhance energy efficiency 

of the whole thermoprocessing equipment. 

Fig. 5: Optimisation action on a combustion-air manifold to reduce pressure 

fluctuations (LH before, RH after) 

mechanical/electrical knowledge of the individual components 

that has been sufficient for such jobs over many years. 

In the ideal case, such heating checks should take place in 

close co-operation with the end user who knows the system 

very well and can give important advice on the basis of his 

observations. 

Fluctuations in the operating pressures of supply media are 

frequently encountered here. The end user generally notices 

this only indirectly by higher gas consumption which, however, 

appears to him as normal and, in extreme cases, by 

failures occurred such as, for instance, breakdown of burner 

flame. Pipelines unfavourably dimensioned in terms of fluid 

technology have the same effect as undersized combustionair 

fans. Fig. 5 shows such a pipeline LH before and RH after 

the optimisation action. Pressure fluctuations in air supply 

could be considerably reduced, emission values improved, 

burner failures reduced, and system efficiency increased. 

In terms of efficiency-enhancing maintenance, a service 

report should include a check of heating system and 

demonstrate to the end user those or similar weak points 

of his system along with potential countermeasures as well 

as potentials for improvement resulting therefrom. A check 

with regard to meeting the currently valid safety regulations, 

for instance, DIN EN 746-2 should also be included in this 

respect. As, however, this really takes place rather seldom in 

terms of maintenance by an externally contracted company, 

efficiency enhancement in this form is in a way the “free exercise” 

of maintenance. 

CONCLUSION 

Exclusively reactive methods for care and maintenance 

according to the motto “Rather wait than maintain” are 

nowadays a thing of the past. In terms of efficiency-enhancing 

maintenance that is naturally the supreme discipline of 

maintenance, weak points and optimisation potentials are 

LITERATURE 

[1] Hiller, M. and Steck-Winter, H.: Co-operative maintenance of 

thermoprocessing equipment. gwi – gaswärme international 

No. 3/2013, Vulkan Verlag Essen, 2013 

[2] Mäder, D.; Lohr, R. and Schmiel Gamarra, O.: Practical burner 

applications in consideration of DIN EN 746-2. gwi – gaswärme 

international No. 2/2013, Vulkan Verlag Essen, 2013 

[3] Mäder, D.; Rakette, R. and Lohr, R.: Energy-efficient operation 

of natural-gas burners. gwi – gaswärme international, No. 

5/2009, Vulkan Verlag Essen, 2009 

AUTHORS 

Dipl.-Eng. (FH) Dirk Mäder 

Noxmat GmbH 

Hagen, Germany 

Tel.: +49 (0) 2334 / 442358 

maeder@noxmat.de 

Octavio Schmiel Gamarra 

Noxmat GmbH 

Oederan, Germany 

Tel.: +49 (0) 37292 / 650361 

schmiel@noxmat.de 

Dipl.-Eng. Mario Schulze 

Noxmat GmbH 


Tel.: +49 (0) 37292 / 650369 

m.schulze@noxmat.de 

René Lohr 

Noxmat GmbH 


Tel.: +49 (0) 37292 / 650343 

lohr@noxmat.de 



REPORTS 

Sensory combustion optimisation 

of gas combustion systems 

by Frank Hammer 

Today, the quality of gas is already subjected to non-negligible fluctuations in the natural gas grid. New repositories, an 

altered distribution structure, and, especially, the supply of regenerative gases such as biogas and wind-hydrogen increasingly 

alter the concentrations of hydrocarbon, hydrogen, and inert gas components in the gas and thus its combustion 

properties. This has an effect on the combustion process and therefore on the efficiency and emissions of gas furnaces. 

A combustion control system to compensate for these gas quality variations and other disturbances on the process is 

therefore essential. In particular, the use of robust exhaust gas sensors for the measurement of oxygen (O 2 ) and for the 

detection of unburned gas components such as CO, H 2 , and HC (CO e ) allow simple control strategies for the self-adaptive 

optimisation of combustion and increases the reliability and operational safety of the gas combustion system. 

The objective of any combustion control system 

should be the maximisation of efficiency at the simultaneous 

minimisation of pollutants. The influence of 

the air value l or rather, the remaining oxygen content on 

the efficiency and the polluting emissions of a combustion 

plant is fundamentally shown in Fig. 1. Too much excess 

air leads to exhaust gas heat loss, whilst a lack of air leads 

to efficiency losses due to incomplete combustion. Ideally, 

the plant is operated at the optimum air value, which may 

lie at l opt = 1.02 in the case of today’s plants, shortly in front 

of the so-called emission edge. 

Challenges for every combustion process are presented 

by gradually changing conditions and quick, externally 

active disturbance variables, such as: 

■■ 

■■ 

■■ 

■■ 

■■ 

Combustion air (temperature, pressure, humidity), 

Fuel (calorific value, temperature, viscosity), 

Contamination (burner, combustion chamber, boiler, 

exhaust gas duct), 

Chimney (wind, temperature, draught), 

Mechanics (play, hysteresis, component failure). 

Typical fluctuations in air temperature of ± 20 °C lead to 

O 2 changes of ± 1.5 % by volume O 2 . Table 1 shows the 

influence of additional disturbance variables on the O 2 

content in furnace exhaust gas. If a combustion process is 

adjusted to a certain point, it is “blindly” exposed to these 

O 2 fluctuations without sensor monitoring. An increase 

in O 2 according to Fig. 1, leads to an efficiency loss due 

to an increase in the amount of exhaust gas because of 

excess air. A reduction in O 2 , especially in case of a lack 

Table 1: Typical disturbance variables and their effect on the O 2 content in 

furnace exhaust gas 

Fig. 1: Typical curve of the pollutant emissions and 

efficiency depending on excess air 

Disturbance variable for 

combustion 

Typical fluctuation of the 

disturbance variable 

O 2 change in Vol.% 

Ambient temperature ± 20 °C ± 1.5 Vol.% 

Ambient pressure ± 25 mbar ± 0.8 Vol.% 

Calorific value ± 10 % ± 2.0 Vol.% 


95

REPORTS 


of oxygen, leads to a risk of incomplete combustion with 

high polluting emissions of CO e when exceeding the emission 

edge. The efficiency drops drastically since unburned 

combustible gas gets unused outside through the flue. 

A monitoring and safe adjustment of the combustion 

for the compensation of such disturbance variables is thus 

unavoidable for both environmental and safety reasons. In 

the follow, the exhaust gas sensor required for this purpose, 

the classic O 2 control and the even more efficient CO e / 

O 2 optimisation that can be implemented as a result are 

introduced. 

THE SENSORS 

For monitoring the dynamic combustion process and for 

the compensation of disturbances, quickly reacting sensors 

must be placed ideally directly into the exhaust gas duct of 

the combustion plant. These in-situ exhaust gas sensors are 

exposed to high loads in flue gas. In addition to the known 

combustion products, these loads include temperature, 

pressure, humidity, water steam, additives, HF, SO 2 , SO 3 , 

H 2 SO, ash, dust, heavy metals, boiler abrasion, vibrations, 

and so on. Robust, highly dynamic gas sensors based on 

solid electrolyte ceramics are thus used for this task. The 

best known example of a solid electrolyte sensor is the 

l-probe, which is mainly used in automobile applications. 

Lamtec develops and produces its own solid electrolyte 

sensors for measuring O 2 and detecting CO e . Fig. 2 shows an 

example of the combination probe KS1D for the simultaneous 

measurement of O 2 and CO e with relevant data and facts 

(from left to right: top: thimble-like sensor element/sensor/ 

installation situation of the probe; middle: KS1D probe with 

measuring gas extraction and built-in fitting/installation 

situation of the probe; bottom: technical data of KS1D) 

Fig. 3 contains a principle drawing of the thimble-like 

structure of the KS1D probe. It is located in the exhaust 

gas duct of the combustion plant. The functional ceramics 

(yttria-stabilised zirconia) separates the reference gas 

chamber (ambient) from the measuring gas chamber (flue) 

in a gastight manner. The “inside” of the functional ceramics 

contains a reference electrode made of platinum, whilst 

both measuring electrodes for O 2 and CO e are located on 

the “outside” of the ceramics in the measuring gas. The 

O 2 electrode 1 made of platinum and the CO e electrode 2 

made of a platinum/noble metal alloy differ only in regard 

to material. The different catalytic and electrochemical 

properties of the electrodes are what permit the detection 

of CO e . By means of an integrated heater, the probe is 

heated to and regulated at temperatures of T = 650 °C. At 

this temperature, the solid electrolyte ceramics is a good 

oxygen ion conductor which allows forming both sensor 

signal voltages U S1 between electrode 1 and the reference 

electrode and U S2 between electrode 2 and the reference 

electrode that can be measured. 

The sensor voltage at both electrodes U Si with i = 1,2 

initially correspond with the known Nernstian voltage, 

USi = U0,i + R Ti/4F · ln (pO2,ref / pO2,meas) (1) 

which depends on the partial oxygen pressure p O2,meas in 

the exhaust gas. The oxygen partial pressure of the environment 

is known as a reference and lies at a constant of p O2,ref 

= 21 Vol.%. The universal gas constant R and the Faraday 

constant F are also known. A simple 1-point calibration in 

air where p O2,meas = p O2,ref = 21 Vol.% results in U Si =U 0,i and 

thus directly the sensor-specific offset voltage U 0,i at the 

set sensor temperature T i . 

In the presence of combustible CO e gases, a non-Nernstian 

sensor voltage U COe forms at the second measuring 

electrode, which is added to the pure Nernstian oxygen 

signal voltage. The resulting sensor signal at electrode 2, 

thus results in 

U S2 =U S1 + U COe (2) 

For the combustible CO e components, the following results: 

U COe =U S2 - U S1 (3) 

Fig. 2: Combination probe KS1D for the simultaneous measurement of O 2 

and CO e 

In Fig. 4, both signals U S1 and U S2 of KS1D are shown with 

respect to the O 2 content in the exhaust gas of a typical 

combustion plant. In addition, the concentration of the 

unburned CO e components is shown in ppm on the second 

y axis. 



REPORTS 

Fig. 3: Functional principle of KS1D 

Fig. 4: Principle signal curve of both KS1D sensor voltages 

depending on excess air 

A typical CO e curve when slowly reducing O 2 and hence 

heading towards incomplete/bad combustion shows a 

significant increase of combustibles CO e at the emission 

edge due to a lack of combustion air (also refer to Fig. 1). 

In the excess air range in the case of clean, CO e -free 

combustion, both sensor signals U S1 and U S2 are identical 

to each other and show the current percentage of oxygen 

in the exhaust gas duct according to Nernst. In the vicinity 

of the emission edge, however, the sensor signal of the 

second electrode U S2 rises disproportionally due to the 

cumulative non-Nernstian CO e signal. For the locating of 

the emission edge, both the absolute sensor signals U S1 

and U S2 and the relative sensor signal change according 

to time dU S2 /dt, i.e., the signal dynamics, especially of the 

CO e electrode, are used. 

O 2 CONTROL 

To prevent the risk of an incomplete combustion, most 

industrial combustion plants are set to an air value λ with 

sufficient safety distance to the emission edge using 

classic O 2 control according to today’s technological 

standards. Fig. 1 shows the resulting, nominal operating 

range, which can extend to l nom = 1.3 and beyond. 

The safety distance to the emission edge must be 

selected to be larger, the greater the measuring inaccuracy 

and measuring error of the O 2 measurement, 

e.g., due to false air, and the greater and more dynamic 

the fluctuations are, especially in regard to changing gas 

quality. Depending on the process, this safety distance is 

necessary but unfavourably affects the efficiency since 

the optimisation potential up to the plant and fuel specific 

combustion optimum in the vicinity of the emission 

edge is not used. 

The classic O 2 control adjusting to a constant O 2 value 

mostly compensates these fluctuations. With a loaddependent 

O 2 setting, the efficiency of the plant can be 

increased even further. Beyond the O 2 control, the emission 

edge strategy for combustion optimisation described in 

the following enables to settle much closer to the emission 

edge up to the operating point with maximum efficiency. 

CO e /O 2 OPTIMISATION (EMISSION EDGE 

STRATEGY) 

For the locating of the emission edge, the fuel/air ratio is 

reduced dynamically towards a smaller air value l without 

influencing the burner-firing rate until the CO e sensor signal 

U S2 spreads from the O 2 signal U S1 at the emission edge 

(Fig. 4) and both the absolute sensor signal U S2 and the 

sensor signal dynamics dU S2 /dt increase significantly due 

to the incipient bad combustion. A small increase of the air 

value ultimately results in the optimum working point l opt 

of the system right in front of the emission edge. This cyclic 

procedure is repeated continuously in order to be able to 

guarantee operation close to optimum combustion, even 

in case of changed conditions or burner loads that lead to 

a shift in the emission edge. 

Fast changes or disturbances in a plant that is already optimally 

set are detected immediately due to the permanent 

monitoring of the CO e emissions. Additional system information 

regarding the current O 2 content in the exhaust gas 

and supplemental plausibility considerations may be used, if 

desired. Using these information, the plant will immediately 

be brought back into a “safe” operating mode with sufficient 

excess air and then, starting from a safe characteristic curve 

using the routine described above, led up to its optimum 

operating point under the changed conditions again. 


97

REPORTS 


Fig. 5: Boiler with dual-fuel burner equipped with BurnerTronic BT300, speed control, in-situ gas sensor and sensor 

electronics for optimise CO e /O 2 

The CO e /O 2 optimisation has been used successfully 

worldwide for over 10 years. The most important advantages 

of the CO e /O 2 optimisation in comparison with an 

O 2 control are as follows: 

■■ 

■■ 

■■ 

■■ 

■■ 

■■ 

Higher energy savings through continuous self-optimisation 

in every load point, 

Better control performance through significantly shorter 

setting times, 

Independent of false air, 

Failsafe, 

Robust, 

Maintenance-free. 

SAVINGS CALCULATION 

For combustion control, a complete range of electronic 

burner control devices, fuel/air ratio controllers, IR/UV sensors, 

flame monitors, and CO e /O 2 measuring devices with 

the pertinent sensor systems is available on the market. 

For medium-sized plants from 0.3-5 MW, the BurnerTronic 

BT300 is the first device worldwide in its price class that 

can be used for both O 2 control and CO e /O 2 optimisation 

(Fig. 5). It combines all advantages of an electronic fuel/ 

air ratio control with an electronic burner control device. 

Since the market introduction about 3 years ago, more than 

3,000 plants per year and rising have been equipped and 

Table 2: Conservative savings calculation for the modernised 5 MW dual-fuel burner in Fig. 6 

Savings for burner 1: Low load Medium load High load 

Operating hours h/a 800 800 6,400 

Fuel costs (assumed) €/h 46 105 159 

O 2 reduction through O 2 control Vol.% 1.28 1.46 1.33 

Savings through O 2 control €/a 464 1,223 13,598 15,286 

Additional O 2 reduction due to CO e /O 2 optimisation Vol.% 0.33 0.22 0.33 

Additional O 2 reduction due to CO e /O 2 optimisation €/a 120 186 3,353 3,660 

Savings due to speed controlled fan €/a 2,974 

Total savings €/a 21,920 



REPORTS 

Fig. 6: 5 MW dual-fuel burner converted for CO e /O 2 optimisation 

with LT3F sensor electronics and switch 

cabinet with integrated BT300, speed control, etc. 

