A long-term test of high-efficiency and ultra-low-emission burner technology from WS Wärmeprozesstechnik at Waelzholz demonstrated that hydrogen can be used as a fuel gas to heat silicon strip lines.
Energy-efficient and low-emission heating of silicon strip lines using hydrogen as a fuel was the focus of an extensive test C.D. Wälzholz GmbH & Co. KG successfully completed together with WS Wärmeprozesstechnik in 2022.
As early as summer 2021, WS delivered several patented FLOX® burners for the installation in an existing silicon strip line. This line uses SiSiC radiant tubes to heat the furnace to a temperature of approximately 1922°F. After commissioning, the WS burners successfully operated with 100% hydrogen for one year.
The long-term test showed that a switch to hydrogen as a fuel is very possible for the furnace under investigation. Commenting on the possibility of such a switch, Mr. Peter Höfinghoff, expert for thermal process engineering in the technical office at Waelzholz, concluded: “Even after a year of operation, the burners are running very well and without faults. We were able to sufficiently demonstrate that by using WS burners, a conversion to hydrogen is technically feasible without any problems.”
With the findings from the test operation, the company is laying a foundation stone for the future hydrogen strategy at its headquarters in Hagen.
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The four heat treat industry-specific economic indicators gathered by Heat TreatToday each month --- starting in June of this year --- are predicting continued growth along with some economic contraction in the month of September.
The numbers, which were compiled the first week of September, show that responding parties anticipate inquiry levels will continue to be down for September as compared to August, but that the value of September bookings shows some growth. Backlogs are anticipated to grow by several points, while the overall health of the manufacturing economy is down. Please keep in mind that this is only the 4th month of data collection, so keep following this study as this bank of information builds.
The results from this month’s survey (September) are as follows; numbers above 50 indicate growth, numbers below 50 indicate contraction, and the number 50 indicates no change:
Anticipated change in the Number of Inquiries from August to September: 48.4
Anticipated change in Value of Bookings from August to September: 54.3
Anticipated change in Backlog Size from August to September: 53.5
Anticipated change in the Health of the Manufacturing Economy from August to September: 49.0
Data For September 2023
The four index numbers are reported monthly by Heat TreatToday and made available on the website.
Heat TreatToday'sEconomic Indicatorsmeasure and report on four, heat treat industry indices. Each month, approximately 800 individuals who classify themselves as suppliers to the North American heat treat industry receive the survey. Above are the results. Data started being collected in June 2023. If you would like to participate in the monthly survey, please click here to subscribe.
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Renewable fuels or hydrogen have entered the scene as these are fuels that contain little or no carbon. So, no carbon in the fuel means no CO2! These fuels present an excellent opportunity to significantly reduce carbon.
This Sustainability Insight article was composed by Brian Kelly, manager of Application Engineering at Honeywell Smart Energy and Thermal Solutions (SETS) and president of the Industrial Heating Equipment Association. It can be found in Heat Treat Today's August 2023 Automotive Heat Treatingprint edition.
The need to understand the impact of greenhouse gases (GHGs), especially carbon-based emissions, on climate change is gaining much more interest recently from organizations that have industrial heating processes. Most industrial heating processes are fueled by carbon-based fossil fuels such as natural gas, propane, fuel oil, diesel, or coal. In basic terms, if you have combustion processes in your organization, you are emitting carbon (CO2). Impacts on climate change due to these carbon emissions have prompted government and corporate actions to reduce carbon. These actions are creating unique new opportunities for more sustainable and lower carbon process heating methods. In this article, we will focus on ways to reduce carbon in typical fossil fuel fired heat treat thermal processes. First step: Figure out where you are today. Do you know?
