MANUFACTURING HEAT TREAT

A New Era: Tracking Quality Digitally

/ CONTROLS TECHNICAL CONTENT, INSTRUMENTATION TECHNICAL CONTENT, MANUFACTURING HEAT TREAT

What are advanced management systems and how does deep integrative system management software help automotive heat treaters improve processes while saving on time and unnecessary expenses? Explore the future of software technology for the management of heat treating operations in this Technical Tuesday by Sefi Grossman, founder and CEO of CombustionOS.

This informative piece was first released in Heat Treat Today’s August 2024 Automotive print edition.

The heat treating industry is on the brink of a technological transformation. Just as the momentous adoption of websites and emails transformed the nature of work for manufacturers, the advanced software systems are thrusting us into a new era of simplicity, automation, and deep integrations.

This article explores how advanced systems — an application of ERP (enterprise resource planning) and MES (manufacturing execution systems) combined with the power of AI — is revolutionizing facility operations, enhancing quality, efficiency, and profitability.

What Are Advanced Systems?

Advanced systems simplify, streamline, and automate operations by lifting the data burden off of plant personnel. While most existing systems focus on the part inventory workflow, more advanced systems go beyond by directly integrating into the heat treat process to track at bin/tray/tree level.

This requires real-time scheduling control, barcode scanning, digitizing recipe and process (no more paper), and direct sensor/PLC integration. Because of its critical nature, an advanced system is most likely an on-premise and cloud “hybrid solution” that is not crippled by internet connectivity issues. This allows it to still utilize rapidly evolving cloud systems that provide external services like messaging, big data storage, and AI to name a few.

Precise Processing

Figure 1. CombustionOS developers spend extensive time with operators and plant managers to create interfaces that are intuitive and easy to use. Pictured is access to job data stats from a mobile device being used outside of the manufacturing plant.

Repeatable, accurate methods to ensure optimal time, temperature, and atmosphere of the decided heat treatment processes are possible with advanced systems.

Utilizing existing sensors and hardware interfaces, data is collected in short intervals, transformed into meaningful data formats, and stored in a database. Network technologies such as HTTP, Modbus, and other analog to AI technologies make this possible with minimum additional hardware. The data is managed locally on the facility network, and synchronized with cloud services for further processing, analysis, and long-term history storage.

With a close monitoring of all these variables, facilities can tighten acceptable specification ranges. Deep integration with equipment ensures that data flows seamlessly from sensors and devices to the central system.

This real-time data collection and processing enables facilities to monitor operations continuously and make informed decisions quickly. For example, integrating data from temperature sensors, pressure gauges, and other monitoring devices ensures that all critical parameters are tracked and managed effectively. Additionally, if a temperature reading deviates from the acceptable range, the system can immediately alert the relevant personnel, allowing them to take corrective action before it becomes a critical issue.

 In addition to quality assurance, integrated artificial intelligence tools optimize job scheduling. Unlike traditional date/time calendar methods, AI systems predict job completion times based on real-time process data. This is particularly useful for roller furnace setups, where continuous processing occurs, but it is also beneficial for batch furnaces. Optimized scheduling improves resource allocation and operational efficiency, ensuring that jobs are completed on time and to the required specifications. The difference between a “calculation algorithm” and AI is that, with AI, you do not have to pre-program it. It automatically learns and adjusts for known variability in your hardware and even the personnel that are operating the equipment.

Finally, the automation of these systems captures and records all necessary information accurately. This reduces the risk of non-compliance, improving the overall quality of the final product. For example, a Detroit-based heat treating facility reported that accessing real time data to ensure compliance with industry standards has allowed them to spend 40% less time on documentation tasks.

Figure 2. Having increased control over the process gives more peace of mind to operators that components perform as needed.

Alleviating Burden on Maintenance and Inventory

Predictive maintenance is one of the most significant applications of AI in the heat treating industry. Traditional maintenance schedules are often based on fixed intervals, which can lead to unnecessary downtime or unexpected failures. AI driven predictive maintenance, on the other hand, uses real-time data to determine the optimal times for maintenance activities. This approach not only reduces downtime but also extends the lifespan of equipment.

A Detroit-based heat treating facility implemented an AI-driven predictive maintenance system (PMs) and saw a 25% reduction in equipment downtime. By analyzing data from critical parts, inventory, process tracking history, and various sensors, the AI system could predict when components were likely to fail, allowing the maintenance team to inspect and address issues proactively beyond their standard PMs. This not only improved operational efficiency, but also saved significant costs associated with emergency repairs and unplanned downtime.

Additionally, the integration of QR codes for inventory and process tracking enables quick and accurate data entry compared to manual logging. For instance, when racking parts out of bins, operators can simply scan QR codes, which automatically update the system with the relevant information. This not only speeds up the process but also minimizes the chances of human error.