Fig. 7: Comparison of the energy consumption of the unregulated 

and speed-controlled combustion air fan via the burner 

load 

optimally operated with this component – for the sake of 

a clean environment! 

Fig. 6 shows one of the boilers of a thermal processing 

plant for the food industry with a 5 MW dual-fuel burner 

(oil/gas). All boilers of the plant were recently equipped 

with a CO e /O 2 optimisation and a load-dependent speed 

control of the combustion air fan. To estimate the profit of 

the conversion measures, the plant and operation specific 

boundary conditions and some of the measurement data 

from before and after the conversion are included in the 

savings calculation. 

As a boundary condition, typical fluctuations according 

to Table 1 are included in the savings calculation. The 

exhaust gas temperature was measured at 150 °C at high 

load and at 120 °C at low load. The combustion air temperatures 

typically lie at 35 °C in the summer and at 10 °C 

in the winter. To calculate the savings, fuel costs of € 0.35/ 

kWh gas are assumed. 

Through the use of a speed-controlled combustion air 

fan instead of a fan with valve control operated at constant 

speed, an additional saving in electrical power is achieved 

according to Fig. 7. For the calculation of the electrical savings, 

energy costs of € 0.12/kWh el are assumed. 

In Table 2, the results of the mostly conservative savings 

calculation based on the well-known Siegert formula are 

briefly introduced. According to this table, the annual savings 

due to O 2 control reach up to € 15,286 for each boiler of 

this plant. The additional gain due to CO e /O 2 optimisation 

amounts to € 3,660. The CO e /O 2 optimisation using a single 

probe (KS1D) is an additional benefit and comparable with 

a pure O 2 control in regard to expense. For this reason, it 

is easy to use for all plants, increasingly of interest for boilers 

with medium-sized output, and recently available as 

well. The savings due to speed control amount to another 

€ 2,974 per year. This results in a total savings of € 21,920 

a year per boiler! In addition to these fuel or cost savings 

for plant operators, the environment also benefits from an 

annual CO 2 reduction of about 130 t per boiler in this plant. 

AUTHOR 

Dr.-Ing. Frank Hammer 

Lamtec Meß- und Regeltechnik für 

Feuerungen GmbH & Co. KG 

Walldorf, Germany 

Tel.: +49 (0) 6227 / 6052-0 

hammer@lamtec.de 

+++ www.heatprocessing-online.com +++ www.heatprocessing-online.com +++ 


99


Thermoprocessing 

Technologies 


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Volume 1: Fundamentals | Processes | Calculations 

This Handbook provides a detailed overview of the entire thermoprocessing 

sector, structured on practical criteria, and will be of particular assistance 

to manufacturers and users of thermoprocessing equipment. 

In Europe thermoprocessing is the third largest energy consumption 

sector with a very diversified and complex structure. Therefore it is split 

into a large number of subdivisions, each having a high importance 

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for the design and the execution of respective equipment represented 

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So this second edition is based on the contribution of many highly 

experienced engineers working in this fi eld. The book’s main intention is 

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materials and parts in industrial application. Additionally it offers a summary 

of respective thermal and material science fundamentals. Further it 

covers the basic fuel-related and electrical engineering knowledge and 

design aspects, components and safety requirements for the necessary 

heating installations. 

Editors: Franz Beneke, Bernhard Nacke, Herbert Pfeifer 

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✘


REPORTS 

Energy efficiency – potential 

options for industrial furnaces 

by Christian Sprung 

The subject of energy efficiency, and how to increase it, is becoming more and more significant for industry and will be 

one of the challenges facing it in the coming years. This applies in particular to the energy-intensive sectors. The driving 

forces behind this development are social and political pressure on the one hand, while on the other hand, ever-increasing 

energy costs are also fuelling the subject. For this reason, energy costs are increasingly becoming a substantial location 

factor. The main obstacle when it comes to implementing concrete measures for increasing efficiency is presented by 

the high investment costs associated with them. However, the complexity involved in analyzing interlinked systems in a 

production plant also makes it more difficult to search for the optimal solution. In many cases though, even small measures 

requiring correspondingly small investments can bring about a measurable improvement. The following article attempts 

to illustrate the wide range of technical options available specifically for gas-fired industrial furnaces. At the same time it 

should be pointed out that there is no ready-made solution. Individual and comprehensive investigation must always be 

carried out to determine which approach offers the best results in terms of costs and benefits for each individual case. 

Energy-intensive industries in Germany can for the 

moment breathe a sigh of relief. This applies in 

particular to companies active in the fields of steel 

and NF metals production. The Federal German government 

has come to an agreement with the EU Commission 

and has achieved the dismissal of the subsidy 

proceedings brought against Germany. This removes 

the obstacles to the reform of the Renewable Energy Act 

(EEG) already adopted on April 8 th by the Federal Cabinet. 

From the viewpoint of the energy-intensive industries in 

Germany, one of the most crucial aspects of the act is 

that such branches of industry shall continue to receive 

rebates under the EEG levy. Furthermore, the companies 

own generation of electrical power shall continue to be 

accepted from the levy. The withholding of these privileges, 

as had been demanded by a number of political 

parties and associations, would have signified enormous 

problems of competition on the global market for steel 

and aluminium producers in Germany. Thus, for example, 

during the “Steel Market 2014” conference, Hans Jürgen 

Kerkhoff, President of the German Steel Federation, estimated 

that the annual additional burden on the German 

steel industry would have been at least € 1 billion [1]. It 

would have been difficult, or even impossible, to cope 

with such additional costs in what is in any case a strained 

market environment. 

WHY IS ENERGY EFFICIENCY 

BECOMING INCREASINGLY IMPORTANT 

IN GERMANY? 

Following the rulings of April 8 th and 9 th , can one now 

say that topics such as the “change in energy policies and 

attitudes”, CO 2 emissions and energy efficiency have disappeared 

from the list of pending challenges? This is definitely 

not the case! Thus, irrespective of these one-off rulings, 

nothing has changed in the long-term framework conditions 

within Europe. Also the two main factors fuelling all 

of the developments and efforts being made in this sphere 

thus remain unaffected or are likely to be aggravated. 

One of these factors is the constantly increasing external 

pressure on industry: The so-called 3 X 20 resolutions were 

adopted at the 2007 Environment and Climate Change 

Summit. Under these resolutions, the member states of 

the EU undertake to reduce greenhouse gas emissions and 

energy consumption by 20 % in each case and to increase 

the proportion of renewable energies by 20 % by 2020 (all 

percentage values relating to 1990). The national objectives 

in Germany even go over and above these values. 

On March 3, 2014, the Group of Environment and Energy 

Ministers from 13 EU member countries issued a joint declaration 

on an ambitious climate and energy framework for 

the European Union by 2030. The declaration included for 

example an appeal to the European Council to ensure a 


101

REPORTS 


Fig. 1: Energy flow diagram (2012) for the Federal Republic of Germany 

in petajoules [2] 

Fig. 2: For the processing industries: a) Share of energy costs in 

gross value-added for 2008, b) increase in energy costs 

between 2003 and 2008 in % [4] 

reduction in greenhouse gases of at least 40 % compared 

to 1990 by 2030, and to aim at an expansion of renewable 

energies by at least 27 % by 2030. Here too, the German 

demands in respect of climate protection, renewable energies 

and energy efficiency go significantly further than the 

contents of the declaration. 

This list could be extended at random. One need only 

open the newspaper, switch on the television or enter the 

requisite search words into the internet. In all of the above 

endeavours, German industry is very much in the foreground 

with an energy consumption of 2,599 petajoules [2] 

in 2012 (ahead of traffic: 2,571 PJ and households: 2,431 PJ) 

(Fig. 1; [2]). This applies above all to the energy-intensive 

sectors such as chemicals, glass, NF metals, steel, paper 

and cement. 

For the steel industry it is only a slight consolation that 

in an international comparison of specific emissions (per 

ton of crude steel in each case) and energy consumption, 

Germany lies well below the figures for Russia and 

China, for example. On the contrary: This signifies a further 

strengthening of the pressure of international competition 

already existing. 

A second driving force for developments in the field 

of energy efficiency is the rising pressure of costs: Thus, 

the average energy costs for German industry rose from 

approx. € 20 billion in 1997 to approx. € 45 billion [3] in 

2011. The average share of energy costs in gross valueadded 

during the same period increased from 4.8 % to 

7.2 % [3]. On diversifying these costs further and taking a 

quick look at the costs for the individual sectors and the 

development of these over the past few years (Fig. 2; [4]), 

it quickly becomes clear that this pool of costs is becoming 

an increasingly important location factor, for instance for 

the German steel industry. 

But also a comparison of energy costs within the EU 

illustrates the significance of this factor for German industry. 

Thus, in 2011, the prices for industrial electricity in Germany 

were around 115 €/MWh [3], whereby Germany occupied a 

somewhat undesirable third place among the then 27 EU 

countries (average EU27: 95 €/MWh). Prices for natural gas 

take fourth place at 50 €/MWh (average EU27: 38 €/MWh) 

[3]. 

FACTORS INHIBITING THE ACHIEVEMENT 

OF AN INCREASE IN ENERGY EFFICIENCY 

The various figures indicated as examples are very succinct: 

The improvement of energy efficiency is becoming 

increasingly important and will be one of the challenges 



REPORTS 

for the future. A large variety of technical solutions are 

already available today for enhancing efficiency. Even so, 

the implementation of concrete measures is still a rarity. As 

before, when it comes to new investments, it is usually the 

investment volume itself and criteria such as productivity, 

product quality and specific location factors that occupy 

the top place in the list of priorities. Energy efficiency often 

plays a rather subordinate role. What is the reason for this? 

An indirect answer to this question has already been 

given: Technical solutions that make possible higher energy 

efficiency cost money, or at least more money than conventional 

technologies! Even if this is not a completely new 

revelation, this aspect definitely cannot be quoted often 

enough. This then clearly highlights the dilemma which 

an industrial firm faces. To survive on the market, it always 

has to find a balanced compromise between the burdens 

of investments on the one hand, and the operating costs 

on the other, these latter naturally involving energy needs 

and the pressures imposed by various official requirements. 

The logical conclusion here is that this is a subject where 

global agreements are definitely needed, since “pushing 

ahead” on a national or regional basis will necessarily lead 

to distortions in competition. 

It is confirmed by various investigations [5-7] that it is the 

investment costs which represent the main obstacle to the 

implementation and introduction of the relevant measures 

for enhancing of efficiency. A further important factor that 

hinders concrete energy-saving measures is the extreme 

complexity, in many cases, of the range of tasks to be performed. 

For example, on considering the flow quantities 

of gas, electricity and other utilities in an integrated metallurgical 

works, involving a coke-oven plant, blast furnace, 

converter, rolling mill and “in-house” 

power station, it rapidly becomes clear 

that a systematic and comprehensive 

analysis of all relevant utilities and their 

consumption figures cannot be dealt 

with as a matter of course. Thus, an 

answer to the question “Do you know 

what is the largest consumer of energy 

in your works?” will quickly turn into a 

scientific treatise. A further difficult factor 

here is that most of the utilities and 

energy sources are conducted through 

the works in circuits, and this results in 

the mutual interaction of the individual 

systems. Individual isolated solutions 

should therefore be examined critically 

before they are introduced, since 

improvements at one point may well 

cause deterioration at another location. 

The following can be regarded as a 

general rule in the discussion on introducing 

concrete measures for the increasing of energy 

efficiency: Patent solutions do not exist, and nor does the 

“best technology for all situations”. It is more the case that in 

each concrete individual instance and under consideration 

of the respective infrastructure, a search must always be 

made for an integrated optimum approach. 

What is good for one industrial firm may by no means 

be the best solution in another firm, particularly as the cost 

aspects for each concrete case must always be included 

in the considerations. Plant owners, plantmakers and also 

consulting firms have to make equally strong efforts here. 

Modern energy management systems can assist with 

the complex analysis of an entire industrial firm or works. As 

a plantmaker active worldwide in the field of metallurgical 

plant and rolling mill technology, SMS Siemag makes its 

Energy Advisor available as an energy management system 

according to ISO 50001, and this also performs energy 

data management over and above mere monitoring. It is 

thus able to be used already in the planning phase of a 

new plant. Fig. 3 shows the essential modules and the 

structure of the system. Its main task is primarily to systematically 

record and archive all relevant measured data 

from the individual units. This gigantic data stock is then 

evaluated and displayed in a very wide variety of ways at 

the next level. This also makes it possible to display large 

and complex works systems in a structured manner and 

to create the necessary transparency, which in turn is the 

basic prerequisite for a fully comprehensive analysis. Since 

this is not a one-off procedure but involves the permanent 

recording of data, trend analyses and boundary-value 

alarms can be employed to provide further information on 

the ongoing production and on the condition of individual 

Fig. 3: Modules and functions of the SMS Siemag energy management system, “Energy Advisor” 


103

REPORTS 


Fig. 4: Categories of possible measures for increasing the energy efficiency in gas-fired industrial furnaces 

plant units, thus enabling early intervention and taking of 

countermeasures. This system thus also supplies important 

data for the planning of systematic maintenance. 

INCREASING OF ENERGY EFFICIENCY 

USING THE EXAMPLE OF GAS-FIRED 

INDUSTRIAL FURNACES 

Using the example of gas-fired industrial furnaces for the 

heating and heat-treatment of steel, a number of fundamental 

aspects relating to improvement of efficiency are 

explained below (without claiming to be complete). As 

Fig. 5: Defective roller sealing in a roller hearth furnace 

already mentioned, the list of technologies which enable 

savings to be made in energy consumption is long. This is 

true above all also for the field of industrial furnaces. There 

is hardly a specialist journal or publication that does not 

deal in one way or another with this subject, illustrating 

the advantageous technical features of special plant and 

equipment. The present article will refrain from listing and 

analyzing all of these solutions individually. Instead, an overall 

view is to be provided, which will also contain smaller 

and (in respect of expenditure) medium-sized measures. 

A system supplier has the task of taking into consideration 

all technical possibilities within a concrete project in 

order thus to achieve an integrated solution which is also 

optimum for each individual case, in other words, to analyze 

the costs and benefits relating to the possible plant and 

equipment variants and to elaborate the best solution on 

this basis. 

If it is wished to assess the expenditure involved by 

measures for improving efficiency, these measures can be 

roughly divided into three categories in accordance with 

the magnitude of the required investments. Fig. 4 shows 

such a classification with the corresponding examples. This 

figure, of course, cannot as yet make any statements on the 

amount of the respective potential savings. This can only be 

assessed on a project-specific basis, i.e. according to concrete 

cases. The only rule of thumb that can be employed 

in this context is that if a higher proportion of energy can 

be retained in the process or even, wherever possible, does 

not have to be introduced in the first place, this will always 

be preferable to the recovery of energy, since the latter 

necessarily always involves losses in operating efficiency. 



REPORTS 

MEASURES INVOLVING 

LOW INVESTMENT COSTS 

The fist category, i.e. measures involving low additional 

investment costs, includes for example the raised awareness 

of all employees who work each day with the furnace 

equipment. If, for example, a furnace door is left 

open unnecessarily, the heating system will only be able 

to keep the furnace at operating temperature by additionally 

supplying a substantial quantity of heat which 

will at the same time be escaping into the furnace bay. 

Something like this can be avoided without any need 

for investments. 