Assess Your Carbon Footprint
Brian Kelly
Image Source: Honeywell
More and more companies are interested in understanding their GHG/carbon footprints, so they can determine what processes are their biggest CO2 offenders, and on what assets to focus on in order to have the largest impact on reducing carbon. Whether your thermal processes are being heated by fossil fuels (typically natural gas) or electrically, each will have a carbon footprint. Fuel gases are being burned to provide the heat and they produce CO2 as a result. Most electrical power is currently being produced by fossil fuels, so electricity will have a CO2 amount associated per kW. What can be done to burn less fuel in your furnaces or ovens, which directly relates to reducing CO2?
Tune Your Combustion Systems
Radiant tube burner with plug recuperator in a U-tube
Source: Honeywell
Over time combustion systems drift and are not at their optimum air/fuel ratio. By simply tuning your burner system on a routine basis, you can fire at the optimum air/fuel ratio for the process and be as efficient as possible. For example, if a furnace is firing on natural gas, operating at 1800°F, and currently operating at 35% excess air, tuning your burners to 10% excess air could save approximately 15% in fuel consumed. The fuel costs will be reduced, and the resulting CO2 will be reduced by that same percentage!
Maintain Your Furnaces/Ovens
A simple review of your furnaces or ovens to observe any hot spots, openings, faulty seals, or refractory issues will identify areas that will cause your systems to operate less efficiently, thus using more energy. Repairing these problems and consistently maintaining them will have the systems running more efficiently and producing as little carbon as possible.
Upgrade Your Firing Systems To Be More Efficient
Direct fired self-recuperative burner
Source: Honeywell
Incorporating preheated combustion air into furnace combustion systems can significantly reduce fuel consumption and therefore the resulting carbon. The two main methods for introducing hot air into a combustion system are recuperation and regeneration. The most popular air preheating method in heat treating applications is recuperation. For a direct fired furnace, this can take the form of a central stack recuperator or self-recuperative burners. Self-recuperative burners have grown in popularity in recent years as they get rid of the need for hot air piping, recuperator maintenance, and most are often pulse fired, which will not only maximize efficiency but also promote temperature uniformity in the furnace and often be lower in emissions. For indirect fired (radiant tube) furnaces, you can apply/add a plug recuperator to an existing cold air fired burner in a furnace that has a U or W-tube to preheat the combustion air or apply self- recuperative burners installed in Single-Ended Radiant (SER) tubes to optimize your furnace firing. The SER tube material can be upgraded to silicon carbide which allows higher temperatures/flux rates that can provide the opportunity to increase throughput and reduce the possible CO2 per cycle.
Combustion air preheating can result in energy savings of close to 25% over cold air combustion.
Renewable Fuels/Hydrogen
Renewable fuels or hydrogen have entered the scene as these are fuels that contain little or no carbon. So, no carbon in the fuel means no CO2! These fuels present an excellent opportunity to significantly reduce carbon. Hydrogen has been of interest because it has the opportunity to be a zero-carbon industrial fuel when produced with renewable energy such as wind, solar, hydro, or nuclear power. As these methods become more prevalent, they bring down the price of hydrogen and increase its availability. This could be a significant driver to greatly reduce CO2 in thermal processes. These topics as well as many others are being discussed in an on-going Sustainability Webinar series hosted by IHEA to provide education and insight into the ever-changing sustainability landscape.
Single ended self-recuperative radiant tube burner
Source: Honeywell
About the author:
Brian Kelly is manager of Application Engineering for Honeywell Smart Energy and Thermal Solutions (SETS) and current president of the Industrial Heating Equipment Association (IHEA).
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The primary advantage of pre-mix burners is the reduction of comparative emissions. But converting a nozzle mix to a pre-mix burner involves more than a burner exchange. There are many factors to consider when designing any combustion system. This article is a brief outline of the functioning technology for two common low-temperature (below 1200°F) combustion systems.
This Technical Tuesday article was composed by Robert Sanderson (PE), Director of Business Development, Rockford Combustion for Heat TreatToday'sAugust 2023 Automotive Heat Treating print edition.
What Is Low Temperature?