Reducing Operational Costs

The adoption of advanced ERP and MES systems has led to substantial cost savings for many facilities. These systems reduce operational costs through the implicit automated integrations that technologies like CombustionOS bring. Here are just a few ways that operational costs have been cut:

  • Decreasing shipping and receiving management from three to just one employee
  • Minimizing rework costs by timely process alerts
  • Reducing personnel by replacing constant manual oversight with accurate, digital tracking systems
  • Lowering administrative costs by utilizing a more efficient and accurate invoice automation platform

Case Study: A client reported comprehensive cost savings, including a 20% reduction in shipping and receiving time, fewer logistics and furnace operators needed, a 33% decrease in rework costs, a 15% savings in maintenance costs, and a 25% reduction in accounting overhead. These efficiencies translate into substantial payroll savings and improved profitability.

How To Implement

Figure 3. When racking parts out of bins, operators can simply scan QR codes, which automatically update the system with the relevant information.

One of the most significant advancements in heat treating technology is the deep integration with various equipment types. Unlike traditional ERP systems, which often lack true integration, advanced systems work backwards from equipment data, building ERP functionalities around this integration to ensure seamless and accurate data flow.

First, there are advanced systems that can handle data from both digital and analog sensors. So, for heat treaters who are juggling a variety of sensors and systems, looking for an integrative advanced system that has adaptability will ensure compatibility with existing equipment while keeping an eye on cost. Facilities can continue using their current equipment while benefiting from advanced monitoring and control capabilities.

Second, advanced ERP/MES systems can take collaboration with multiple vendors. Rather than uproot current systems and relationships, work with an advanced systems provider who is able to collaborate with other software and systems. Advanced ERP/MES systems provide comprehensive solutions that include deep equipment integration and full ERP functionalities. This approach reduces the complexity and cost of integration, ensuring that all components work together seamlessly.

Key Applications

Most operations in a heat treat department will benefit from advanced systems due to the time-saving automations that the system integrates. But many heat treaters are looking to adapt and integrate older systems and often more complex designs, like roller hearth furnaces. Here are some steps that experts will take to guide you through to make the digital integration smooth and effective:

  1. First, it is important to understand you don’t need to boil the ocean. Starting with a more advanced inventory tracking system that employs barcodes can set the underpinnings for a more integrated system while providing immediate benefits to your logistics.
  2. Then, it is also key to get a deep understanding of your current process and map out your operational workflow. Using a flowchart program helps
    visualize the process to make sure all stakeholders are on the same page.
  3. Some aspects of your current process are probably outdated (perhaps created by someone who is no longer at the company), while others are key to the core of how you operate. Understanding the difference is crucial to make sure you unlock potential automation without disturbing your core process and flow.
  4. You’ll then need to prepare every required form, document, chart etc. that you use in the operation. For process control, recipes, and lab testing, provide many parts/iterations to capture the complexity.
  5. Finally, take inventory of any existing digital systems you have adopted, like inventory tracking, spreadsheets, or custom software. The existing system
    network, including servers, Wi-Fi setup, and hardware (PCs, printers, scanners, etc.) will be utilized as much as possible in the transition to reduce the need to purchase and set up different equipment.

Conclusion

The future will require constant innovations and thoughtful leveraging of increasingly advanced systems. Unlike static, homegrown, or “pieced together” solutions, the most advanced systems are constantly updated with new features, ensuring they remain at the cutting edge of technology. Engaging directly with plant personnel to understand their needs and challenges allows systems like CombustionOS to evolve and improve continuously.

The heat treating industry is on the cusp of a technological transformation, driven by advancements in ERP, MES, and AI. These technologies offer the potential to enhance quality, efficiency, and profitability, making them essential for the future of manufacturing. By embracing automation, integrating advanced AI capabilities, and committing to continuous innovation, the industry can achieve new levels of operational excellence.

About the Author:

Sefi Grossman
Founder & CEO
CombustionOS
Source: Author

Sefi Grossman has been at the forefront of technology revolutions for the past two decades and has been leading the technology company CombustionOS for nearly seven years.

For more information: Contact Sefi at sefi@combustionos.com.

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This Week in Heat Treat Social Media

/ FEATURED NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Welcome to Heat Treat Today’s This Week in Heat Treat Social Media. We’re looking at hot summer events, hot summertime activities, and hot heat treat industry events coming soon to a social media page near you. Check out these posts, podcasts, and videos for a roundup in Heat Treat Social Media.

As you know, there is so much content available on the web that it’s next to impossible to sift through all of the articles and posts that flood our inboxes and notifications on a daily basis. So, Heat Treat Today is here to bring you the latest in compelling, inspiring, and entertaining heat treat news from the different social media venues that you’ve just got to see and read! If you have content that everyone has to see, please send the link to editor@heattreattoday.com.

1. Heat Treating Skateboards > Hot Moves

This space is usually reserved for something rich and technical, but it’s summertime in the northern hemisphere and heat treating is just as essential for the proper working of items affiliated with leisure and outdoor activities as the products that make the world go round (e.g., automotive, aerospace, etc.). “Skateboarding is not just a sport; it’s an art form, a mode of transport, and a way of life for many. But did you know that the metal trucks on a skateboard—those T-shaped pieces that mount the wheels to the deck—are a product of meticulous heat treatment?” (from Bodycote on LinkedIn, November, 2023)

Check out this recent post from Bodycote laying out how critical it is to safety and experience for skateboard trucks to be heat treated with the same level of skill that it takes to execute an ollie or a shuvit.