But a large amount of energy-saving can often also be 

attained via the maintenance of a furnace system, involving 

little expenditure. Here, primarily, the condition of the 

refractory lining and its regular improvement should be 

mentioned. In Fig. 5 a damaged roller seal can be seen. 

At this location, the heat can escape into the bay virtually 

unimpeded. This effect is all the more serious the higher 

the furnace chamber temperature is set, whereby the heat 

radiation into the bay increases at a disproportionate rate. If 

such effects occur in conjunction with a defective furnace 

pressure control system, which may result in a slight negative 

pressure, the unnecessary losses will be multiplied yet 

further because the infiltrating air entering will also have 

to be warmed up by the heating system. 

Thus, under the key heading of “maintenance”, a further 

aspect can now be indicated: A large amount of energy 

can be wasted if the measurement and control equipment 

is not working properly or if its settings 

have become distorted over time. For 

example, a deficiently measuring air or 

gas orifice may cause the real air factor, 

lambda, to be increased. A 10 % deviation 

in the air factor will already lead to 

a rise in the specific gas consumption of 

the plant in the range of 2-3 %. 

Another factor which must also not 

be underestimated in ensuring the best 

possible operation of a furnace system 

is the optimum utilization of the hearth, 

i.e. to be as complete as possible. This is 

because a system which has been set to 

a given temperature will consume energy 

even if no material is being heated 

in the furnace. Purely on the computational 

level, such a situation will result in 

an infinitely high specific consumption. 

Consequently, if the furnace system is 

being poorly utilized, a higher specific 

consumption will arise in comparison 

with a system in which the hearth is 

fully utilized. 

Incomplete utilization will be the case, for example, 

when there are large gaps between the individual pieces 

of material being heated. This could be caused by using 

small batches with constant changes in the geometry and 

required heating times or constant interruptions in the 

feed of material to the furnace. For the sake of completeness, 

it must be mentioned that if the furnace operation is 

impeded due to the material being discharged too slowly 

after being processed in the furnace, this will also result 

in a considerable increase in the specific consumption, 

even if no unnecessary gaps are present in the material 

in the furnace. 

The extent to which sub-optimal hearth utilization 

affects the specific consumption of the system depends 

on the type of furnace involved. The decisive factor here is 

how high the proportion of no-load losses of a system is in 

relation to the overall energy balance. This becomes clear 

in Fig. 6. Thus, if the hearth utilization in a walking-beam 

furnace for the heating of slabs is reduced, this will result 

in a steep rise in the specific excess consumption. On the 

other hand, the effects on a roller hearth furnace with noncooled 

furnace rollers will not be so serious. The reason 

for this different curve characteristic is the fact that in a 

walking-beam furnace, the proportion of no-load losses in 

the overall balance, particularly due to the water or steamcooled 

rail system, is considerably higher than in a roller 

hearth furnace without actively cooled components in the 

furnace chamber. This effect is reinforced if the walkingbeam 

furnace is assumed to have a partially damaged 

Fig. 6: Influence of hearth area utilization on specific gas consumption for various furnace types 


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REPORTS 


Fig. 7: a) Batch-type furnaces for heat treatment of plates with roller table and plate-handling 

machines; b) Possible means of subdividing the furnace chamber into two areas to be operated 

independently 

Fig. 8: a) Quench hardening equipment for heat-treatment of plates; b) Procedural principle for 

model-assisted stopping of plate cooling and self-annealing 

rail insulation. However, if the roller hearth furnace is now 

imagined to have water-cooled rollers, the increase in specific 

excess consumption will be even more abrupt than in 

the walking-beam furnace with damaged rail insulation. 

An additional reason for sub-optimum hearth utilization 

may already appear during the planning of a new furnace 

system. If the design is unduly burdened with “exotic” product 

dimensions, this sub-optimum 

hearth utilization will be predetermined 

and become apparent later. 

Such “exotic” sizes are considered 

to mean the dimensioning of the 

system for products with extreme 

geometrical dimensions which, however, 

only represent a very small portion 

of the overall product mix. As 

a consequence, the furnace will be 

underutilized for a large proportion 

of the production and will operate 

inefficiently. 

In such cases it may make sense to 

split up the overall production. The 

major part of the production will 

then take place via a continuously 

operating roller hearth furnace, while 

special products will be relocated 

to a furnace system that is operated 

batch-wise. In Fig. 7, such a system 

is shown with two batch-type furnaces 

for the solution heat treatment 

of special-steel plates. The roller table 

upstream of the furnace is directly 

coupled with the hot rolling mill via a 

cooling and transfer bed, which enables 

the energy-saving hot-charging 

of the plates. Operating parallel to 

this line in the neighbouring bay is 

a continuous roller hearth furnace 

which is arranged directly in line with 

the rolling mill. 

The batch-type furnaces are 

designed for particularly wide and/ 

or thick plates from the overall product 

range and can be operated at 

temperatures of up to 1,250 °C. It is 

precisely these parameter combinations 

which are not possible on the 

roller hearth furnace, or this furnace 

is not designed for this. To keep the 

hearth utilization of the two batchtype 

furnaces themselves also at a 

high level, the furnace chamber can 

be subdivided by an intermediate 

door into two chambers to be operated separately. This 

special equipment arrangement makes it possible, for each 

furnace, either to treat two plates of length between 3 and 

8 m independently of one another or to charge one long 

plate (8 to 16 m). This will enable efficient operation of the 

system. If utilization is low, furthermore, one of the two 

furnaces can be switched off altogether. This would not 



REPORTS 

be possible with one single large, continuously operated 

furnace which caters for the entire production. 


MEDIUM INVESTMENT COSTS 

This category would comprise smaller investments and 

modernizations. Examples here are the utilization of 

electric motors with an improved efficiency class. Here, 

above all in the lower power range (< 30 kW) considerable 

increases in efficiency can be achieved. Especially 

for pumps or fans, significant energy savings can be 

obtained by using frequency converters for speed control. 

The ability to set the drive speed to the delivery 

requirements makes it possible to do without “energygobbling” 

guide vane controls or throttling controls. 

Moreover, the installation of a waste-heat boiler for 

generation of steam or hot water in the offgas flow of 

a furnace allows energy to be reused which would otherwise 

be discharged to the surroundings via the stack. 

Such installations, however, only make sense if the corresponding 

network and the requisite infrastructure 

are present inside the works and the respective energy 

source can be fed in to these without problems. 

A further type of measures involving medium investment 

costs is the use of intelligent computer-based calculation 

models. An example from this area, the introduction 

of an energy management system, was already 

explained in the third section. A somewhat different 

approach is followed by the so-called process models. 

Such systems help to record all of the relevant data on 

what are often highly complex systems, to analyze these 

data online and to derive from them, likewise online, 

optimized operating practices and reference values. 

Among these, the furnace control systems should be 

mentioned. The use of such software is to be recommended 

in virtually all cases involving medium to large 

industrial furnaces. For smaller furnace systems, on the 

other hand, the costs and benefits need to be examined 

more precisely. It should naturally be considered here 

that not only optimization as regards an energy-saving 

operating practice but also other optimization strategies 

can be catered for by such a system of models. 

However, a considerable amount of energy can also 

be saved indirectly during the cooling or quenching of 

plates. Thus, the classical sequence in the hardening and 

tempering of plates is the quenching of the material from 

temperature ranges in which an austenitic microstructure 

is present, combined with a subsequent, separate 

renewed tempering of the plate in order to attain the 

final properties. Powerful online models for the cooling 

process enable the quench process to be controlled in 

such a manner that only the near-surface regions of 

the plate need to be cooled into the martensite range. 

Here, cooling is stopped in a controlled manner before 

the core zones of the plate have reached the martensitic 

transformation temperature. The remaining heat in the 

core that will re-heat the near-surface zones after the 

water cooling has been stopped then leads to a kind of 

self-tempering or recovery (Fig. 8) of the plate. It is thus 

possible to do completely without separate annealing 

of the plate, i.e. reheating to tempering temperatures 

as a further process step. Of course, such elimination of 

a complete process stage is only possible with certain 

products and grades but, in these cases, it represents 

an enormous savings potential. 


HIGH INVESTMENT COSTS 

As mentioned at the beginning, this article refrains from 

making a detailed investigation, and listing the advantages 

and disadvantages, of all modern energy-efficient burner 

systems or, for example, the substitution of combustion air 

by oxygen. Nevertheless, a general note should be permitted 

at this stage: The benefit (i.e. the possible energy-saving 

potential) of a special item of equipment in relation to the 

higher investments normally associated with this may in all 

cases only be considered for a concrete overall system with 

all of its operating parameters. If this integrative type of 

consideration is performed, it may well be possible that the 

results deviate from those supplied by a purely theoretical 

consideration of stand-alone equipment items. As also in 

everyday areas of life, it is true that the more expensive variant 

does not automatically represent the better solution. 

Here is a brief example: In an open-heated roller hearth furnace, 

plates are to be heated up to temperatures of 920 °C 

at a given hourly productive output. Towards the entry, the 

furnace chamber temperatures are slightly reduced (e.g. 

800 °C) as is usual for such furnaces. For this reason, it is 

not possible anyway to promptly reach an average furnace 

chamber temperature of e.g. 900 °C in the entry section if 

the furnace is charged with a plate at room temperature. 

If nonetheless a correspondingly high setpoint is selected 

for heating, this results in strong permanent fluctuations 

of the load conditions with extreme load peaks in the 

entry section. These substantially increase the inevitable 

thermal shock to which the hearth rollers are subjected. It 

is absolutely recommended to reduce the temperatures 

in the entry section in order to minimize breakage of the 

furnace rollers and increase their service life. 

For heating of the system described previously, it is now 

necessary to clarify the question of whether use should 

be made of normal high-speed burners combined with a 

central recuperator or recuperative burner. The investment 

for a heating system with recuperative burners is normally 

higher than for a solution involving a central recuperator. 

On the other hand, higher air-preheating temperatures 


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Table 1: Comparison of the advantages and disadvantages of a recuperative burner and a central recuperator 

Recuperative Burner 

Central recuperator 

+ Efficient heat recovery directly in the burner / no loss of energy 

en route 

+ Simple and maintenance-friendly design 

+ Burner can be supplied with cold air + Size can be adapted individually 

- Due to the eductor air additionally required, the air consumption 

amounts to a value which is approx. 2.5 times that of a conventional 

burner 

- Only standard sizes available / large power ratings (> 500 kW) 

cannot be implemented. 

- In case of exhaust gas temperatures > 1,000 °C, ceramic recuperators 

must be used 

- High investment costs 

+ Investment costs are lower than for a 

recuperative burner system 

- Energy losses in the air and exhaust 

ducts 

- Air valves and fittings must be designed 

for operation with hot air 

can usually be achieved with recuperative burners. A brief 

comparison of the advantages and disadvantages of both 

configurations is provided in Table 1. 

As already explained, it is not sufficient to decide in 

favour of one of the two systems on the basis of these fundamental 

interrelationships. Instead, an integrated energy 

balance must be drawn up for the furnace system with all of 

the relevant parameters. In Fig. 9 the results of this energy 

balance are displayed for both variants of the heating system. 

Calculation was made for plates with a thickness of 

50 mm and a length of 10 m with fully continuous operation. 

The width of the plates was varied between 1,000 and 

Fig. 9: Results of the energy balance when utilizing recuperative burners or a central recuperator 

at a roller hearth furnace 

2,000 mm, with the parameters otherwise remaining the 

same, with varying throughput rates and hearth utilizations 

being obtained as a result. As already explained above, 

the effect of this variation on the specific consumption is 

such that these consumption rates fall as the throughput 

rates increase. When discussing costs resulting from the 

consumption, it should be noted that the costs of electricity 

are currently more than three times those of natural gas (for 

the calculation of assumed values): Natural gas: 3 Cent/kWh; 

electricity: 10 Cent/kWh) This leads to differences between 

the bars shown in the diagram (energy consumption in 

kWh/t) and the respective pertaining curve values (costs 

in € per 1,000 t). 

It becomes clear from the diagram 

that the heating system with a central 

recuperator supplies better results, 

even though it is the supposedly less 

energy-efficient solution. Even though 

the difference in consumption diminishes 

towards low throughput rates, 

the higher proportion of electricity for 

the recuperative burners means that in 

respect of costs the central recuperator 

is the “front runner” here. 

The reason for this is to be found in 

the slight lowering of furnace chamber 

temperature towards the furnace entry 

section. This means that in the case of 

a central recuperator all of the furnace 

offgases leave the furnace at somewhat 

lower temperatures in comparison with 

a decentralized exhaustion system 

installed at the individual recuperative 

burners. Thus, already before the heat 

recovery takes place via air preheating, 

more heat can be retained directly in the 



REPORTS 

process. This example is intended 

to illustrate that when evaluating 

the optimum solution, a pure comparison 

of the performance data 

of individual plant components is 

not sufficient. 

The final example of possibilities 

for enhancing the energy efficiency, 

taken from the field of CSP® 

technology, is intended to illustrate 

the potential possibilities for savings 

that are available if, besides 

the plant technology utilized, the 

process control itself is optimized 

from the point of view of energy 

consumption. 

CSP® stands for Compact Strip 

Production, the casting of steel 

into thin slabs which after a slight 

temperature increase and equalization 

in a roller hearth furnace are 

rolled down directly. The fact that 

the slabs are hot-charged directly 

into the furnace means that this is 

a highly efficient technology from 

the outset. For further enhancement 

of the efficiency, a package 

of measures has been developed 

for the complete CSP® facility. Here, 

the furnace has a key function. 

Typically, in this furnace, the slabs 

are heated up to rolling temperatures 

of 1,150 °C. For many products, 

however, 1,100 °C upstream 

of the rolling mill is already fully 

adequate. It was therefore seen 

to be feasible to lower the furnace 

temperatures as the first 

step towards energy-saving. To 

be able nevertheless to heat up 

individual slabs to temperatures 

of 1,150 °C whenever necessary, 

the furnace was combined with 

inductive heating modules on its 

exit side, which are switched on 

in a highly flexible manner as and 

when required and thus be able to 

provide the temperature increase 

still needed (Fig. 10). 

In conjunction with the reduction of chamber temperatures 

in the roller heath furnace, the water-cooled rollers, 

which are otherwise customary in these furnaces, can be 

substituted by so-called “dry” rollers which are uncooled. 

Fig. 10: a) Basic overview of the components of a CSP® facility; b) Detailed view of the area at the 

furnace exit with inductive heating equipment 

Fig. 11: Specific energy consumption of a CSP® roller hearth furnace with differing furnace chamber 

temperatures and roller designs 

This results in a further clear reduction in the energies that 

need to be supplied for operation of the furnace, particularly 

as no effects resulting from the wear of refractory materials 

arise on an uncooled furnace roller. The water-cooled 


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REPORTS 


pipe used with the rollers otherwise customarily employed 

for this process is usually insulated with refractory concrete. 

This insulation is exposed to extreme stresses due to the 

permanent slab transport, which means that parts of this 

insulation may become worn or even fall off completely. 

This causes the heat dissipation via the water-cooling of 

the rollers to become increased to a considerable extent. 

If both measures are implemented, i.e. lowering of the 

furnace chamber temperatures by 50 °C and substitution 

of the water-cooled rollers by dry rollers, the specific consumption 

can be reduced by approx. 50-70 %, depending 

on the actual operating point (Fig. 11). The reference variables 

here are the values for the non-worn water-cooled 

rollers. If, on the other hand, defects occur on the insulation, 

even more dramatic results are obtained as regards savings. 