Contact us with your Reader Feedback!Robert Sanderson P.E.
Director of Business Development
Rockford Combustion Solutions
(Source: Rockford Combustion Solutions)
“Low temperature” is a nebulous term. What may be considered high temperature to one user may be regarded as low temperature by another. For this review, low temperature is any heating process where the firing chamber conditions are below auto-ignition temperature of the fuel — which, for many hydrocarbons and other combustible fuels, is about 1200°F — and sufficiently low that the chamber construction could be a metal-lined interior with external insulation.
Low-temperature applications vary, but they are commonly used to heat larger volumes of process air directly. As such, the burner’s air consumption is not a factor in the overall process efficiency.
Technology In Focus: Nozzle Mix vs. Pre-Mix Burners
Nozzle mix burners come in a great variety of designs. Some are simple gas spuds, others are linear arrays of fuel jets. A step up from these basic designs are machined fuel nozzles made to blend air and fuel. Some nozzle mix burners rely upon process fans to supply combustion air while others incorporate combustion blowers.
Regardless of the specific burner configuration, low-temperature burners are often capable of large temperature lifts, high heat-flux inputs, and wide operating ranges.
The control systems for nozzle mix burners are traditional fuel and air designs that many users will be familiar with. These burners are typically capable of operating on various fuels with relatively low utility pressures.
Pre-mix burners are also available in both point and line heat release designs. Pre-mix burners commonly feature low emissions, often the driving factor for their selection. To manage emissions, the general operating characteristics of pre-mix burners often include soft heat-flux inputs, narrow operating ranges, advanced fuel/air control systems, singular fuel designs, and elevated utility pressures.
These features vary somewhat with each design, but all are aspects commonly used as emissions control mechanisms. The control of pre-mix systems is more complex, and it is common for end-users to have training to understand better the proper operation and maintenance required to uphold their safe performance.
A notable difference between nozzle and pre-mix burners is the fuel/air blending design.
Many nozzle mix designs combine the fuel and air within a fuel nozzle directly at the point of combustion. The mixing of these streams may be staged or partially blended, depending on the nozzle design. Pre-mix burners, in contrast, typically have aggressive blending zones to thoroughly aerate the fuel, producing a homogenous, combustible mixture. This mixture is then distributed to the burner’s combustion zone. For safety, integrated with pre-mix burners will be a flashback arrestor or a similar fuel safety design feature.
Behind each nozzle and pre-mix burner system are fuel and air control systems. Because the two burner categories differ, each fuel control system style is unique and designed for that burner’s operating parameters.
The System at Large
An appropriately designed combustion system will consider the process conditions, user needs, and burner parameters in the design of the fuel and air control systems. If any aspect is lacking, the result can be an underperforming combustion system.
About the author:
Robert (Bob) Sanderson has years of experience knowledge and is experienced in a variety of industries. Throughout Bob’s 32+ years of experience experience in the combustion field, he has worked in automotive, abatement-oxidation, aerospace, agriculture, food and beverage, HVAC, heat treating, glass, asphalt, pyrolysis, reducing furnaces, dryers, immersion heaters, and power generation. Bob has been employed by companies such as Eclipse, Honeywell, and Haden, Inc. Bob brings systems integration and the application experience of how systems interact in various environments to his current role at Rockford Combustion. Bob is a member of the NFPA-86 technical committee.
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After much anticipation, the day to welcome Heat Treat Today’s 40 Under 40 Class of 2023 has arrived. For the sixth year in a row, Heat Treat Todayis pleased to honor forty young professionals in the North American heat treat industry who have proven themselves to be rising industry leaders. These individuals represent many backgrounds — business developers, engineers, maintenance managers, and action leads to name a few — and yet they all have one thing in common: a commitment to the North American heat treat industry and a vision for its future.
Join us today in welcoming these new leaders to the honored ranks of Heat Treat Today’s40 Under 40!