2. It’s a Beautiful Day in the Heat Treat Neighborhood

What’s everyone been up to on the social channels?

Summer Engineering Institute reshaping the Future of Heat Treating

Future Leaders: Report to the Dome!

Take Us Out to the Old Ballgame!

It may Be Summer but It’s Never Too Early to Think About the Fall

‘Tis also the season for Registration for 2024’s industry events and social media provides an excellent platform for getting the word out. Here are some of the events taking place just in September — don’t delay! Registration is still open for all of these!

Marking Milestones

3. Learn with Us

Sometimes, it’s the small things on social media that grab your attention or give you the “ah ha!” moment. And sometimes things affecting the industry in other places cause us to go “hmm.” Do any of these short posts make you say “eureka”?

Queueing and Sequencing (and more!)

Quiz Time

4. Open Your Ears: The Podcast Corner

You can’t read everything, we get it. Heat Treat Today is here to recommend two informative podcasts to enjoy on your daily commute!

Tune in to Listen to Heat Treat Radio #110! Isolated Heat, the Future of Vacuum Furnaces

smiling bearded man on blue background, HTR 110 logo, isolated heat text

Sharpen your hearing: Heat Treating Knives on the TTT Podcast

5. Junk Food and a Logo Extravaganza

Click through to see what Kowalski Heat Treating thinks about junk food and how that thinking gets them counting logos.

Have a great weekend!

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US DOE Strategy: Ramifications for Heat Treaters

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES, MANUFACTURING HEAT TREAT, OP-ED

As heat treaters strive for a sustainable future, pressure mounts to make the right choices while running commercially viable operations. In this Technical Tuesday installment of a continuing series, guest columnist Michael Mouilleseaux, general manager at Erie Steel, Ltd., explores the potential ramifications of the DOE effort for industrial decarbonization in the heat treating industry. The first installment, “US DOE Strategy Affects Heat Treaters”, appeared on April 10, 2024, in Heat Treat Today, as well as in Heat TreatToday’s March 2024 Aerospace print edition.

This informative piece was first released in Heat Treat Today’s May 2024 Sustainability Heat Treat print edition.

As regulatory agencies set industrial decarbonization goals aimed at achieving net zero greenhouse gas emissions (GHGE) by 2050, heat treaters should prepare for action. But where do heat treatment technologies stand today, and what is the path going forward?  

Background

President Biden’s 2021 executive order calling for a “clean energy economy” led the U.S. Department of Energy (DOE) and the Environmental Protection Agency (EPA) to develop “The Industrial Decarbonization Roadmap,” a strategic plan for reducing industrial emissions. The plan identified five sectors — chemical, petroleum, iron and steel, cement, and food and beverage production — as targets for mitigation efforts. According to “The Roadmap,” process heating operations within these five industries represent the greatest opportunity to apply what were established as four pillar technologies:

  • Energy efficiency
  • Low carbon fuels, feedstocks, and energy sources (LCFFES)
  • Carbon capture, utilization, and storage (CCUS)
  • Industrial electrification using green electricity

In May 2023, heat treating was specifically named as a target process for reducing GHGE during the DOE’s Office of Energy Efficiency & Renewable Energy’s Low Carbon Process Heating Forum.  

A Closer Look at the Technology Pillars

To determine the path forward, it’s important to understand where heat treatment technology stands today regarding the four pillars.

Energy Efficiency: Among energy efficiency opportunities are furnace insulation, controls, and burner design. According to furnace and controls manufacturers that I have spoken with, advancements in insulation and heating system controls offer less than a 20% opportunity in efficiency improvement over

LCFFES: In the U.S., the primary hydrocarbon fuel for heat treating is natural gas, which has an average (commodity) cost of $2.57/MMBTU. Hydrogen has been endorsed as the preferred replacement. Hydrogen manufacturing and distribution issues aside, hydrogen has a 2023 (commodity) cost ranging from $14.00 to $40.00 per MMBTU, and a carbon footprint of 30–130% that of natural gas. “Green hydrogen” is “under development.”

CCUS: Carbon capture, utilization, and storage is currently relegated to natural gas production operations where the captured CO2 is injected into existing wells to “enhance” production. Although the DOE suggests development of advanced CO2 capture technologies are still underway, a 2023 Congressional Budget Office report states there are “fifteen CCS facilities . . . operating in the United States . . . [with] an additional 121 . . . in development.” It is fair to state there are no CCS (carbon capture and storage) facilities currently operating on the scale of a heat treating operation.

Electrification: For electrification to be impactful, electricity must be generated via green sources. Currently, 40% of the electricity generated in the U.S. comes from natural gas, 20% from coal, 19% from nuclear, 10% from wind, and 3% from solar. It is my opinion that, regardless of the incentives federal and state governments offer wind and solar energy operations, they will not reach the scale — and most certainly not the reliability — necessary to achieve the stated 2035 GHGE goals.