CONCLUSION 

On the subject of enhancement of energy efficiency, patent 

solutions do not exist, and nor does the “best technology 

for all situations”. An assessment as to which individual 

measures represent a favourable approach also from the 

point of view of the costs involved is to a large degree 

dependent on the details of the project-specific, individual 

set of tasks to be dealt with. For this, the application of 

concrete technologies must always be considered in an 

integrative manner. The list of possible solutions for increasing 

the energy efficiency is a long one. Here, it is not always 

necessary to make the largest investments that are involved 

with these solutions. To some extent, even small measures 

may result in visible progress. 

LITERATURE 

[1] Kerkhoff, H. J.: Tagung Stahlmarkt 2014, published in stahl 

und eisen 134 (2014) Nr. 3 

[2] Arbeitsgemeinschaft Energiebilanzen, September 2013 

[3] Bundesministerium für Wirtschaft und Technologie, Energie 

in Deutschland – Trends und Hintergründe zur Energieversorgung, 

aktualisierte Ausgabe Februar 2013 

[4] Rheinisch-Westfälisches Institut für Wirtschaftsforschung, 

Energieeffizienz in der energieintensiven Industrie in 

Deutschland, Projektbericht November 2010, Quelle: Statistisches 

Bundesamt FS4R4.3 

[5] KfW Bankengruppe, Abteilung Volkswirtschaft, KfW-Befragung 

zu den Hemmnissen und Erfolgsfaktoren von Energieeffizienz 

in Unternehmen, Dezember 2005 

[6] Institut für Ressourceneffizienz und Energiestrategien GmbH, 

Fraunhofer-Institut für System-und Innovationsforschung ISI, 

Evaluation des Förderprogramms “Energieeffizienzberatung“ 

als eine Komponente des Sonderfonds Energieeffizienz 

in kleinen und mittleren Unternehmen (KMU), Schlussbericht 

November 2010 

[7] Prognos AG, Rolle und Bedeutung von Energieeffizienz und 

Energiedienstleistungen in KMU, Endbericht Februar 2010 

AUTHOR 

Dr. Christian Sprung 

SMS Siemag AG 

Düsseldorf, Germany 

Tel.: +49 (0) 211 / 881-6724 

christian.sprung@sms-siemag.com 



10 


Years 

• 10 Ye 

0 Years Anniversary Issue • 10 Years Anniversary Issue • 10 Years Anniversary Issue 



REPORTS 

Induction assisted hybridwelding 

processes to join heavywalled 

steel components 

by Jörg Neumeyer, Bernard Nacke 

So far joining of heavy-walled steel components having a sheet thickness above 10 mm is executed by multilayer submerged 

arc welding. The increasing demand for high-strength fine grained steel requires an enhanced productivity that 

can only be realized by robust and high-performance processes within a single process step. 

Workpieces made of fine grained steel offer very 

high solidity at low material effort and are suited 

excellent at the production of crane vehicles 

and for weight reduction at shipbuilding. Especially, these 

materials enable the construction of higher wind energy 

plants to cover the raising energy-demand of the world 

population, particularly in China, India and Brazil. The politically 

forced climate aims postulate a ratio of 35 % of the 

whole electric current generated by renewables. To realize 

this objectives on the one hand existing wind energy plants 

have to be upgraded (“Repowering”), on the other hand 

new plants on- and offshore require higher steel-based 

towers and basements. 

PROBLEM APPROACH 

The approach to raise the fabrication rate and production 

capacity of welded heavy plates made of fine grained 

steel is provided by the hybrid welding technology that 

facilitates high output power to join plate thicknesses 

above 10 mm. An application that uses a laser process 

and a metal-arc welding process simultaneously in a single 

common melting bath enables high welding penetration 

depths and speeds as well as increased gap bridging [1]. 

The limits of the welding process are defined by 

extremely tight temperature tolerances. The demanded 

temperature regime of a welding process can be ideally 

influenced and controlled by an induction preheating. By 

means of the so far implemented applications the demand 

of a homogeneously preheated seam at thick-walled sheets 

can be met only insufficiently. A bifid beam assignment first 

produces a mechanical and therefore electrical connection 

of both sheets. Subsequent, a perpendicular arranged 

inductor causes an induced current that flows along the 

weld flanks and through the connection to achieve an 

optimal preheating in the relevant areas. The following 

hybrid-welding process, that contains the second stronger 

laser-beam part and the metal arc welding process, joins 

and finally fills up the weldseam (Fig. 1). The described concept 

targets the robust applicability at often used welding 

Laserbeam- 

Source 

Welding direction 

Oscillating 

scanner or double 

focus optics 

10 % 

Mirror 

Weld pool 1 

(contacting) 

Induction 

coil 

Scanner 

Induction 

preheating 

100 % 

Mirror 

Weld pool 2 

(closing and 

filling) 

Oscillating 

MAG arc tube 

Fig. 1: Induction assisted laser-metal-arc hybrid welding process 


111

REPORTS 


Fig. 2: Test rig for investigation of an induction heating unit 

positions and clearances. At the same time the production 

speed shall raise and so-called middle rip defects have to 

be avoided. 

Beside the single consideration of the electromagneticthermal 

coupled induction heating process also knowledge 

of structure-mechanic properties of the welded components 

and characteristics of the coupled hybrid-welding 

process are essential. Therefore an interdisciplinary team 

(hybrid welding, steel construction, electrical engineering) 

was arranged to accomplish the postulated objectives. 

OPTIMIZATION BY SIMULATION 

For the design of the induction heating application that 

shall be adapted especially to this problem extensive FEAsimulations 

and parametric studies by use of the commercial 

software package ANSYS ® are executed. During the 

development the claimed temperature regime along the 

weld flanks must be considered. The geometric dimensions 

of the inductor and the electromagnetic values are 

optimized keeping the acceptable maximum temperature 

and the temperature distribution at the start of the welding 

process in mind. 

The induction assistance already demonstrated its 

capability to increase the productivity and to improve the 

microstructure at beam welding processes of sheets with 

a thickness up to 10 mm [2, 3]. Thick-walled components 

between 10 and 23 mm often exhibit solidification cracks 

and therefore low welding qualities at one-layered welding 

procedures. 

To counter this difficulty the employment of an assisting 

induction heating application is investigated that pre-heats 

the welding region optimally by use of a special arrangement. 

In contrast to the already successful implemented 

inductors here the current is driven perpendicular to the 

10 

43 

42 

350 

Messung Measurement 

Simulation 

Power Leistung in kW in kW 

8 

6 

4 

2 

41 

40 

39 

38 

37 

36 

35 

34 

Temperaturerhöhung raise in in K/3,000 K/3000 W 

Temperature in °C 

300 

250 

200 

150 

100 

50 

0 

1 3 5 7 10 20 30 40 50 

Frequency Frequenz in kHz 

33 

0 

7 10 13 16 19 22 25 

Time Zeit in in s s 

Fig. 3: Visualisation of the analyses results for determination of the 

optimal frequency 

Fig. 4: Comparison of simulation and measurement 

1 


250 

200 

150 

100 

50 

0 

0 50000 100000 150000 200000 


REPORTS 

scanning direction to generate a direct heating 

within the weld flanks. During first feasibility 

studies that were executed by FEA-simulations 

and physical heating trials the fundamental 

functionality of this procedure was affirmed 

(Fig. 2). 

Using numerical parametric studies as well 

as self-developed analytical correlations the 

geometric parameters of the inductor were 

optimized at which the inductor’s length and 

its width were the most focused values. These 

two quantities are directly influencing the width 

of the heated area that especially defines the 

temperature gradients subsequent to the induction 

heating part and the length of the heated 

area that defines the required electrical power 

and the concentration of the heat generation. 

The frequency of the inductor current and 

hence of the induced eddy current has a strong 

effect onto the distribution of the heat sources, 

the electromagnetic efficiency and the process 

efficiency. By numerical investigations the frequency 

that realizes a high and coevally homogenous 

temperature was estimated (Fig. 3). 

The comparatively weak contacting process 

that is performed before the induction heating 

leads to an electrical and mechanical contact of both 

components. Additional it effects a heat dumping in the 

workpiece. The induction heating process is highly depending 

on the specific material properties which again are 

depending on the temperature. The quantitative and qualitative 

impacts of the laser energy onto the temperature are 

investigated within these studies. 

Start conditions 

pos blank = 0 

ϑ = f(x 1 ,y 1 ,z 1 ) 

v = Δpos / Δt 

Geometry preparation 

Harmonic Analysis 

ρ = f(ϑ), μ = f(ϑ, H) 

H (x n 

, y n 

, z n 

) 

Transient Analysis 

λ = f(ϑ), c p = f(ϑ) 

Electromagnetic calculation 

Magnetic field distribution 

μ m 

(x, y, z) ≈ μ m→∞ 

(x, y, z)? 

p (x n 

, y n 

, z n 

) yes 

Adjustment of the permeability 

Heat generation distribution 

Thermal calculation 

Fig. 5: Executed simulation procedure 

no → m = m + 1 

Temperature distribution 

ϑ ( x n 

, y n 

, z n 

) 

Start 

New Position 

pos blank = pos blank + Δpos 

t = tend? 

Finish 

EXPERIMENTAL INVESTIGATION 

By the definition of all required geometric and electric 

parameters the inductor could be built at the Institute 

of Electrotechnology and provided to the Laserzentrum 

Hannover for the execution of physical tests. The comparison 

of measured data that were extracted with thermocouples 

and optical measurement procedures shows 

a high accordance between simulation and experiment 

and therefore verifies the calculated results. To achieve an 

even better congruence the consequences of the material 

properties (heat conductivity, heat capacity) are analyzed 

by numerical parametric studies (Fig. 4). The evaluation of 

the physical experiments also shows the relation between 

applied electrical power and heading speed and reassures 

the assumptions. 

After completion of the physical welding tests investigations 

concerning the resulting microstructure were 

conducted at the Institute for Steel Construction/Leibniz 

Universität Hannover and at the Laserzentrum Hannover. 

Regarding a thermomechanical rolled fine grained 

steel “S700MC” having a sheet thickness of 10 mm the 

induction assistance enables a good controlling of the 

hardness distribution within the basic material, the heat 

affected zone and the welded area. Further investigations 

at a “X70”-steel having a sheet thickness of 13.2 mm show 

that a huge implemented induction power results in large 

excess penetration. This problem can be solved by using 

the productivity-increasing effect of higher process velocities. 

By use of a welding consumable with a high content 

of manganese and by use of induction assistance the analyzed 

sheets could be joined without middle rip defects. 

Beside the thermal dependency the permeability also 

possesses a dependency of the magnetic field strength [4]. 

So far the property-distribution was only implemented with 

a temperature dependency in the FEA-simulation tool at 

which the quantitative values are basing on empiric studies. 

An additional algorithm in the simulation considers 

the dependency of the magnetic field strength. The algorithm 

is based on a self-developed function and enables 

the adaption of the material specific values according the 

present field strength in fine sub-divisions (Fig. 5). Generally 

a high conformance of the temperature curves of the 

previous results and the calculations that were done taking 

the field strength into account was ascertained. 

An important criterion of the investigations was the 

focused energy insertion in the seam to assist the hybrid 

Temperature distribution 

ϑ (x n-1 , y n-1 , z n-1 ) 

μ (x n 

, y n 

, z n 

) 

Relative Permeabilität 

Datenblatt 

Funktion 

Magnetische Feldstärke H [A/m] 

Permeability distribution 

yes 

no → n = n + 1 


113

REPORTS 


welding process. To accomplish this claim special geometry 

variants with engraved inductors and tubular workpieces 

are developed and interpreted with numerical simulations. 

Compared to the reference system this analyzed 

inductors lead to the aspired increase of the current and 

heat generation in the weld flanks and therefore of the 

temperature raise. 

To differentiate between the developed inductor and 

the so far applied inductors for welding processes up to 

10 mm comparative calculations were executed. The simulation 

results could expose the advantages of the perpendicular 

inductor relating to focused power insertion and 

high temperature homogeneity in the weld seam for the 

smallest thickness of 10 mm and for the highest thickness 

of 23 mm as well. 

CONCLUSION 

The performed studies are able to show that the demand 

on the singe-layered production of heavy-walled steel 

sheets can be fulfilled by support of an optimized induction 

heating assistance. The adjustment of the laser and 

metal-arc parameters with the induction unit leads to a 

save and powerful joining process with high velocities 

while respecting high qualities of the weld seam. 

LITERATURE 

[1] Dilthey, U.: Pilotstudie zum Einsatz des Laser-MSG-Hybridprozesses 

zum Hochleistungsschweißen von Stahl. Studiengesellschaft 

Stahlanwendung Düsseldorf, 2011 

[2] Mach, M.: Modelling and Application of Induction-Assisted 

Laser and Laser-Hybrid-Welding Processes, Sierke Verlag, 

2012, ISBN 978-3-86844-450-6 

[3] Meier, O.: Laserstrahlschweißen hochfester Stahlfeinbleche 

mit prozessintegrierter induktiver Wärmebehandlung, Dissertation, 

PZH Produktionstechnisches Zentrum Hannover, 

2005, ISBN 3-936888-93-0 

[4] Nacke, B.: Ein Verfahren zur numerischen Simulation induktiver 

Erwärmungsprozesse und dessen technische Anwendung, 

Dissertation, Fakultät für Maschinenwesen der Universität 

Hannover, 1987 

AUTHORS 

Dr.-Ing. Jörg Neumeyer 

Institute of Electrotechnology 

Leibniz Unversität Hannover, Germany 

Tel.: +49 (0) 511 / 762-2872 

etp@etp.uni-hannover.de 

Prof. Dr.-Ing. Bernard Nacke 

Institute of Electrotechnology 

Leibniz Unversität Hannover, Germany 

Tel.: +49 (0) 511 / 762-5533 

nacke@etp.uni-hannover.de 


Vulkan-Verlag 


22 - 24 October 2014 


Germany 


Edition 11 

FOCUS ON 

“The labour shortage is 

definitely affecting us” 

Thomas Brüser is Managing Director of Gefran Deutschland GmbH with headquarters 

in Seligenstadt. In this interview with heat processing he talks about the future of 

the energy industry and technological challenges and tells us about his personal contribution 

to saving energy. 

Read all 

interviews online 

The energy mix of the future: would you venture a 

forecast? 

Brüser: In the next 30 years, development of regenerative 

energies will certainly reach a share of more than 90 %. 

Fossil and nuclear energy sources in the future will be of 

only secondary importance in the energy mix. This development 

is already apparent today in many innovations 

and is essential in the long run if we want to maintain our 

standard of living. 

Germany in the year 2020: how will everyday life have 

changed as a result of the changes in the energy industry? 

What will people use to fuel their cars? How will 

they heat their houses? How will they generate light? 

Describe a possible scenario. 

Brüser: Modern houses with solar installations and optimal 

thermal insulation today already generate more 

energy than their inhabitants need. Rising energy prices 

in the coming years will cause a trend toward energyoriented 

renovations of buildings. As a result, old buildings 

will be brought up to the aforementioned energy 

standard. In 2020 a critical mass of people will live in 

energy-efficient houses and this trend will continue at an 

accelerated pace. Presumably the change in mobility will 

be much more pronounced. Transportation in the year 

2020 will be dominated by electromobility, where there 

will be rapid progress, reduction of individual transport 

through the use of flexible traffic systems, such as a 

combination of rail, car sharing and bicycle rentals. This 

will presumably be achieved by easy-to-use identification 

systems (“mobility credit cards”). 