Do you have a young professional in mind who qualifies as a rising young leader? The nomination page is now live for 40 Under 40 Class of 2024 submissions. Do it now! Go to www.heattreattoday.com/40under40nominate.
Heat TreatToday offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry. Enjoy these 19 news bites that will help you stay up to date on all things heat treat.
Equipment Chatter
Global commodities group, Anglo American, and thyssenkrupp Steel have signed a memorandum of understanding to collaborate on developing new pathways for the decarbonization of steelmaking. The collaboration will focus on joint research to accelerate the development of high-quality input stock for lower carbon steel production, using both conventional blast furnace and direct reduction iron.
SECO/WARWICK delivered additional CAB lines to SUZHOU RETEK in China.
Tenova was contracted by Sinova Global to supply the basic engineering of a new silicon metal plant in Tennessee. The site will be North America’s most modern and efficient silicon metal plant, a greenfield development for Sinova Global.
Collaborative R&D between Anglo American and thyssenkrupp Steel for greener steelmaking technologiesTwo CAB lines for SUZHOU RETEKSinova Silicon Metal Plant from Tenova
Company and Personnel Chatter
Brighton Science and Hubbard-Hall partner to provide the Infinity Surface Cleaning Intelligence Program, which is designed to aid manufacturers to prepare surfaces and prevent problems.
Thermal-Vac Technology, Inc. announced the completion of a new microgrid from Verdant Microgrid, LLC. Collaboration with the following companies ensured the completion: Eos Energy Enterprises of Edison, NJ; Stronghold Engineering, Inc. of Perris, CA; and GridSwitch Asset Management Services of Moon, PA.
Bryan Stern has joined Gasbarre as the product development manager for Gasbarre Thermal Processing Systems. Bryan’s experience, knowledge, and forward-thinking will allow him to support existing clients and advance the company’s growing footprint in the vacuum furnace market.
Ipsen recently launched a new website with the goal of providing a better user experience for customers worldwide. IpsenGlobal.com now incorporates all Ipsen locations, products, and services under one domain.
Furnaces North America 2022, the premier trade show and technical conference in the North American heat treating industry, attracted over 1,200 attendees from around the world. The show produced by the Metal Treating Institute in partnership with its media partner, Heat Treat Today.
Bryan Stern, Product Development Manager, Gasbarre Thermal Processing SystemsNew website: IpsenGlobal.comFNA Technical Sessions, many exhibitors and attendees
Kudos Chatter
Doug Peters, CEO of Peters’ Heat Treating, received the Winslow Award, an honor that is given to an individual or business that has made valuable economic improvements.
A two chamber vacuum oil quench furnace has received Nadcap accreditation. Solar Manufacturing designed the furnace for Solar Atmospheres of Western PA.
Ayla Busch was honored with the German Leadership Award 2022. This award was presented at the annual alumni convention of the Collège des Ingénieurs and is an award for innovative corporate leadership in the German economy.
Texas Heat Treating, Inc. announces that both Round Rock and Texas Heat Treating Worth just completed ISO 17025 lab audits. The audits came back with no findings.
Representatives from TAV VACUUM gave a speech during the first day of the 27th IFHTSE Congress & European Conference on Heat Treatment 2022. The talk was about the heat treatment of titanium alloys, specifically, “Vacuum heat treatment of Ti6Al4V alloy produced via SLM additive manufacturing.”
RETECH, a SECO/WARWICK Group company, was acknowledged as “The Most Innovative Metallurgical Equipment Specialist in 2022 for the USA” by Acquisition International Magazine. Additionally, Earl Good, its managing director, has been honored by The Corporate Magazine in the “Top 20 Most Dynamic Business Leaders of 2022.″
Nitrex Metal, Inc. announced that it was selected for the “American Dream” series airing on Bloomberg and Amazon Prime. The series explores the entrepreneurial stories of men and women who founded and built incredible companies from the ground up.