Cost also must be considered. The average U.S. cost for electricity was $0.086/KWH in 2023. In California, however, the cost for electricity generated with 40% renewables was $0.1819/KWH. In Germany, it was $0.289/KWH with 55% renewables. To put this into perspective, today the differential in (industrial) electricity (commodity) costs demonstrably increase as the percentage of that electricity is generated by “green” sources. To think that this trend is going to be reversed by federal mandate is paradoxical.  

A Realistic Look at the “Road Map”

While industrial decarbonization targets called for an 85% reduction in GHGE by 2023 and net zero by 2050, the goals seem unreachable using currently available technology. Replacing natural gas with hydrogen will result in significant cost increases as the commodity is 5–15 times more expensive, the equipment will require retrofitting to accommodate hydrogen, and the national infrastructure will need to be modified for hydrogen.

Electrification of existing gas-fired processes will result in a cost increase of four times, according to DOE estimates; however, based on today’s cost trends, 7–9 times higher is more likely. Additionally, the cost of converting equipment to electric operation must be considered. Mitigation efforts suggested by the DOE include improvements in efficiency that rely on yet-to-be-developed technologies and cost reductions in electricity facilitated by the wholesale use of renewable energy.

Overall, decarbonization efforts are noble. The timeframe and methodology, however, are unrealistic as they are based on the use of still-conceptual technologies.  

What Can Heat Treaters Do?

Following the lead of the automotive industry may be key. This sector reacted to the government mandates for GHGE reductions by going all in for electrification — with projections of 50% electric vehicles by 2030. A funny thing happened; these vehicles were not wholly accepted by the American public. The auto industry, led by the dealers, with the support of the UAW, and the car manufacturers petitioned their U.S. Representatives to “pause” these requirements. This political pressure caused the EPA to roll-back the implementation schedule.

Heat treaters must act now with a similar effort, but it must be aimed at preventing the promulgation of regulations that rely on still-conceptual technologies within an unachievable timeframe. Contact your local government leaders; let them know what we do means jobs and tax revenues. Contact your U.S. Representatives and Senators to let them know heat treaters are critical to our national security, the transportation system, and, in fact, the infrastructure of this country. What we do should not be outsourced, and we need to be given all the considerations of a critical industry.

The next column in this series will address the role of process heating in GHGE, analyze DOE assessments of GHGE for industry and process heating operations, and propose a fact sheet intended for use in our effort to set a realistic timeline for decarbonization goals In the next column, we’ll address potential ramifications of the DOE effort for industrial decarbonization in the heat treating industry to help you be better informed and prepared.    

About the Author:

Michael Mouilleseaux General Manager at Erie Steel, Ltd.

Michael Mouilleseaux is general manager at Erie Steel, Ltd. He has been at Erie Steel in Toledo, OH since 2006 with previous metallurgical experience at New Process Gear in Syracuse, NY, and as the director of Technology in Marketing at FPM Heat Treating LLC in Elk Grove, IL. Michael attended the stakeholder meetings at the May 2023 symposium hosted by the U.S. DOE’s Office of Energy Efficiency & Renewable Energy.

For more information: Contact Michael at mmouilleseaux@erie.com.  

Attend the SUMMIT to find out more about the DOE’s actions for the heat treat industry.

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Streamline Essential Nadcap Certifications

/ AEROSPACE HEAT TREAT TECHNICAL CONTENT, MANUFACTURING HEAT TREAT, OP-ED

Nadcap certifications are integral to aerospace heat treating. Maintaining compliance, however, can be a headache. Learn how a new technology is streamlining Nadcap certifications.

This article by Chantel Soumis was originally published in Heat Treat Today’s March 2024 Aerospace Heat Treat print edition.

Challenges to Capture Nadcap Certifications

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The Nadcap certification (National Aerospace and Defense Contractors Accreditation Program) plays a critical role in maintaining the integrity of heat treating processes, especially in the aerospace and defense industries. Recognized globally, the certification sets rigorous standards for heat treatment facilities, ensuring that heat treating processes produce parts and materials with the necessary strength, durability, and reliability.

The certification addresses the data that needs to be documented concerning all aspects of the heat treat processing, such as temperature control, process documentation, and quality management. A survey from the Performance Review Institute (PRI) indicates that 80% of aerospace and defense companies consider Nadcap accreditation as a requirement when selecting suppliers, and 90% of aerospace and defense prime contractors would disqualify a supplier without Nadcap accreditation. And when such a strict standard is implemented and then subject to regular audits, a 40% reduction in nonconformance costs are likely, as was reported by companies in the aerospace and defense sector in a study by the National Center for Manufacturing Sciences (NCMS).

While compliance with Nadcap and other heat treat certifications demonstrates a commitment to quality and opens doors to lucrative contracts with aerospace, defense, and other precision industries, actually capturing the data can be tedious. The effort and cost of employing disconnected systems — capturing measured data from system A, making the certification documents in system B, and then emailing the certification results to clients from system C — can be cut by synthesizing these actions into one system.