Sun, wind, water, geothermal heat, etc.: which regenerative 

energy source do you think will be most important 

in the future? 

Brüser: In the future all regenerative energy sources will 

gain in importance. The important challenges are decentralisation, 

energy storage and intelligent networks. The 

technical problem of actual power generation is long 

since solved, even if great progress is still being made with 

respect to efficiency and costs in the area of PV modules. 

But with present-day technology it would already easily 

be possible to implement autonomous power supply in 

residential buildings. 

In which of the technologies currently under development 

would you invest today? 

Brüser: Certainly in energy storage technologies, such 

as battery systems or energy conversion. Another good 

investment with high potential would be power-to-gas 

technology, in which excess electricity from photovoltaic 

systems, for example, is used during lunchtime to manufacture 

gas. 

What is your estimate of the future importance of fossil 

fuels such as oil, coal and gas? 

Brüser: Fossil energy sources will become less important 

simply due to dwindling availability and therefore rising 

costs. Also, the direct negative effect on the quality of 

human life due to increasing air pollution will cause fossil 

fuels to gradually disappear from the energy mix. 

And nuclear power? What effects can be expected 

based on Germany’s current standpoint? 

Brüser: Nuclear energy, aside from political discussions, will 

also no longer play a role in the relatively near future, simply 

due to its inefficiency. For a recently approved nuclear 

power plant in England, for example, the stipulated feed-in 

tariff is higher than for new PV systems. 

On the subject of energy transition: what changes will 

have to take place at the (world) political, social and 

ecological level to realistically be able to speak of a 

transition? 

Brüser: A complex topic such as the energy transition is 

not conceivable with the current political options, sim- 


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FOCUS ON Edition 11 

RESUME 

Thomas Brüser 

Born on 22 July 1960 in Munich 

Married, four children 

Education 

1982 – 1985 Study of Electrical Engineering at TH Nürnberg 

Georg Simon Ohm 

1986 – 1990 Study of Communications Engineering at 

TH Nürnberg Georg Simon Ohm 

Degree: 

Engineer (University of Applied Sciences) 

Career 

1990 – 1995 Product Development and Marketing 

at Heinz Kleiber Optische Temperaturmeßtechnik 

1995 – 1997 Project and Quality Management at Telefunken 

microelectronic GmbH 

1997 – 1999 Product Manager and Branch Manager at 

Corins Deutschland GmbH 

1999 – 2012 Branch Manager and Sales Manager at 

Gefran GmbH Deutschland 

2008 – today Works Manager of Siei-Areg GmbH 

2013 – today Area Manager for Germany, Austria and 

Switzerland at Gefran GmbH Deutschland 

ply because politicians have neither the staying power 

nor the necessary expertise. But there is at least a latent 

ecological consciousness among the population. At the 

latest when a critical number of people worldwide have 

understood that regenerative energies are the only and 

simultaneously most economical possibility for sustaining 

an environment worth living, also in the future, the 

energy transition will organise itself, “despite politics” 

so to speak. 

What is your challenge to the federal government in 

this context? 

Brüser: Fundamentally I would wish for more reliability and 

constancy in measures to bring about the energy transition, 

instead of the current disconnected attempts that only 

have the goal of postponing real change. I am critical of the 

massive support of a few protagonists through exemption 

from the EEG levy. For one thing, that helps companies 

that benefit from the lower market electricity prices as a 

result of renewable energies. For another, it puts SMEs at 

a strong disadvantage. The imminent EEG levy on private 

consumption would make it difficult especially for these 

companies to benefit from modern technologies. The most 

important thing, however, would be an honest and logical 

information policy, preferably starting with children and 

youths in school. 

There are at least two problems with renewable energies: 

the lack of an infrastructure and the stagnation 

on the part of established companies by relying on 

conventional forms of energy. Will that change in the 

foreseeable future? 

Brüser: I see no problem with the lack of infrastructure. 

It will presumably occur only if centralised energy supply 

concepts, such as off-shore wind turbines are to gain 

acceptance and be retained. In a well-planned decentralised 

energy supply there is no lack of infrastructure. The 

problem of stagnation on the part of a few established 

companies is in fact more serious. But there will be many 

changes here as well in the coming years, due to a change 

in the way people think and due to better information 

channels, resulting in a future worth living, with affordable 

energy. 

Regardless of the energy form and the technology, 

many people think that “energy efficiency” is the key 

to the energy issues of the future. What is your view on 

this? What do you think is the most important development 

in this area? 

Brüser: Not to need energy in the first place is better than 

to generate it, because there are negative aspects even to 

the best regenerative energy technologies. A great deal has 

already been achieved, for example passive houses or elec- 


Edition 11 

FOCUS ON 

tric cars, so that our standard of living can be safeguarded 

with a fraction of the energy consumption. 

What are the advantages of electric process heat technology, 

in your opinion? 

Brüser: Very precise controllability and efficiency. Infrared 

radiators, for example, can be used to put heat exactly 

where it is needed, without significant losses. This is possible 

only with electrical processes. 

What is your attitude towards the heat treatment 

industry? 

Brüser: Heat treatment for me is simply a production process 

that is necessary to give a material certain properties. 

Like all other production processes, it should make the 

most efficient possible use of resources. 

How do you assess the development toward increased 

efficiency? 

Brüser: Increased efficiency and productivity are a natural 

part of any economic activity. The aspect of conservation 

of resources in addition to productivity of capital and the 

workforce seems to me a “natural” development. 

How will energy consumption change, in your opinion? 

Brüser: The primary energy consumption, at least in highly 

developed industrial nations, will most probably decrease 

in the coming years. However, consumption of electricity 

will increase due to electromobility. 

What is the role of your company on the energy market 

today? 

Brüser: Certainly a secondary role, since our products influence 

the energy market only indirectly. “Energy efficiency” 

is relevant for us, however, due to our innovative drive systems 

with integrated energy recovery and our innovative 

automation technology. 

What will be the role of your company on the energy 

market in 20 years? 

Brüser: There will be no significant change here. Our contributions 

will be primarily in the area of “energy efficiency” 

in the future, as well. 

What will be your company’s most important innovation 

/ most important project? 

Brüser: We see our role as supporting our customers for 

example in the construction of furnaces or machines for 

plastics extrusion. Innovations at our company therefore 

are always based on the requirements of our OEMs and are 

very difficult to plan. There will certainly be an increased 

focus on the software content of our products – with a 

view toward Industry 4.0 – as well as research projects in 

the field of sensor elements, for example. 

What economic, technological and social challenges 

do you expect? 

Brüser: Meeting economical and technological challenges 

for me is simply a part of what we have to do as a company. 

The social aspects are different than 10 or 20 years ago, due 

to demographic changes. Important issues in this respect 

include adapting the company to an ageing workforce 

and preparing young people for “lifelong learning”. Even if 

these tasks might seem to be self-evident, they represent 

a genuine challenge in real life. 

How do EU expansion and globalisation affect your 

business? 

Brüser: As with many changes, both present a risk as well 

an opportunity. Above all we try to see 

the aspect of opportunity and 

creativity with the assumption 

of a positive effect on 

our company. 

How important is 

the brand name 

for product success 

in the industrial 

sector? 

Brüser: The 

brand is becoming 

more important 

also in the 

industrial sector, 

because brands 

provide orienta- 

“The energy transition is not 

conceivable with the current 

political options.” 


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FOCUS ON Edition 11 

tion in the flood of information. We have been working 

intensively on our brand image the past few years. 

Has the labour shortage prevented or delayed your implementation 

of developments in Germany? 

Brüser: The labour shortage is definitely affecting us. We 

need six to nine months to fill a position for a technician 

or engineer. 

Does a management team need more media competence 

to convince investors? 

Brüser: Although I am not directly familiar with this, I would 

say that this is the case. 

What would you like to change in your company? 

Brüser: I would introduce even more systematic hiring 

and advancement of talented employees, because in the 

end, the employees are decisive for all other factors in a 

company. 

How important are foreign expansions to your company? 

Brüser: Very important. We are continuously opening subsidiaries 

and have plants on four continents. 

Is your company open for renewable energies? 

Brüser: Gefran is very open for renewable energies. Our 

products include, for example, converters for PV systems. 

Does your company already use renewable energies? 

Brüser: Yes, we have a large PV installation at one of our 

factories in Italy. 

How open is your company for new technologies? 

Brüser: As a technological enterprise we are not only open for 

new technologies, we live from them. For example, we cooperate 

closely with leading universities and research institutes. 

What was/is your biggest contribution to saving energy 

as a private person? 

Brüser: In 2005 we built a house with excellent energy 

standards (triple glazing, a ventilation system with heat 

recovery, etc.). Back then the contractors thought we were 

crazy; today, all of these things are standard. 

How could one describe your relationship with the 

employees? 

Brüser: Tough in action, gentle at heart. 

What do others especially value about you? 

Brüser: You would have to ask the others about that. But 

I hope that dependability is a trait that people attribute 

to me. 

What moral values are especially relevant for you at 

present? 

Brüser: The same ones that already applied thousands of 

years ago. The Ten Commandments or the Sermon on the 

Mount are just as relevant as ever. 

Do you have any role models? 

Brüser: Mahatma Gandhi for his humanity, several entrepreneurs 

who have achieved great things, and Miguel 

Indurain (a former racing cyclist) for his elegance. 

How were you brought up? 

Brüser: As was usual in the 70s – very tolerant. 

How should children be brought up today? 

Brüser: By setting examples! 

What good cause would you give your last shirt for? 

Brüser: Abolishing hunger, especially among children. This 

is possible in the long run only through better education. 

What do you wish for the next generation? 

Brüser: A life just as good as the one our generation has. 

From a historic perspective, we live in times of paradise. 

What is your life motto? 

Brüser: To help make the world the way I would like it to 

be for my children. 

What was the most important invention of the 20 th century 

in your opinion? 

Brüser: Information technology, in all of its forms. 



Edition 11 

FOCUS ON 

What character traits are important to you personally? 

Brüser: Integrity and honesty. 

Whose career has impressed you most? 

Brüser: That of David Packard. He made the transition 

from a gifted engineer with visions 

to a genuine pioneer of modern 

entrepreneurship. 

When do you not think about 

your work? 

Brüser: When I am with my wife 

and family, while hiking in the mountains, climbing on rocks 

or indoors and while listening to music. 

What is your personal advice for future generations? 

Brüser: Preserve this beautiful world and do whatever it 

takes to ensure that everyone can live happily in it. 

What contributed especially to your development? 

Brüser: A happy childhood and adolescence. 

“Not to need energy in 

the first place is better 

than to generate it.” 

Where do you see yourself in 10 years? 

Brüser: In 10 years my career will gradually be coming to an 

end. By then, I would like to have helped with the advancement 

of as many young talented people as possible. 

What is the meaning of life, in 

your opinion? 

Brüser: That is a very personal 

question, but religion and spirituality 

play a part. 

What would you do differently 

in life if you had the choice? 

Brüser: I would spend more time with my family and get 

involved in social projects. The only real bottleneck is my 

time budget. 

What do you wish for the world? 

Brüser: Above all peace and then I wish that all people 

can have everything they need for a happy life – no more 

and no less. 

What can you absolutely not do without? 

Brüser: First of all, my wife and family. Then perhaps several 

books, a few music CDs and the opportunity to spend 

time in nature. 

What career would you like to pursue if you had the 

choice? 

Brüser: Exactly the career I now have. 

What country would you like to live in? 

Brüser: I like living in Germany, but I could also imagine 

living in almost any other country of the world. 

What country would you emigrate to? 

Brüser: I have no preference. 

Thank you for this interview. 



10 


Years 

• 10 Years Anniversary Issue • 10 Years Anniversary Issue • 10 Years Anniversary Issue • 10 Years Anniversary Issue 

10 


Years 

• 10 Years Anniversary Issue • 10 Years Anniversary Issue • 10 Years Anniversary Issue • 10 Years Anniversary Issue 


119

International Symposium on Lead and Zinc Processing 

held in conjunction with 

Lead-Zinc 2015 is the 6th symposium that is devoted to the theory and practice of the extractive metallurgy 

of lead and zinc. It is organized by GDMB Society of Metallurgists and Miners, and co-organized by the Minerals, 

Metals and Materials Society (TMS), the Metallurgical Society of the Canadian Institute of Mining, Metals 

and Petroleum (MetSoc), the Mining and Materials Processing Institute of Japan (MMIJ), and will be held in 

conjunction with the 2015 European Metallurgical Conference (EMC 2015). Lead-Zinc 2015 will bring together 

plant operators, engineers and researchers to discuss all aspects of the hydrometallurgical, electrometallurgical 

and pyrometallurgical processing of these commercially important metals. At the operations level, the 

intent is to outline benchmarking technologies as well as present plant operations and recent commercial developments. 

The recycling of lead and zinc from a wide range of sources will be extensively discussed. At the 

research level, the emphasis will be placed on the understanding of existing technologies and the development 

of new processing concepts. Environmental concerns associated with the processing of both metals will be 

considered. The Lead-Zinc 2015 Symposium is expected to attract participants from around the world.

Edition 7 

PROFILE+ 

This is where we focus in regular intervals on the main institutions and organisations active in 

the field of thermoprocessing technology. This issue spotlights the Chair of Thermodynamics 

and Combustion of the Otto-von-Guericke University Magdeburg. 

Chair of Thermodynamics and Combustion 

The research work of the Chair of Thermodynamics 

and Combustion is focused 

on the analysis, mathematical modeling and 

simulation of thermoprocesses in Industrial 

furnaces and of quenching processes in 

continuous casting and hardening of metals. 

The processes researched are summarized 

in the lower part of Fig. 1. For fine and 

granular materials rotary kilns are used, for 

the thermal treatment of lumpy materials and 

stones shaft kilns, for the melting of granular 

materials and scrap cupola furnaces, for the 

thermal treatment of shaped materials tunnel 

kilns and for flat shaped material roller kilns. 

All industrial kiln processes are principally 

counter current flow heat exchanger. The 

one flow is the solid material and the other 

flow the gas. To simulate the temperature 

profiles, the energy generation, the heat 

transfer and the gas-solid-reactions must be 

known as summarized in the upper part of 

the figure. To heat up the material, in a special 

zone heat is generated by combustion of 

a fossil fuel. The combustion behavior, the 

flow and the mixing of flows are simulated 

using computational fluid dynamics (CFD). 

The kind of heat transfer is different in every 

kiln. Therefore various laboratory kilns exist 

in which the heat transfer can be measured. 

To measure the thermophysical properties a 

lot of equipment is available. To analyze the 

gas-solid-reactions a special thermo-gravimetric-apparatus 

was developed for samples 

up to 1,000 g of weight. In thermoprocesses 

the axial profiles of the gas temperature, the 

materials temperature, the wall temperature, 

the gas concentrations and the solid reaction 

are calculated using special numerical solvers. 

Therewith, the impact of the lot of influencing 

parameters can be visualized and quantified. 