Jim Oakes, president of Super Systems, has been awarded the first ever Furnaces North America (FNA) Industry Award at the trade show’s opening night kickoff reception.
At the recent 2022 MTI fall meeting held in Indianapolis, IN, the Metal Treating Institute recognized Roy Adkins, director of Corporate Quality, with the MTI Award of Industry Merit. This award is given in recognition of current and ongoing commitment to the betterment of the commercial heat treating industry with one or more significant accomplishments.
Hubbard-Hall has been awarded the Top Workplaces 2022 honor by HearstMedia Services in Connecticut. The award is based solely on employee feedback gathered through a third-party survey that is administered by employee engagement technology partner Energage LLC.
Pelican Wire Calibration Laboratory received “ISO/IEC 17025:2017” accreditation from ANSI National Accreditation Board.
Doug Peters Receives 53rd Annual Winslow AwardLars Wagner, COO at MTU Aero Engines AG, presents Ayla Busch with the award.Solar Atmospheres of Western PA's Nadcap Accredited FurnaceRETECH company and managing director receive honorsNitrex Metal, Inc. part of "American Dream" TV seriesIndustry Award to Jim Oakes, president of Super SystemsRoy Adkins (center) with past MTI Presidents, Jim Oakes (left) and Don Hendry (right)
Heat TreatToday is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to sarah@heattreattoday.com.
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The wait is over. Join Heat Treat Today in welcoming a new group of rising industry leaders for the fifth year in a row! Heat Treat Today is honored to recognize forty young professionals in the North American heat treat industry as the 40 Under 40 Class of 2022.
Siemens Energy, a recognized manufacturer of gas turbines and other energy technologies, has selected an eco-friendly vacuum furnace with high-pressure gas hardening (6 bar abs.) and high vacuum for one of its production facilities.
The vacuum furnace from SECO/WARWICK, known as Vector®, will execute efficient and ecologically clean processes in a high vacuum range. Consisting of a dry pump, a Root’s pump, and five Oerlikon/Leybold turbomolecular pumps, the furnace will meet the manufacturer's restrictive requirements.
Maciej Korecki
Vice President of Business of the Vacuum Furnace Segment
SECO/WARWICK
(Source: SECO/WARWICK)
The Vector also contains a metal heating chamber, which prevents direct heat loss to the vacuum chamber’s wall and ensures high process purity. The efficiency is also influenced by the ability to conduct the heating and cooling process at 6 bars with two gases (nitrogen or argon).
Maciej Korecki, vice president of the Vacuum Segment at the SECO/WARWICK Group, states, “This is our first order from a Siemens Energy production facility, but in the past, we have supplied equipment to gas turbine manufacturers."
Commenting on the future of clean energy for the power industry, Korecki further notes, "Gas turbines can run on a variety of gases, including hydrogen. Green hydrogen, as an energy carrier without a carbon footprint, will gradually increase its market share not only in the energy industry, but also in other economic sectors, contributing to gradual decarbonization of the atmosphere."
How can increased cybersecurity measures benefit today’s heat treaters and their clients? Find out more with an exploration of 2FA and MFA!
Today’s read is a feature written by Joe Coleman, cybersecurity officer at Bluestreak Consulting™. This column was first released in Heat Treat Today’sAugust 2023 Automotive Heat Treat print edition.
Introduction
Joe Coleman Cybersecurity Officer Bluestreak Consulting™ Source: Bluestreak Consulting™
This 9th article in the series from Heat Treat Today’s Cybersecurity Desk will explain the significance of 2FA (2-Factor Authentication) and MFA (Multi Factor Authentication), their benefits, and how they can help secure your data and your clients’ data.
2FA and MFA have proven to be effective methods to enhance online security. And, if you provide any products or services to a DoD (Department of Defense) contractor, this is mandatory for all users accessing your computer systems and critical data. Implementing 2FA is a minimum requirement and is better than just a username/password combination. MFA takes your security to a whole new level.
