Influence of the natural aluminium oxide layer on ... - ALU-WEB.DE

MELTING, RECYCLING & HEAT TREATMENT
• increased performance
• reduced warm-up time or start-up time <strong>of</strong>
your equipment
• energy saving potential <strong>of</strong> up to 70% for
your processes
• operational cost saving <strong>of</strong> 50% by
substituting electrical heating systems.
Heating systems for casting moulds:
higher production rates, quicker
and more precise preheating
The final step in <strong>the</strong> casting process is <strong>the</strong>
most sensible – <strong>the</strong> temperature pr<strong>of</strong>ile <strong>of</strong> <strong>the</strong>
casting tools is essential for <strong>the</strong> quality <strong>of</strong> <strong>the</strong>
products. Since every individual mould requires
its optimum heating device, promeos
<strong>of</strong>fers customized heating tools, individually
adapted to shape and process (Fig. 3).
The modular ‘Lego-like’ design <strong>of</strong> <strong>the</strong> flamefree
porous burner units enables promeos in
a unique way to design ‘custom-made suits’
for different tools at reasonable cost. Opti-
mum mould preheating, leading to significantly
reduced scrap production (‘initial cast-
Fig. 3: Drying curve refractory concrete
+ reduced preheating time The homogeneously distributed heat input at a
high energy density allows an unmatched quick
heating <strong>of</strong> <strong>the</strong> ladle. Generally <strong>the</strong> heating-up
times are cut down 50% and more.
+ increased durability(exact heat-up curves,
homogeneous temperature distribution with
functions for drying, sintering and warming)
So called ‘hot spots’ that are due to local fire or
flames as well as cold areas (‘temperature holes’)
are completely eliminated. A minimal loss <strong>of</strong>
material and an increased durability <strong>of</strong> <strong>the</strong> ladle
lining are <strong>the</strong> positive consequences. The temperature
control device allows continuously variable
temperature regulation and even a precise
realization <strong>of</strong> given temperature curves.
+ 65% reduction <strong>of</strong> operating costs* Energy savings <strong>of</strong> 65% are not unusual. This is
due to <strong>the</strong> extremely improved heat transfer and
<strong>the</strong> continuously variable power control, required
for temperature holding during stand-by time.
+ 80% CO 2 emission savings* 70% less CO 2 emissions and significantly lower
levels <strong>of</strong> pollutants (CxHy and NOx) mean > 80%
reduction <strong>of</strong> CO 2 equivalents.
Σ ROI < 24 months, guaranteed
< 12 months, mostly
* Maximum value proven by customer data
Table 2: Ladle heating systems: benefits / value proposition
Fig. 4: Heating system for casting moulds
ing’) is not longer a miracle. The required investments
pay back in less than 24 months –
a must in times <strong>of</strong> increasing resource efficiency
constraints (see Table 1).
Ladle heating systems: preheating
allows energy savings <strong>of</strong> up to 65%
The transport ladles lined with refractory material
are heated to a target temperature in
<strong>the</strong> empty state. A well-adapted insulated cap,
which includes <strong>the</strong> burner, is placed on top <strong>of</strong>
Usually your investment is recovered within a
period <strong>of</strong> max. 12 months. We will compile you
with a detailed amortization calculation with
every <strong>of</strong>fer you receive from us.
<strong>the</strong> ladle. The burner transmits <strong>the</strong> heat onto
a radiating body which transfers <strong>the</strong> combustion
energy as infrared radiation to <strong>the</strong> lining
<strong>of</strong> <strong>the</strong> ladle.
The heat is homogeneously and effectively
transmitted all over <strong>the</strong> ladle wall. The hot
gas flow is directed to <strong>the</strong> bottom <strong>of</strong> <strong>the</strong> ladle
and afterwards through a slit between <strong>the</strong>
radiating body and <strong>the</strong> lining <strong>of</strong> <strong>the</strong> ladle to
<strong>the</strong> hot gas outlet, whereby <strong>the</strong> heat transfer
is additionally improved. The promeos ladle
heating substitutes existing ‘fires’ to closed
systems with energy savings <strong>of</strong> up to 65%. It
<strong>the</strong>refore combines maximum energy efficiency
with ideal industrial safety and maximum
process reliability.
Reliable Drying and Sintering: The variable
power control enables <strong>the</strong> realization <strong>of</strong> ex-
Fig. 5:
Ladle heating
system
act given drying and sintering pr<strong>of</strong>iles and in
addition an optimum stand-by functionality
with minimum energy consumption. promeos’
ladle heating systems is a reliable solution for
an optimum casting process (see Fig. 3 and
Table 2).
Heating <strong>of</strong> launders and filter
boxes: for a better process control
The above explained advantages <strong>of</strong> homogeneously
and efficiently heated ladles are also
valid for launders and filter boxes – <strong>the</strong> better
<strong>the</strong> material transportation systems, <strong>the</strong>
better <strong>the</strong> casting quality.
promeos burner systems, integrated into
<strong>the</strong> lid <strong>of</strong> filter or into <strong>the</strong> covers <strong>of</strong> launders
provide a homogeneous heating <strong>of</strong> <strong>the</strong> filter
and <strong>the</strong> refractory lining. While hot spots are
avoided and <strong>the</strong> lifetime <strong>of</strong> <strong>the</strong> refractory is
enhanced, <strong>the</strong> temperature loss <strong>of</strong> <strong>the</strong> liquid
metal can be reduced tremendously. Increased
energy efficiency by reduced melting temperatures
and improved material quality are evident
(see Fig. 6 and 7 and Table 3 next page).
64 ALUMINIUM · EAC CONGRESS 2011