Digitizing Certification Management for Complete Compliance Control

Many organizations facilitate the certification process via digital means. This may be through the use of digital quality management systems (QMS) or enterprise resource planning (ERP) software that includes modules designed for certification management. These tools help automate record keeping, provide alerts for upcoming certification renewals, and streamline the overall certification tracking process, ensuring that heat treating operations remain compliant and efficient.

Nadcap Scanner tracking a process via QR code

But more should be done.

Veterans Metal, a metal finishing plant in Clearwater, Florida, was driving manual processes: everything was written down and data was being entered into spreadsheets for tracking purposes. Like many heat treaters, each step the company took to process a part required manual intervention to write down 20+ line items of information and then incorporate the associated data entry into spreadsheets.

The company was looking to modernize their plant.

After careful evaluation of Veterans Metal’s processes and needs, Steelhead Technologies developed and deployed the Steelhead Certification Scanner (or Nadcap Scanner) line that includes a handheld scanner and a system of QR codes to facilitate an easier user experience, including an interface that allows for swift operator proficiency, typically within minutes. This digital interface allows users to measure data, create certifications, and email this from the one system.

Smart Scanning in Action

The metal processing company received a 15-minute walk-through of the Nadcap Scanner, how to process parts, and where to find the data within the system. Using the handheld device, operators scanned QR codes (specifically created by Steelhead Technologies) that were placed on processing stations. As parts were moved from one process station to the next manually, a user would scan the accompanying QR code on the next current station, locking in data from the previous process and automatically reflecting that the next step was in process.

When operators scanned a process station, the device showed the remaining time in the process and displayed all parts being processed, custom instructions, and key data collection, such as oven temperature. This timer automatically starts when a process station QR code is scanned, gives a one minute warning when the process is nearing completion, and stops automatically when the next process station QR code is scanned.

Chet Halonen, a plant optimization expert for Steelhead Technologies, presented the “Powered by Steelhead” certification to the Veterans Metal team.

With the intuitive layout and guided steps, operators were easily able to navigate the accreditation process, significantly reducing time spent on extensive training. More importantly, the Nadcap Scanner line eliminated handwritten data entry, margin of error, and additional time needed to develop certifications since the scanner automatically generates them from the data and sends them to clients. The scanner has since been adopted by many other Nadcap-compliant operations across the United States.

Take Nadcap Digital

Achieving Nadcap accreditation is crucial for showcasing a commitment to quality, aligning with industry benchmarks, and accessing lucrative business opportunities. With the advent of digitized solutions like the Nadcap Scanner implemented within a comprehensive manufacturing ERP, companies will streamline the accreditation process, enhance operational efficiency, and bolster compliance with a system that’s “literally just button clicking,” as one manufacturer observed.

Embracing innovative tools not only saves time and resources, but also strengthens market positioning and client relationships. By merging the prestige of Nadcap accreditation with digital advancements, heat treaters can elevate their operations to reach new heights of excellence.

About the Author

Chantel Soumis, Head of Marketing, Steelhead Technologies

Chantel Soumis is serving as the head of Marketing at Steelhead Technologies. With a robust background in manufacturing technology and strategic partnerships, she leverages over 15 years of experience to shape the company’s marketing landscape.

For more information: Contact Chantel at chantel@gosteelhead.com.

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MIT-Backed Startup Tackles Heat Treaters’ High Electricity Bills

/ BRAZING NEWS, CONTROLS NEWS, MANUFACTURING HEAT TREAT

A group of graduates from MIT and Duke University identified manufacturing as an industry overburdened by rapidly growing energy costs and proposed a technology to provide electric bill savings of up to 30%. They will be piloting this technology with a U.S. heat treater, ThermoFusion, a Californian heat treater and brazer.

EQORE, a startup tackling energy issues for manufacturers, is developing smart energy storage systems. They aim to cut industrial energy bills by a third while offering a payback period of 1–3 years. Connected behind the meter, an EQORE system serves as an optimizing filter for electric equipment without changing its operation in any way. The system consists of a wall-mounted computing unit and a compact floor-mounted battery pack. It can be installed inside or outside of a facility and only needs a connection to the electric panel and internet.

The founding team features backgrounds in energy storage engineering from Tesla and Apple, as well as software and business development, and is supported by an innovation fund at MIT. The technology specifically targets reducing demand charges, which can account for 60–70% of industrial electricity costs. Demand charges penalize high variability in electric usage, a characteristic of heat treating facilities like ThermoFusion. For these facilities, a single peak in power usage can drastically increase the entire bill. Remarkably, in some locations in the U.S., demand rates have doubled since 2022. 

After talking to over 200 businesses, utility representatives, and energy experts, the team concluded that the solutions to the demand issue remain limited. Available power optimizations disrupt customer operations, while independent power generation like solar is often out of reach due to its decade-long repayment periods. EQORE’s solution empowers clients to reduce energy costs while maintaining existing production levels.