The aim of the simulations is on the one 

hand a faster and safer design of furnaces 

and on the other hand to optimize the production 

for better quality and lower energy 

consumption. Basic of the modeling is the 

local energy generation (combustion), the 

local heat transfer and the reaction behavior 

of the materials. For the energy generation 

the combustion is calculated using CFD. 

Fig. 2 shows a combustion chamber with 

radial injections, which is used e.g. for the 

combustion of lean gases [1]. The combustion 

behavior of lumpy coke and anthracite 

is measured in special laboratory kilns. In 

these kilns also the reaction behaviour of 

solid materials can be measured in defined 

adjusted gas atmosphere. 

ROTARY KILNS 

For the process modeling in rotary kilns 

the motion behavior of the materials [2-4], 

the heat transfer [5-7] and the flames [8, 9] 

were researched. The transport of materials 

is influenced by rolling motion, slumping, 

sliding, segregation, axial dispersion, dams 

Energy generation 

- Flame and flow 

simulation using CFD 

- Measuring combustion 

behavior of lumpy coke 

particles 

Heat transfer 

- Measuring heat transfer, 

e.g. quenching of hot 

metals using water 

sprays and jets, contact 

heat transfer between 

particles and walls 

- Measuring conductivity 

specific heat capacity 

and expansion up to 

1,600 °C 

Modeling and simulation of processes for 

and flights. Fig. 3 shows as an example the 

moving behavior in a drum with flights for 

increasing rotational speed. The heat transfer 

is coupled by different mechanisms. The heat 

is transferred by radiation and convection to 

the wall and the free board surface of the 

material. Enthalpy is transported in the wall 

by rotation under the material and transferred 

by contact through the covered area to the 

material. The heat transfer and the temperatures 

in the moving bed are measured in 

special laboratory kilns. For the validation of 

the model and for investigation of materials 

reaction behavior a laboratory rotary kiln of 

5 m length and 400 mm internal diameter 

is used, in which at five axial positions the 

temperature profile in the bed and the gas 

concentrations can be measured. With the 

simulations can be demonstrated in which 

way the process is influenced by the design 

Gas-solid-reactions 

- Limestone calcination 

- Dolomite calcination 

- Ore reduction 

- Coke gasification 

- Thermal treatment of solids in industrial furnaces, e.g. rotary kilns, shaft kilns, cupola 

furnaces, tunnel kilns, roller kilns 

- Casting and hardening of ferrous and non-ferrous metals, e.g. DC-, EMC, Mould-, Hazelett- 

Caster 

Fig. 1: Overview 


121

PROFILE+ Edition 7 

Fig. 2: Combustion chamber with two row radial injection [1] 

Fig. 3: Particle flow in drums with flights for increasing rotational speed 

parameters (length, diameter, inclination 

angle of the kiln), the operation parameters 

(rotational speed, throughput, energy input, 

kind of fuel, flame lengths) and the material 

parameters (particle size distribution, angle of 

response, conductivity, density, specific heat 

capacity, reaction enthalpy) [10]. A program 

is available for companies to simulate their 

processes. For reacting materials the specific 

chemical kinetics and equilibrium conditions 

has to be implemented. The program can 

be used: 

■■ 

■■ 

To optimize the production process 

(reduction of energy, improvement of 

quality), 

Training of personal for better understanding 

the process with the interaction 

of the various influencing parameters and 

■■ 

To reduce working time to design kilns 

for new processes. 

SHAFT KILNS 

In shaft kilns mainly the burning of lime 

is researched. Dependent on the requirement 

on quality and reactivity normal shaft 

kilns, parallel flow regenerative kilns, annular 

shaft kilns and mixed feed kilns are used. 

Fig. 4 shows as an example the normal 

shaft kiln. For these kilns the axial profiles 

of solid temperature, gas temperature, gas 

concentration, calcination degree and pressure 

drop are calculated [11-13]. The mixing 

of the cooling air with the injected fuel is 

researched using CFD [14]. Based on the 

simulation the influence on the process of 

the design parameters (diameter, height), 

the operation parameters (throughput, 

energy input, kind of fuel, excess air) and 

the material parameters (size distribution, 

conductivity, pore diffusity, reaction coefficient, 

etc.) can be researched. For these 

kiln programs are available for companies 

to simulate their processes. The aim 

is finding the conditions for optimal kiln 

processes e.g. if throughput, kind of fuel, 

kind of material etc. has to be changed. 

Companies designing the refractory lining 

can use the programs to calculate the 

profiles of the wall temperature. 

TUNNEL KILNS 

The burning of ceramic products in tunnel 

kilns such as bricks, tiles, vitrified clay, porcelain 

and sanitary ware has a low firing 

efficiency. For increasing the efficiency new 

tunnel kiln concepts are required. In cooperation 

with the Brick and Tile Research Institute 

in Essen (Germany) such concepts are developed. 

Therefore, the dryers must be operated 

separately. In this way they can be optimized 

with a higher input temperature of the drying 

air [15-17]. The cooling air of the product 

must be used in the kiln process itself [18]. 

Doing this the heat transfer in the kiln have 

to be increased using ventilators and optimally 

arranged burners with low range of the 

burning zone [19, 20]. The flow in the kiln and 

between the ware is calculated using CFD. It 

is researched in which way the flow can be 

influenced by ventilators and by gas injection 

using jets. With increasing the heat transfer 

the gas flow can be reduced and therewith 

the flue gas losses. 

QUENCHING OF METALS 

The quenching of metals with sprays, nozzle 

jets, mould jets, etc. is researched with a laboratory 

plant. Sheets of different metals are 

heated up to temperatures until 900 °C and 

quenched from one side. The temperature 

field on the other side is measured using an 

Infrared thermocamera with a local resolution 

of 0.2 mm with one thousand pictures 

per second. Fig. 5 shows as an example the 

temperature field of four nozzles. With oneand 

two-dimensional inverse temperature 

analysis the heat flux in dependence on 

surface temperature, the Leidenfrost temperature 

and the DNB-temperature are deter- 


Edition 7 

PROFILE+ 

Fig. 5:Infrared image of the wetting front in a field of four nozzles 

Fig. 4: Normal shaft kiln 

mined. The influence of the water impact, 

the kind of nozzle, the kind of metal, the 

water quality and the surface roughness are 

researched [19, 21-25]. The quality of water is 

an important parameter influencing the heat 

transfer which is not known in a lot of companies. 

Cooling water of 13 different companies 

has been tested under the same conditions. 

The cooling rate differed by a factor of two. 

The more salts are included in the water the 

faster is the quenching impact. A measure of 

the amount of salts in water is the electrical 

conductivity which can be easily measured. 

Salts are dissociated in water which affects 

the electrical conductivity. For time constant 

cooling conditions the temperature and the 

electrical conductivity should kept constant. 

STRESSES AND DISTORTION 

IN QUENCHING PROCESSES 

The influence of the quenching on the structure, 

the stresses and the distortion in continuous 

casting processes and hardening processes 

are simulated using own developed 

codes [26-30]. The advantage is the short 

computing time, the easy usage for industrial 

engineers and the temperature dependence 

of the material properties. With the simulation 

program it is researched in which way thermal 

stresses and distortion can be reduced 

adjusting a locally defined profile of the heat 

transfer. It is shown that the mass lumped 

regions have to be cooled intensively and 

edges and cores only softly. In continuous 

casting processes for steel and aluminum 

(DC casting) the development of the shell 

and the resulting stresses are calculated. It is 

researched in which way with an optimized 

local profile of the heat transfer coefficient 

the maximum stresses can be reduced for 

changing casting speeds and metal alloys. 

MEASURING THERMOPHYSI- 

CAL MATERIAL PROPERTIES 

UP TO 1,600 °C 

All theoretical calculations and simulations 

are as accurate as accurate the material 

properties are known, especially in the high 

temperature range. Therefore, the thermal 

conductivity is measured using a Laser- 

Flash-Apparatus (LFA). A laser beam hits 

the upper side of a disk shaped sample. The 

temperature increase of the bottom side 

is measured using infrared thermography. 

From the one-dimensional analytic solution 

of the Fourier differential equation the thermal 

diffusity and therewith the conductivity 

can be calculated. The specific heat capacity 

is measured using DSC and the thermal 

expansion using a dilatometer. Reaction 

enthalpies and phase change enthalpies 

are measured with a standard DTA. 

For analyzing the reaction behavior of 

granular materials a special differential thermo 

gravimetric is developed. A cylinder of 

60 mm in diameter and 120 mm in length 

are filled with the material and heated up 

in an electrically heated tube furnace with 

regulated temperature profiles. The maximum 

temperature is 1,200 °C. The weight 

is measured and the inside temperatures in 

the core and near the surface. The tube is 

flown through with a gas of given composition, 

e.g. N 2 , CO 2 , or O 2 /N 2 mixtures. The wall 

of the cylinder is porous so that gas can also 

flow through the material. 

LITERATURE 

[1] Nirmolo, A.: Gas Mixing in Cylindrical Chambers 

after Radial Jet Injection with and without 

Combustion. Dissertation OvG Universität 

Magdeburg, 2007 


123

PROFILE+ Edition 7 

[2] Liu, X.: Experimental and theoretical study 

of transverse solids motion in rotary kilns. 

Dissertation OvG Universität Magdeburg, 

2005 

[3] Shi, Y.: The outflow behaviour of particles 

at the discharge end of rotary kilns. 


2009 

[4] Sunkara, K.R.: Granular Flow and Design 

Studies in Flighted Rotating Drums. Disseration 

OvG Universität Magdeburg, 2013 

[5] Queck, A.: Untersuchung des gas- und 

wandseitigen Wärmetransportes in die 

Schüttung von Drehrohröfen. Dissertation 


[6] Agustini, S.: Regenerative action of the wall 

on the heat transfer for directly and indirectly 

heated rotary kilns. Dissertation OvG 

Universität Magdeburg, 2006 

[7] Yogesh, S.: Influence of the Wall on the Heat 

Transfer Process in Rotary Kiln. Dissertation 


[8] Giese, A.: Numerische Untersuchungen zur 

Bestimmung der Flammenlänge in 

Drehrohröfen. Dissertation OvG Universität 


[9] Elattar, H.F.M.: Flame Simulation in Rotary 

Kilns Using Computational Fluid Dynamics. 


2011 

[10] Herz, F.: Entwicklung eines mathematischen 

Modells zur Simulation thermischer 

Prozesse in Drehrohröfen. Dissertation 


[11] Schwertmann, T.: Untersuchung des Optimierungspotentials 

des Ringschachtofens 

zum Brennen von karbonatischem Gestein. 


2007 

[12] El-Fakharany, M.: Process Simulation of 

Lime Calcination in Mixed Feed Shaft Kilns. 


2012 

[13] Do, D.H.: Simulation of Lime Calcinations in 

Normal Shaft and Parallel-Flow-Regenerative 

Kilns. Dissertation OvG Universität 


[14] Xu, Z.: Reduced Model for Flow Simulation 

in the Burner Region of Lime Shaft Kilns. 


2010 

[15] Deppe, D.: Mechanismus und Beeinflussung 

von Trockenausblühungen aus Kalziumsulfat 

bei der Konvektionstrocknung 

von Ziegelrohlingen. Dissertation OvG Universität 


[16] Telljohann, U.: Theoretische und experimentelle 

Untersuchung der Trocknung 

plastisch geformter Ziegelrohlinge. Dissertation 


[17] Tretau, A.: Einfluss der Prozessführung auf 

den thermischen Energiebedarf von Konvektionstrocknern 

in der Ziegelindustrie. 


2008 

[18] Meng, P.: Solid-Solid Recuperation to 

Improve the Energy Efficiency of Tunnel 

Kilns. Dissertation OvG Universität Magdeburg, 

2011 

[19] Specht, E.: Wärme- und Stoffübertragung in 

der Thermoprozesstechnik. Vulkan Verlag 

2014 

[20] Becker, F.; Gelbe, H.; Mörl, L.; Specht, E.: 

Thermischer Apparatebau und Industrieöfen. 

Dubbel 23. Auflage, 2011, Springer 

Verlag 

[21] Bleiker, G.: Filmverdampfung von Einzeltropfen 

auf heißen Oberflächen. Dissertation 


[22] Puschmann, F.: Experimentelle Untersuchung 

der Spraykühlung zur Qualitätsverbesserung 

durch definierte Einstellung des 

Wärmeübergangs. Dissertation OvG Universität 


[23] Attalla, M.A.M.: Experimental Investigation 

of Heat Transfer Characteristics from Arrays 

of Free Impinging Circular Jets and Hole 

Channels. Dissertation OvG Universität 


[24] Abd-Alrahman, K.H.M.: Influence of water 

quality and kind of metal in the secondary 

cooling zone of casting process. Dissertation 


[25] Alam, U.: Experimental Study of Local Heat 

Transfer during Quenching of Metals by 

Spray and Multiple Jets. Dissertation OvG 

Universität Magdeburg, 2011 

[26] Pietzsch, R.: Simulation und Minimierung 

des Verzuges von Stahlprofilen bei der 

Abkühlung. Dissertation OvG Universität 


[27] Brzoza, M.: Reduzierung von Eigenspannungen 

und Verzug von Stahlbauteilen 

durch örtliche Beeinflussung der Abkühlung. 


2006 

[28] Kaymak, Y.: Simulation of Metal Quenching 

Processes for the Minimization of Distortion 

and Stresses. Dissertation OvG Universität 


[29] Nallathambi, A.K.: Thermomechanical Simulation 

of Direct Chill Casting. Dissertation 


[30] Silva González, M.: Experimental investigation 

of the thermophysical properties of 

new and representative materials from 

room temperature up to 1,300 °C. Dissertation 


Author: 

Prof. Dr.-Ing. Eckehard Specht 

Contact: 

Otto-von-Guericke University 

Magdeburg – Chair of Thermodynamics 

and Combustion 

Universitätsplatz 2 

39106 Magdeburg, Germany 

Tel.: +49 (0) 391 / 67-18765 

eckehard.specht@ovgu.de 

www.ltv.ovgu.de 


TECHNOLOGY IN PRACTICE 

90 th anniversary of Otto Junker 

For more than 90 years, Otto Junker has 

been defending its leading international 

role in the manufacture of sophisticated 

industrial furnace systems for metallurgical 

applications and as a supplier of ‘ready 

for installation’ special-steel castings. This 

is good reason for celebrating the 90-year 

anniversary with partners, customers and 

staff during a Junker Furnace Conference 

on September 4 and 5, 2014. 

Today, several thousand industrial furnaces 

built by Otto Junker are in use all over the 

world. They are needed wherever demand 

exists for dimensionally accurate forgings, 

castings and high-quality semi-finished 

products such as plates, strips, foils, sections 

or tubes consisting of diverse metals. 

The equipment is used for melting, casting 

and heat treating metals. Through all these 

years the company has not only maintained 

but even expanded its technological market 

leadership continuously. 

Founded in 1924 at Lammersdorf in the 

Eifel region, the company has dedicated 

itself to metal processing from its earliest 

days. Otto Junker established his enterprise 

to market the water-cooled mould invented 

by his father for casting rolling slabs of 

brass. In the years that followed the company’s 

founder dedicated his efforts to the 

development and production of innovative 

machinery and equipment, maintaining 

close relations with the Technical University 

of Aachen (RWTH) all the time in the awareness 

that continuous technical development 

is indispensable for a company’s success. 