What Is 2FA?
2FA adds an extra layer of security to the usual username/password combination. It requires users to provide a second authentication factor, typically something they possess, in addition to their password. Common examples include a one-time verification code sent via SMS, email, or generated by an authentication app like Google Authenticator or Authy. By requiring the combination of something known (password), along with something possessed (authentication factor), an additional level of security is provided.
What is MFA?
The strengths of Multi-Factor Authentication (MFA) take security a step further by incorporating multiple authentication factors beyond the customary two. These authentication factors can be categorized into three main types: something you know (password or PIN), something you have (smartphone or security token), and something you are (biometrics like fingerprints or facial recognition). MFA offers increased security as it requires multiple factors to be verified before granting access.
Is MFA Better than 2FA?
In terms of security, the more the better should be the correct mindset. MFA is a more secure method than 2FA, because a user must respond to more checkpoints, especially if authentication factors disperse through different access points that aren’t available online (like a token or security key) and require a physical presence. Proving user identity multiple times instead of just submitting items of proof twice (i.e., 2FA), lowers the chance of a breach and helps achieve security compliance requirements.
Implementing 2FA or MFA
Enabling 2FA and MFA is becoming a more and more accessible option across many platforms and services. The most popular websites, email providers, social media networks, and online banking institutions offer 2FA and/or MFA options. Users can typically find the necessary settings in their account security or privacy preferences. It is crucial to follow the provided instructions for setting up and managing these authentication methods properly. In an age where cyber threats are always rising, protecting our online presence is critical. 2FA and MFA have proven to be effective methods in safeguarding our digital lives. By implementing these extra layers of security, companies can enhance their defenses and protect their data and their clients’ data.
What About Your Outside Personnel Support?
Click on the Image for a full list of Cybersecurity Acronyms
Many companies have outside vendor support, and maintenance personnel access their network and systems on a regular basis. For example, they may use VPN access that requires the user to “punch a hole” in the firewall, making it much more vulnerable to unauthorized access. Additionally, it is typically a configuration nightmare for your network and the IT folks to get it working properly.
There is a better way. Through much research and testing, we have found that BeyondTrust is a great tool to use to allow outside vendors secure access to the information they need to see without connecting to your network. It is currently used by 20,000+ organizations worldwide with much success and security. BeyondTrust also records their entire online session so you can see exactly what they accessed and did during the online session. Check out www.beyondtrust.com for more information.
About the Author:
Joe Coleman is the cybersecurity officer at Bluestreak Consulting™, which is a division of Bluestreak | Bright AM™. Joe has over 35 years of diverse manufacturing and engineering experience. His background includes extensive training in cybersecurity, a career as a machinist, machining manager, and an early additive manufacturing (AM) pioneer. Contact Joe at joe.coleman@go-throughput.com.
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Castool Tooling Systems, a tooling provider to extrusion and die-casting companies, expanded its in-house capabilities with a nitrocarburizing system.
The new pit-type nitrocarburizing furnace, a model NX-1625 from Nitrex, is capable of processing large workloads of up to 6000 kg (13,200 lb.) with dimensions of 1550 mm (61”) in diameter and 2500 mm (98.5”) in height. The turnkey solution includes Nitreg®-C controlled nitrocarburizing and ONC® post-oxidation technologies, which can treat shot sleeves made of H13 tool steel while improving strength and longevity and preventing distortion when used in high-temperature and corrosive environments.
Nikola Dzepina
Account Manager
Nitrex
Source: NITREX
Commenting on the recent nitrocarburizing furnace, Nikola Dzepina, account manager at Nitrex, notes, "[Castool, a division of Exco Technologies] have been outsourcing nitriding to our heat treating services for many years and have been impressed with the quality of service and customer experience."
The large capacity furnace is part of a significant investment project that saw several furnace OEM suppliers collaborating to outfit the New Market, Canada, facility with various pieces of heat treating process equipment.
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