Their team is actively looking to engage with more pilot customers and is open to collaborations.  

The original press release is available upon request.

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2 Al Billet Homogenizers & 2 Coolers Headed Coast to Coast

/ ANNEALING NEWS, COOLING SYSTEMS NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Two aluminum homogenizers and two coolers are set to enhance U.S. operations for an aluminum manufacturer with locations across America. One of each unit will be sent to locations on opposite sides of the U.S.

The supplier of these systems is SECO/WARWICK USA. Homogenizers are a type of annealing furnace used in the aluminum industry to prepare log billets for extrusion. They heat the aluminum alloy logs to near-melting temperatures, then allow them to cool slowly, leaving a uniform molecular structure free of stresses or irregularities that compromise extrusion quality.

While proper homogenization requires a slow cool-down period, the large loads at this manufacturer’s location in the western side of the U.S. would take far longer than necessary to cool passively. So, after homogenizing, the load is removed from the homogenizer and placed into a cooler unit. The cooling is accomplished using a bank of high-power fans to keep fresh air passing over the hot ingots but cooling aluminum alloy to room temperature from close to 1000°F is not as simple as just placing the load in front of the fans. Instead, the cooler has walls that contain the heated air so it can be safely ducted to the exterior.

Marcus Lord
Managing Director at SECO/WARWICK Corporation
Source: SECO/WARWICK

Headed to the eastern side of the U.S., the furnace and cooler are of a different style and customized to fit within the tighter footprint available in the facility. It is configured as a two-position traveling furnace with car-bottom loading, which means the furnace is mounted to roll on rails, with a door at both ends, so the load can be staged in open floor space, then the furnace rolls over the top of it. The cooler system is mounted on parallel rails, with an extendable roof and end walls, such that it can enclose the load, still stacked on the same furnace car-bottom. The furnace will replace the first traveling furnace that SECO/WARWICK ever fabricated, installed back in 1975, when the plant was under different ownership.

“We have provided this industry partner with equipment and support for decades and we share their commitment to a cleaner, greener future. These homogenizers and coolers will help them meet that commitment by increasing the energy efficiency of their aluminum production process,” commented Marcus Lord, the managing director at SECO/WARWICK USA.

The original press release can be accessed here.

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Energy-Saving Solutions for Industrial Furnaces

/ BULK GASES & SYSTEMS TECHNICAL CONTENT, MANUFACTURING HEAT TREAT

Poor energy efficiency in industrial furnaces usually impacts companies’ production costs since more energy consumption is required to achieve the desired temperature. This, in turn, has a tangible impact on their carbon emission footprint. In this Technical Tuesday by Alberto Cantú, VP of Sales at NUTEC Bickley, learn energy-saving solutions for industrial furnaces.

This article was originally published in Heat Treat Today’s May 2024 Sustainable Heat Treat Technologies 2024 print edition.

To read the article in Spanish, click here.

According to the International Energy Agency, the industrial sector is one of the main culprits when it comes to global energy consumption. In many situations, industrial furnaces tend to be the pieces of equipment that consume the most energy.

In this article, we will share a series of solutions you can implement to improve energy efficiency, reduce production costs, and be socially and environmentally responsible.

Factors that May Be Affecting Your Energy Efficiency

There are a couple of obvious factors that may be harming your energy efficiency ratings.

Heat Losses in the Furnace Process

These may be due to structural damage to the insulation or incorrect gas flow distribution inside the furnace.

Inefficient Combustion Processes

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Industrial furnace flow check

Inefficiencies here are probably due to inadequate or excessive air/fuel ratios or poor mixture caused by internal damage to the burner.

Some tips we can pass on to help you improve furnace energy savings are:

  • Monitor the temperature on the cold side of the furnace, carefully checking that there are no hot spots.
  • Periodically analyze the composition of the furnace combustion gases, ensuring you are maintaining the expected levels of oxygen and CO.
  • Periodically check that the combustion air and fuel flows are in a stoichiometric ratio.
  • Check at least twice a year that the burners are in good condition and show no damage.
  • Avoid infiltration of cold air into the furnace that could affect the efficiency of the process.
  • Keep the temperature control loops tuned. If there is no temperature control loop, we recommend integrating one.
  • Periodically monitor consumption, either manually or automatically.
  • Ensure there is a program of predictive maintenance on the combustion system.

How Does Predictive Maintenance Work?

Attention to detail during predictive maintenance

This type of maintenance is based on the storage, monitoring, and analysis of data and quantifiable equipment variables in real time, such as temperature, vibration, and frequency.

It is necessary at the outset to understand the processes thoroughly and identify which aspects need to be analyzed, to make this approach work. These aspects include:

  • Temperature — monitoring the temperature may reveal abnormal changes, indicating possible overheating or component failure.
  • Vibration — unusual vibration may indicate machinery wear or imbalance, resulting in more severe damage if not addressed in time.
  • Frequency — analyzing particular patterns and behaviors during heat treat processing can provide insight into what may evolve into future potential problems.