Thus, it was only logical that the foundation 

he set up in 1970 and which became 

the sole owner of the company after Dr. Otto 

Junker’s death should define the promotion 

of science and technology and the support 

of young engineers at RWTH as its main 

objective. Since the start of its sponsorship 

programme in the mid-80s, the Foundation 

has financed well over 100 research projects 

and every year a considerable amount of 

money was spent on scholarships and for 

the Otto Junker Awards conferred to outstanding 

academic degree work. The close 

cooperation with the University of Aachen’s 

departments of electrical engineering and 

metallurgy has remained the basis for key 

innovations until this day. A long-term and 

fruitful cooperation has also been pursued 

with the Aachen University of Applied 

Sciences. 

FURNACE MANUFACTURING 

Industrial furnace building faces exacting 

demands. Apart from the need to meet 

process parameters ever more rigorously 

and to address pressures for more powerful 

and reliable equipment all the time, 

issues of power efficiency increasingly take 

centre stage. After all, industrial furnaces 

account for approx. 40 % of today’s industrial 

energy consumption, and almost 70 % 

of the energy demand of every foundry 

or casthouse is expended on the melting 

operation. Through its development 

and use of energy saving furnace technology 

for both melting and heat treatment 

needs Otto Junker has helped to 

improve energy efficiency. Compared to 

conventional technology and equipment, 

the savings thus gained may amount to as 

much as 30 %. 

As a driver of innovative designs and 

development in automatic process management 

and control solutions, the company 

has contributed in a major way to today’s 

high standard of furnace technology. Today’s 

products often call for new metals or materials 

having greatly improved properties. For 

the production of such materials, special 

industrial furnaces are necessary. The company 

addresses these requirements via a 

number of successful developments, e.g., 

induction furnaces for refining silicon for 

photovoltaic applications and equipment 

Photo: S. Dobler 

Fig. 1: Pull-through type continuous furnace for brass strip 

during assembly 

Fig. 2: Strip annealing furnace 


125


Fig. 3: Graphite rod resistor furnace in foundry service 

Fig. 4: Complete medium-frequency melting plant 

for the high-quality heat treatment of components 

made of novel aluminium alloys. 

EXTENSIVE PORTFOLIO OF 

HEAT TREATMENT EQUIPMENT 

As early as in 1929, Otto Junker developed 

an electrically heated pull-through type 

continuous annealing furnace for brass strip 

which included the entire strip handling 

system and the equipment for simultaneous 

pickling. The system proved highly 

successful so that over 200 installations of 

this type were built by 1963 (Fig. 1). Subsequent 

developments resulted in the launch 

of complex continuous strip treatment lines 

based on strip flotation furnaces, which 

rank among the company’s most successful 

products today. 

In the years that followed, the product 

range was steadily expanded. Today it also 

comprises heat treatment systems for nonferrous 

metals for 

■■ 

Homogenising of slabs and bar stock, 

■■ 

Reheating of rolling slabs and extrusion 

billets, 

■■ 

Intermediate and final annealing of 

plate, strip and coils, 

■■ 

Heat treatment of plate, strip, castings 

and forgings, 

■■ 

Bright annealing of strip and coils 

using primarily 

■■ 

Strip flotation furnace, 

■■ 

Pit furnace, 

■■ 

Pusher furnace, 

■■ 

Chamber furnace, 

■■ 

■■ 

■■ 

■■ 

■■ 

Roller hearth furnace, 

Induction furnace, 

Walking beam furnace, 

Chain conveyor furnace as well as 

Surface treatment installations. 

By way of example, Fig. 2 illustrates an 

energy-efficient strip annealing furnace 

using an operating regime optimized by 

means of mathematical modelling. 

SUCCESSFUL DEVELOPMENT 

OF INDUCTION FURNACE 

TECHNOLOGY 

The design of a graphite rod resistor furnace 

in 1937, which became hugely successful 

as a melting source throughout the 

foundry industry, marked the start of the 

company’s success story as a manufacturer 

of melting and pouring furnaces (Fig. 3). 

Further developments gave rise to 

innovative induction furnace systems for 

melting, holding and pouring a diversity 

of metals, specifically the following: 

■■ 

Coreless medium-frequency induction 

furnaces, 

■■ 

Vacuum induction furnaces, 

■■ 

Channel-type induction furnaces, 

■■ 

Pressurized pouring furnaces as well as 

■■ 

Planning and engineering of complete 

melting and pouring plant. 

Since the early days of industrial use of 

induction furnaces for melting metals in 

the 1950s, the energy consumption could 

be reduced and melting rates increased 

substantially thanks to the R&D efforts of 

Otto Junker. The introduction of mediumfrequency 

technology based on electronically 

controlled frequency converter 

systems contributed substantially to this 

successful development. 

For the melting of grey cast iron the 

energy consumption dropped by about 

25 %. Due to the reduced energy consumption 

and greatly enhanced power density 

(kW/t) of modern furnaces, the maximum 

melting rate increased to as much as 485 %. 

And this trend has not stopped there: Overall 

efficiencies in excess of 80 % are targeted 

thanks to the use of enhanced energy-saving 

coils. Fig. 4 shows the configuration of 

an advanced medium-frequency melting 

installation with key peripheral equipment. 

FROM A TRIAL FOUNDRY TO A 

MARKET LEADERSHIP IN 

HIGH-GRADE STEEL CASTING 

Originally planned exclusively as a testing 

and demonstration facility, the high-grade 

steel foundry has evolved, starting in the 

1940s, into an advanced high-performance 

contract foundry for high-grade steels. 

Extensive investment in foundry equipment, 

machine tools, environmental protection 

and occupational safety technology, supported 

by the use of modern order processing 

and quality control procedures, have 

strengthened and expanded the company’s 

position as a leading manufacturer of highalloyed 

steel castings. The approval of leading 

companies and classification societies 



Fig. 5: Ring bowl after machining 

confirm this high quality standard. Its product 

range comprises finished, ready-forinstallation 

steel castings made chiefly of 

corrosion, heat and wear-resistant grades in 

small-to-medium series, as well as one-off 

castings measuring up to 6 m in diameter 

(Fig. 5). Key products specifically include 

ring bowls for automatic bottling systems, 

grates for waste incineration plants, 

and valves and fittings for the chemical 

industry. Otto Junker’s machine beds for 

lithographic systems for the production 

of microchips account for 30 % of global 

market volume. 

The exploration of new applications, the 

technological refinement of steel casting 

processes and investment into equipment 

and environmental protection characterize 

the activities of Otto Junker’s in-house 

high-grade steel foundry. As a matter of 

fact, synergy effects are tapped through 

the cooperation between equipment 

design and manufacturing units and the 

own foundry. 

INTEGRATED MANAGEMENT 

SYSTEM AND TRAINING 

The company’s existing certified quality 

management system conforming to 

applicable ISO standards was expanded 

in 2013 to comply with environmental, 

occupational safety and energy efficiency 

requirements under ISO 50001, ISO 14001 

and OHSAS 18001. An initial audit conducted 

by TÜV Rheinland in the summer of 2013 

confirmed the successful introduction of 

the new integrated management system 

and its effectiveness for a qualified management 

of in-house workflows. 

Dedicated and competent employees 

are a company’s most important asset, no 

doubt. Training young people for diverse 

industrial trades has a long tradition in the 

company, and it has been pursuing with 

great commitment and success in an effort 

to uphold high standards. In this way, the 

company helps job starters to find their 

way into the employment world while also 

securing its own supply of skilled personnel. 

Apprentices are trained both in the 

well-equipped teaching workshop under 

the guidance of qualified supervisors and 

through hands-on shopfloor training “on 

the job”. Upon completion of their examination, 

all apprentices are given an employment 

contract for at least one year with 

the company to help them make a smooth 

transition into working life. Over the last 

few years the company has continued to 

employ more than 30 apprentices on average 

at any given time. This figure reflects its 

intense commitment to vocational training. 

SUMMARY 

Otto Junker remains dedicated to the company’s 

successful basic strategy, which has 

remained unaltered since its foundation: 

Continuous innovation relying on cuttingedge 

science and technology in the pursuit 

of new and improved products is supported 

by targeted investment aimed at 

strengthening the manufacturing base at 

Lammersdorf as well as the international 

sites. Placing the focus on customer benefits 

and customer satisfaction, the company 

cooperates closely with the users of 

the products. 

Author: 

Dr. Dietmar Trauzeddel 

Contact: 

Otto Junker GmbH 

Jägerhausstraße 2 

52152 Simmerath-Lammersdorf, Germany 

Tel.: +49 (0) 2473 / 601-342 

tra@otto-junker.de 

www.otto-junker.de 


127


High-precision control of metal heating elements 

Constantly rising electricity costs are a 

factor of increasing importance in the 

construction of furnaces. Efficient energy 

management is therefore crucial for business 

success. Low-pressure aluminium diecasting 

is used to produce intelligent heating 

systems consisting of modern heating 

elements in combination with innovative 

power controllers that reduce energy costs 

by 30 % while significantly increasing process 

reliability. 

Wheel rims add a special touch to many 

cars. They are manufactured from steel or 

aluminium alloys. The melting and holding 

of these metals are by nature energy-intensive 

processes. A new retrofittable heating 

technology developed primarily to save 

energy in the production of aluminium rims 

was the goal of a joint research project of 

the companies amTec Furnace Technologies 

GmbH (amTec), Sandvik Materials Technology 

Deutschland GmbH (Kanthal) and 

Gefran Deutschland GmbH (Gefran). 

PREVENTION OF ENERGY 

LOSSES 

In the rim manufacturing process the aluminium 

bars are first melted in a shaft furnace. 

From there, the molten material is 

transported in transfer ladles to an impeller 

station. Addition of additional alloy components 

during constant stirring of the 

molten mass achieves the optimal metal 

quality. The completed alloy is then transported 

to a low-pressure furnace (Fig. 1), 

where the rims are cast. The entire process 

is designed so that the metal flows with 

practically no turbulence to minimize the 

formation of metal oxides to the greatest 

extent possible. The low-pressure process 

results in cast parts with excellent mechanical 

properties. Especially this last process 

step requires a heating system that can 

be operated without transformer equipment. 

In the past, heating elements made 

of silicon carbide (SiC) were used here. 

They withstand high surface loads and 

high temperatures, which makes their 

use in a furnace relatively unproblematic. 

Since they require a voltage of only 82 V, 

however, the standard mains voltage of 

230 or 400 V must be adapted by means 

of transformers or thyristors. The thyristor 

operates in a phase controlled process in 

which part of the sine wave is suppressed 

and is no longer available as usable energy. 

In both cases 100 % of the power must be 

paid for, although only 40 to 60 % of the 

current can actually be used. The phase 

control process also introduces harmonic 

components into the power grid, which 

has to be compensated by expensive filters. 

According to amTech Managing Director 

Dr. Jens Flücklich it makes little sense and 

does not increase the efficiency to connect 

an expensive energy management 

system to such a system with low efficiency 

or high reactive power. He had the idea 

that a metal heat conductor with constant 

ohmic resistance could be the solution. For 

the tests, Kanthal provided suitable heating 

elements with a linear resistance that 

can be operated at 230 V. This eliminates 

the need for transformation and the subsequent 

energy losses. The result is virtually 

100 % efficiency with no harmonic components 

requiring compensation (Fig. 2). 

POWER CONTROLLERS WITH 

OVERCURRENT PROTECTION 

The new heat conductors are integrated 

in a cascade control system with the onboard 

GFW control loop (Fig. 3), which 

allows faster control of the system – 

partly because the metal heat conductors 

react much more quickly than SiC 

heating elements to disturbances. This 

also means, however, that they require 

much more precise and finer control. The 

GFW power controllers with overcurrent 

protection of the Xtra series from Gefran 

provide such control (Fig. 4). In addition, 

the company offers energy management 

software that required only very 

little adaptation of the parameters for 

the specific application. The GFW Xtra 

features numerous options for controlling 

the process as well as programming 

options for fast and easy configuration. 

Source: amTec Furnace Technologies GmbH 

Fig. 1: Transfer of the aluminium alloy into the 

low-pressure casting furnace 

Fig. 2: amTec low-pressure casting furnace with 

the new heating system 

Fig. 3: Installation in control 

cabinet 



Source: Gefran Deutschland GmbH 

Fig. 4: GFW power controller with overcurrent protection 

from the Xtra series 

Fig. 5: Graphical display of the system with a soft-start ramp 

It is completely bus-capable, therefore 

enabling integration in the overall control 

system. But the intelligent power controller 

also offers another decisive advantage: 

it uses IGBT (Insulated-Gate Bipolar Transistor) 

technology. The software quickly 

and continuously measures the current at 

the load. If it exceeds a configured value 

the circuit is interrupted immediately 

before the load or the power component 

can be damaged. The power cut 

takes place within microseconds. Various 

options are available for resuming heating 

operations. Generally, automatic reset 

is the preferred option. This allows a very 

fast restart of the system with a soft-start 

ramp (Fig. 5). No intervention by a technician 

is necessary in this case. This sets 

the Xtra power controller apart from conventional 

thyristor power controllers. If 

the fuse is triggered in those controllers, a 

certified electrician must open the device 

and replace the internal fuse. During this 

entire procedure production is not possible. 

If this state goes unnoticed, the 

downtime can easily last four to six hours 

and in the worst case scenario no suitable 

fuse is in stock or no certified electrician 

is available. In addition, if the fuse is triggered 

the power cut is delayed, since the 

thyristor is not cleared immediately, but 

only in the zero crossing. This short time 

can already be enough to destroy the 

load and the power component. 

SHORTER DOWNTIMES, HIGHER 

MACHINE AVAILABILITY 

The power controllers of the Xtra series are 

different. The electronic fuse is extremely 

easy to operate and a short-circuit – for 

example due to condensation or metal 

spatter – does not automatically result in 

machine downtime. On the contrary: the 

fuse detects whether the damage is permanent 

and signals an alert accordingly. In 

the event of a temporary disruption such 

as a short-circuit through the refractory lining, 

mains voltage fluctuations, humidity 

or dust at the load, the power controller 

restarts the heating system. It also detects 

problems early on and precisely identifies 

which components – heating elements, 

transition resistors, etc. – caused the disruption. 

In addition, each phase is controlled 

separately. Failure of one heating element 

therefore does not cause an overload in 

the remaining intact elements. They remain 

undamaged. The Xtra power controllers 

therefore ensure a high level of production 

reliability as well as user and maintenance 

friendliness. The shorter downtimes and 

higher machine availability have a direct 

positive effect on productivity and profit. 

Especially in the operation of continuously 

heated furnaces or in two and three-shift 

systems, the use of Xtra power controllers 

significantly reduces the necessity of intervention 

by a technician. Production is much 

more trouble-free. 

LONG-TERM TESTS STARTED 

The power controller from Gefran also 

brought other advantages for the tests: 

since it not only records the necessary test 

data, but also features an integrated PID 

input and analogue inputs for the thermal 

elements, a significant reduction of the 

necessary lab equipment is possible. Initial 

tests in practice showed that the power 

consumption can be drastically reduced 

by use of the new heating technology. The 

energy costs of the new system are up to 

30 % lower than those of current processes. 

The elimination of transformers also means 

there is no loss of efficiency. In addition, the 

service life increased, while power losses 

decrease. Long-term tests for determining 

the reduction of reactive power, for 

example, have just started. Jens Glücklich 

assumes that it will be possible to deliver 

the first system with the new heating technology 

before the end of this year. 