Th ese actions will depend on appropriate measurement and detection control systems, the primary variable for these being sensors and algorithms. Firstly, sensors play a fundamental role in predictive maintenance, as they can detect subtle changes in the equipment’s performance, making it possible to identify potential failures before they occur. It is advisable to have access to an inventory of recognized sensor and spare parts brands, allowing you to measure your equipment’s variables.

Secondly, algorithms identify patterns and trends indicative of possible issues by processing large data amounts, allowing timely and planned interventions.

Factors Influencing Measurement Time

The time it can take to measure variables during a predictive maintenance process depends on many internal and external factors. Below we address some of them.

External Factors

Data analysis is a key component for effective preventative maintenance
  • The process — each industrial procedure has its own characteristics and requirements. For example, constant and real-time monitoring might be required in a continuous process, while a specified intervals approach might be best in other situations.
  • The product — some products may require frequent or strict monitoring due to their nature and characteristics.
  • Customer philosophy — some customers may have stricter standards or request more frequent monitoring to ensure the quality and reliability of their products.

Internal Factors

  • Capacity — strategic planning and scheduling measurements may be necessary if the equipment is limited or employed for other processes.
  • Availability of qualified personnel — ensuring that qualified staff are available at the right time to interpret the data obtained is crucial.
  • Energy-saving solutions for industrial furnaces — this is where you need to be able to rely on your combustion expert partner to advise on the most up-to-date energy-efficiency solutions you can implement in order to improve furnace performance and to help you reduce production costs.

Systems To Improve Furnace Energy Efficiency

Today, some systems that can significantly assist in reducing energy consumption can be implemented in your furnaces, thus preventing losses and/or eliminating inefficient processes. Here are some systems that can be implemented:

Energy Recovery Systems

These can be added to your furnaces to recover the heat from the flue gases so that they can be used again, heating the combustion air. Some options for these systems are self-recuperative burners and regenerative burners.

Flue Gas Measurement Systems

These guarantee that your furnaces always have the correct proportion of air and gas in their system. With them, you can continuously monitor the status and thus make decisions based on these data to adjust any out-of-proportion levels.

Preventive Maintenance Services

Besides the tips and systems for energy saving already mentioned, there are other actions that save energy, reduce costs, prevent failures in your industrial furnaces, improve their operation, and more.

Two of these are:

  1. Audit and diagnosis service: The furnace input and output variables are measured in order to indicate current efficiency levels and to identify possible areas for improvement.
  2. Burner calibration service: The air/fuel ratio is checked to ensure burners operate in the correct range.

Conclusion

In summary, if you consider implementing any of the tips and systems presented here, you can improve energy efficiency in your industrial furnaces and significantly reduce your operating costs. Be sure to check out the International Energy Agency if you are looking for further information on this topic.

About the Author

Alberto Cantú, Vice President of Sales, NUTEC Bickley

Alberto Cantú is the vice president of Sales at NUTEC Bickley. Cantú has more than twenty years of professional experience and has written prolifically for a variety of journals. Cantú is an honoree from Heat Treat Today’s 40 Under 40 Class of 2020.

For more information: Contact Alberto at albertocantu@nutec.com.

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Ahorro de energíapara hornos industriales

/ BULK GASES & SYSTEMS TECHNICAL CONTENT, MANUFACTURING HEAT TREAT

La baja efi ciencia energética en los hornos industriales suele impactar los costos de producción de las empresas, ya que se requiere más consumo de energía para alcanzar la temperatura deseada. Esto, a su vez, tiene un impacto tangible en su huella de emisiones de carbono.

This article was originally published in Heat Treat Today’s May 2024 Sustainable Heat Treat Technologies 2024 print edition.

To read the article in English, click here.

De acuerdo a la Agencia Internacional de Energía, el sector industrial es uno de los principales culpables en lo que respecta al consumo global de energía. En muchas situaciones, los hornos industriales tienden a ser los equipos que más la consumen.

En este artículo, compartiremos una serie de soluciones que pueden implementarse para mejorar la efi ciencia energética, reducir los costos de producción y ser social y ambientalmente responsables.

Factores que pueden estar afectando tu efi ciencia energética

Existen un par de factores obvios que pueden estar perjudicando tus índices de eficiencia energética.

Pérdidas de calor en el proceso del horno

Estas pueden deberse a daños estructurales en el aislamiento o a una distribución incorrecta del fl ujo de gas dentro del horno.

Procesos de combustión inefi cientes

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Gran atención al detalle en el mantenimiento predictivo

Probablemente debido a relaciones aire/combustible inadecuadas o excesivas, o a una mala mezcla causada por daños internos en el quemador.