Author: 

Katrin Broichhausen 

Contact: 

Gefran Deutschland GmbH 

Philipp-Reis-Straße 9a 

63500 Seligenstadt, Germany 

Tel.: +49 (0) 6182 / 809-0 

katrin.broichhausen@gefran.de 

www.gefran.com 


129


New kiln and dryer system for terracotta tiles 

Fig. 1: The kiln – frontal view 

The kiln was designed for a higher productivity 

and a good quality of terracotta 

tiles. Another direction was to reduce the 

gas consumption by recovery the flue gas 

heat from the kiln. The combustion air fan 

and the exhaust fan are operated using frequency 

inverters for an accurate control and 

energy savings. The accuracy of the temperature 

control in the kiln is better than ± 3 °C 

by using the continuous control at higher 

power and On/Off control at low power. The 

use of the burners for cooling eliminates an 

additional cooling system. The kiln and the 

dryer processes can be controlled from the 

local HMI and from the computer. 

This kiln was built by Electro-Total Bucharest 

(Romania) for Macon Deva in order to 

increase the production capacity and energy 

efficiency. The performance criterion requested 

by the customer was the productivity, the 

specific gas and energy consumption and 

the firing quality of the terracotta tiles. The 

important condition for the dryer was the 

primary recovery of flue gas from the kiln. 

The kiln is a batch-type with mobile 

hearth having the inner size of 6,900 x 4,810 

x 1,500 mm (Fig. 1). The kiln performs the 

firing of 7,000 kg of terracotta tiles in 23 hours. 

The firing curve consists of heating, soaking 

and controlled cooling, with the uniformity 

condition obtained on the entire diagram. 

The kiln thermal insulation is made of 

ceramic fiber modules for walls, roof and 

door. The refractory concrete is used for the 

fixed and mobile hearth and the ceramic 

fiber blankets are used for flue gas pipes 

thermal insulation. The kiln is provided with 

two rows of burners mounted on the side 

walls. The flue gas exhaust from the lower 

level of the batch is made via ceramic tubes 

mounted inside the kiln. The temperature 

control system is based upon the information 

received from the six thermocouples 

mounted on the side walls of the kiln. Two 

thermocouples are used for each zone, one 

on the left side and one on the right side, for 

Fig. 2: BIO Burner 

the most accurate information. The kiln has a 

protection for high temperature using three 

thermocouples mounted in the roof. 

The burning system was built using Elster 

Kromschroeder equipment with impulse 

burners type BIO-80 with low CO and NO X 

emissions (Fig. 2). The air/gas ratio is controlled 

by pressure regulators with solenoid 

valve type VAG mounted on each burner. This 

type of burner allows the controlled cooling 

using only the burning system air pipes without 

any additional cooling system (Fig. 3). 

The combustion air fan and the exhaust fan 

are operated using frequency inverters, for an 

accurate control and energy saving. The frequency 

inverters have an important function, 

providing a synchronized acceleration and 

deceleration between the combustion air 

fan and the exhaust fan. Large pressure variations 

must be avoided in the kiln because 

this could blow the sand from the hearth 

channel on the terracotta tiles leading to a 

rejection of the batch. 

A 3-way valve is installed on the exhaust 

fan circuit for heat recovery. This valve directs 

the flue gas to the dryer, when the flue gas 

temperature exceeds 100 °C. The dryer is 

tunnel-type and its heating system works 

both independently and with heat recovery. 

The dryer burner has an adequate power to 

independently perform the drying process. 

This situation occurs between two batches, 

when the kiln is turned off. 



The PLC based process control systems 

of the kiln and the dryer are interconnected 

in order to work in heat recovery mode (for 

the dryer). The control system provides constant 

temperatures and air flow to the dryer 

admission. The control system primarily uses 

the heat recovered from the kiln. The kiln 

and the dryer processes can be controlled 

(in terms of diagrams, alarms, etc.) both 

from the local HMI and from the computer 

located in the control room of the plant. The 

computer also stores all the records referring 

to batch data, analogue measurements and 

gas and energy consumption related to each 

batch or over a period of time (Fig. 4). 

A firing diagram for terracotta tiles (heating, 

soaking, cooling) is available if needed. 

The accuracy of the temperature control 

is better than ± 3 °C for temperatures 

exceeding 300 °C. In order to achieve this 

accuracy the continuous control is used at 

high power and the On/Off control is used 

at low power. 

PERFORMANCE 

The kiln can produce 7 t batch in a 24 h cycle 

while the gas consumption is 1,120 Nm 3 / 

batch. Furthermore the kiln consumes 

230 kWh/batch of electrical energy. The 

control accuracy is ± 3 °C during the entire 

heating and cooling cycle. 

The dryer achieves a productivity of 14.2 t 

batch in 24 h. The drying time is about 36 h. 

Within 24 h the gas consumption is 320 Nm 3 

with heat recovery gas. Before the modernization 

the dryer consumed 1,000 Nm 3 /24 h. 

Thus, the reduction of the energy consumption 

and, vice versa, the increase in efficiency 

is evident. 

CONCLUSION 

The whole system combining the performance 

of the kiln and the heat recovery for 

the dryer generates important gas savings. 

The temperature uniformity is achieved both 

through the kiln design and also by combining 

the two control modes (continuous and 

On/Off) of the burners. A superior uniformity 

of the temperature is achieved using the 

thermocouples mounted on the left and 

right sides of the kiln walls. The use of the 

burners for cooling eliminates the need for an 

additional cooling system (separate piping, 

fan, etc.) and reduces the total cost of the kiln. 

Authors: 

Dr.-Ing. George Velichi 

Ing. Florin Parlog 

Ing. Marin Gurgu 

Ing. Cristi Mitroi 

Ing. Andrei Suciu 

Ing. Alexandru Voicu 

Fig. 3: The burning system (air /gas pipes) 

Contact: 

Electro-Total 

Str. Mecet nr. 42-44, 

Sector 2 

024086 Bucuresti, Romania 

Tel.: +40-21-252-57-81 /-83 

office@electro-total.com 

www.electro-total.com 

Fig. 4: The kiln – 

synoptic diagram 


131

INDEX OF ADVERTISERS 

INDEX OF ADVERTISERS 

Company Page Company Page 

AFC-HOLCROFT, Wixom, Michigan, USA 47 

AICHELIN Holding GmbH, Mödling, Austria 41 

ITPS Asia 2014, Mumbai, India 15 

Linn High Therm GmbH, Eschenfelden, Germany 51 

ALD Vacuum Technologies GmbH, Hanau, Germany 53 

LOI Thermprocess GmbH, Essen, Germany 

front cover 

ALUMINIUM 2014, Düsseldorf, Germany 

S. 19, insert 

METAL MIDDLE EAST 2015, Dubai, United Arab Emirates 24 

Bürkert GmbH & Co. KG, Ingelfingen, Germany 13 

ceramitec 2015, München, Germany 27 

Elster GmbH, Osnabrück, Germany 9 

EMC European Metallurgical Conference 2015, Düsseldorf, Germany 120 

Optris GmbH, Berlin, Germany 21 

Process-Electronic GmbH, Heiningen, Germany 77 

Schwartz GmbH, Simmerath, Germany 49 

SECO / Warwick Europe S.A., Swiebodzin, Poland inside front cover, 5 

FABTECH 2014, Atlanta, GA USA 31 

SMS Elotherm GmbH, Remscheid, Germany 

back cover 

FLUXTROL, Auburn Hilss, Michigan, USA 7 

GEFRAN Deutschland GmbH, Seligenstadt, Germany 17 

SMS Siemag AG, Düsseldorf, Germany 45 

Tube India International 2014, Mumbai, India 78 

Graphite Materials GmbH, Zirndorf, Germany 55 

Heat Treatment 2014, Moscow, Russia 33 

Business Directory 133 - 152 

IPSEN International GmbH, Kleve, Germany 37 

International Magazine for Industrial Furnaces, 



your contact to the 

heat processing team 

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132 heat processing 4-2013 

www.heatprocessing-online.com




2014 

Business Directory 

I. Furnaces and plants for industrial 

heat treatment processes ......................................................................................... 134 

II. 

Components, equipment, production 

and auxiliary materials ................................................................................................ 144 

III. Consulting, design, service 

and engineering ............................................................................................................ 151 

IV. Trade associations, institutes, 

universities, organisations ......................................................................................... 152 

V. Exhibition organizers, 

training and education .............................................................................................. 152 

Contact: 

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Tel.: +49 (0)201 / 82002-24 

Fax: +49 (0)201 / 82002-40 

E-mail: b.schwarzer-hahn@vulkan-verlag.de 


www.heatprocessing-directory.com 

133

Business Directory 3-2014 

I. Furnaces and plants for industrial heat treatment processes 

thermal production 

Melting, Pouring, casting 

134 heat processing 3-2014 4-2013

3-2014 Business Directory 


Heating 

Powder metallurgy 

4-2013 3-2014 heat processing 

135



Heating 


Heat treatment 




137







More information available: 



139







cooling and Quenching 

surface treatment 

Joining 




141



Joining 




recycling 

energy efficiency 

retrofit 




143


II. Components, equipment, production and auxiliary materials 

Quenching equipment 

Fittings 

Burners 

transport equipment 

Your contact to 

HEAT PROCESSING 


Tel. +49(0)201-82002-24 

Fax +49(0)201-82002-40 

b.schwarzer-hahn@vulkan-verlag.de 







Tel. +49(0)201-82002-24 

Fax +49(0)201-82002-40 





145



Burners 

Burner equipment 

Burner applications 




Tel. +49(0)201-82002-24 

Fax +49(0)201-82002-40 





resistance heating 

elements 




147



Forging accessories 

inductors 




Measuring and automation 




149



Power supply 

refractories 


III. Consulting, design, service and engineering 



151


IV. Trade associations, institutes, universities, organisations 

V. Exhibition organizers, training and education 



153

International Magazine for Industrial Furnaces, 



BRAND NEW 

Already shopped 

Know-how today? 

The new web presence of hp 


Vulkan-Verlag 



155

COMPANIES PROFILE 



COMPANY: 


Dürnauer Weg 30 

73092 Heiningen 

Germany 

BOARD OF MANAGEMENT: 

Jens Baumann, Edgar Falkowski, Karl-Michael Winter 

HISTORY: 

Founded in 1974, Process-Electronic Analyse- und Regelgeräte 

GmbH specialised in the development of oxygen probes and 

measuring and control devices in combustion and heat treating 

atmospheres. In 2004 the company entered into a partnership with 

Nitrex Metal Inc., now major shareholder in PE. 

GROUP: 

Acquisitions in North America and the foundation of Process-Electronic 

Poland lead to the internationally active United Process Controls 

Group in 2007, with sites in the US, Canada, Europe and China 

as well as a network of affiliated companies throughout the world: 

Furnace Control Corp., Marathon Monitors Inc., Process-Electronic 

GmbH, Waukee Engineering Company Inc. 

SHAREHOLDINGS: 

Process-Electronic GmbH is owner of Process-Electronic France 

SARL, Besançon / France, formerly Selma Electronique. 

COOPERATION: 

The company is in close contact with universities and institutes and 

has a cooperation with the IWT Stiftung Institut für Werkstofftechnik. 

NUMBER OF STAFF: 

Approx. 25 

EXPORT QUOTA: 

Approx. 40 % 

Contact: 

Jens Baumann 

Sales Manager 

Tel.: +49 (0) 7161 / 94888-0 

j.baumann@process-electronic.com 

PRODUCT RANGE: 

Oxygen and hydrogen probes and IR and dewpoint analysers 

for the metalworking; high temperature applications and 

environmental technology; electronic measuring and control 

systems for heat treatment installations; process control and 

data processing systems, automation technology, quality assurance 

and commercial software systems; consulting, training and 

maintenance services. 

PRODUCTION: 

PE manufactures oxygen probes, hydrogen sensors, temperature 

and atmosphere controllers, programmable controllers as well as 

gas and electrical panels and cabinets and all related software for 

simulation, automation and process control. 

COMPETITIVE ADVANTAGES: 

The company has 40 years experience in all aspects of metal heat 

treating and is a working member in various materials and heat 

processing committees. 

CERTIFICATION: 

DIN EN ISO 9001: 2008. 

SERVICE POTENTIALS: 

Consulting, training and support in process engineering, process 

technology, safety (according to DIN EN 746 /1-3 of industrial furnaces), 

automation concepts, and computer hardware and software 

concepts. 

INTERNET ADDRESS: 

www.process-electronic.com 

156 


3-2014 IMPRINT 


Volume 12 · Issue 3 · September 2014 

Official Publication 

Editors 

Advisory Board 

Publishing House 

Managing Editor 

Editorial Office 

CECOF – European Committee of Industrial Furnace and Heating Equipment Associations 

H. Berger, AICHELIN Ges.m.b.H., Mödling, Prof. Dr.-Ing. A. von Starck, Appointed Professor for Electric Heating at RWTH 

Aachen, Dr. H. Stumpp, Chairman of the Association for Thermal Process Technology within VDMA, CTO Tenova Iron & 

Steel Group 

Dr. H. Altena, Aichelin Ges.m.b.H., Prof. Dr.-Ing. E. Baake, Institute for Electrothermal Processes, Leibniz University of 

Hanover, Dr.-Ing. F. Beneke, VDMA, Prof. Y. Blinov, St. Petersburg State Electrotechnical University “Leti“, Russia, René 

Branders, President of CECOF, Mike Debier, CECOF, Dr.-Ing. F. Kühn, LOI Thermprocess GmbH, Dipl.-Ing. W. Liere-Netheler, 

Elster GmbH, H. Lochner, EBNER Industrieofenbau GmbH, Prof. S. Lupi, University of Padova, Dept. of Electrical Eng., Italy, 

Prof. Dr.-Ing. H. Pfeifer, RWTH Aachen, Dipl.-Phys. M. Rink, Ipsen International GmbH, Dipl.-Ing. St. Schalm, Vulkan-Verlag 

GmbH, M.Sc. S. Segerberg, Heattec Värmebehandling AB, Sweden, Dr.-Ing. A. Seitzer, SMS Elotherm GmbH, Dr.-Ing. P. Wendt, 

LOI Thermprocess GmbH, Dr.-Ing. J. G. Wünning, WS Wärmeprozesstechnik GmbH, Dr.-Ing. T. Würz, CECOF 

Vulkan-Verlag GmbH, Friedrich-Ebert-Straße 55, 45127 Essen, Germany 

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E-Mail: a.froemgen@vulkan-verlag.de 

Editorial Department Thomas Schneidewind, Vulkan-Verlag GmbH Sabrina Finke (Trainee), Vulkan-Verlag GmbH 

Tel. + 49 201 820 02-36, Fax: + 49 201 820 02-40 Tel. + 49 201 820 02-15, Fax: + 49 201 820 02-40 

E-Mail: t.schneidewind@vulkan-verlag.de 

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ISSN 1611-616X 

Mitglied der Informationsgemeinschaft zur 

Feststellung der Verbreitung von Werbeträgern e.V. (IVW)

500,000 

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1 

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With their developments and system 

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As technology leaders, SMS Elotherm 

and IAS combine all competences when 

it comes to induction. 

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HEAT PROCESSING Report: Knowledge management in maintenance of thermal process plants (Vorschau)

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