  • Algunos consejos que podemos brindarte para ayudarte a mejorar el ahorro de energía en el horno son: Monitorear la temperatura en el lado frío del horno, verifi cando cuidadosamente que no haya puntos calientes.
  • Analizar periódicamente la composición de los gases de combustión del horno, asegurándose de mantener los niveles esperados de oxígeno y CO.
  • Verifi car periódicamente que los fl ujos de aire de combustión y combustible estén en una relación estequiométrica.
  • Revisar al menos dos veces al año que los quemadores estén en buenas condiciones y no presenten daños.
  • Evitar la infi ltración de aire frío en el horno que pueda afectar la efi ciencia del proceso.
  • Mantener ajustados los lazos de control de temperatura. Si no hay un lazo de control de temperatura, recomendamos integrarlo.
  • Monitorear periódicamente el consumo, ya sea manual o automáticamente.
  • Garantizar un programa de mantenimiento predictivo en el sistema de combustión.

¿Cómo funciona el mantenimiento predictivo?

Revisión de fl ujos de hornos industriales

Este tipo de mantenimiento se basa en el almacenamiento, monitoreo y análisis de datos y variables cuantifi cables de los equipos en tiempo real, como temperatura, vibración y frecuencia.

Para que este enfoque funcione, es necesario comprender a fondo los procesos e identifi car qué aspectos necesitan ser analizados. Estos aspectos incluyen:

  • Temperatura: monitorear la temperatura puede revelar cambios anormales, indicando un posible sobrecalentamiento o falla de componentes.
  • Vibración: una vibración inusual puede indicar desgaste o desequilibrio de la maquinaria, lo que resultará en daños más severos si no se aborda a tiempo.
  • Frecuencia: analizar patrones y comportamientos particulares puede proporcionar una idea de lo que puede convertirse en futuros problemas potenciales.
  • Estas acciones dependerán de sistemas de control de medición y detección adecuados. Los sensores y algoritmos constituyen los principales sistemas de medición de variables y detección de problemas.

Por un lado, los sensores juegan un papel fundamental en el mantenimiento predictivo, ya que pueden detectar cambios sutiles en el desempeño del equipo, permitiendo identifi car posibles fallas antes de que ocurran. Es recomendable tener acceso a un inventario de marcas reconocidas de sensores y repuestos, lo que te permitirá medir las variables de tu equipo.

Por otro lado, los algoritmos identifi can patrones y tendencias indicativas de posibles problemas mediante el procesamiento de grandes cantidades de datos, lo que permite intervenciones oportunas y planifi cadas. Factores que infl uyen en el tiempo de medición.

El tiempo que puede llevar medir variables durante un proceso de mantenimiento predictivo depende de muchos f actores internos y externos. A continuación, abordamos algunos de ellos.

Factores externos

  • El proceso. Cada procedimiento industrial tiene sus propias características y requerimientos particulares. Por ejemplo, en un proceso continuo se podría requerir un monitoreo constante y en tiempo real, mientras que en otras situaciones un enfoque de intervalos específi cos podría ser el mejor.
  • El producto. Algunos productos pueden requerir un monitoreo frecuente o estricto debido a su naturaleza y características.
  • La fi losofía del cliente. Algunos clientes pueden tener estándares más estrictos o solicitar un monitoreo más frecuente para garantizar la calidad y confi abilidad de sus productos.

Factores internos

  • Capacidad. Puede ser necesaria una planifi cación estratégica y una programación de las mediciones si el equipo es limitado o se emplea para otros procesos.
  • La disponibilidad de personal califi cado. Es fundamental garantizar que haya personal califi cado disponible en el momento adecuado para interpretar los datos obtenidos.
  • Soluciones de ahorro de energía para hornos industriales. Aquí es donde necesitas poder confi ar en tu socio experto en combustión para que lo asesore sobre las soluciones de.

Sistemas de recuperación de energía

Personal altamente capacitado de NUTEC Bickley

Hoy por hoy, se pueden implementar algunos sistemas que pueden ayudar signifi cativamente a reducir el consumo de energía en hornos, previniendo así pérdidas y/o eliminando procesos inefi cientes. Estos son algunos de los que manejamos en NUTEC Bickley:

Sistemas de recuperación de energía

Se pueden agregar a los hornos para recuperar el calor de los gases de combustión y reutilizarlos calentando el aire de combustión. Algunas opciones para estos sistemas son quemadores autorrecuperativos y quemadores regenerativos.

Sistemas de medición de gases de combustión

Garantizan que los hornos siempre tengan la proporción correcta de aire y gas en su sistema. Con ellos, puede monitorear continuamente el estado y así tomar decisiones basadas en estos datos para luego ajustar cualquier nivel desproporcionado.

Servicios de mantenimiento preventive

Además de los consejos y sistemas de ahorro de energía ya mencionados, existen otras acciones que pueden ayudar a prevenir fallas en hornos industriales, mejorar su funcionamiento y más.

Servicio de auditoría y diagnóstico: Se miden las variables de entrada y salida del horno para indicar los niveles de eficiencia actuales e identifi car posibles áreas de mejora.

Servicio de calibración de quemadores: Se verifi a la relación aire/combustible para asegurar que los quemadores operen en el rango correcto.

Conclusión

En resumen, si deseas mejorar la efi ciencia energética en hornos industriales y reducir signifi cativamente tus costos operativos, recuerda seguir nuestras recomendaciones.

Acerca del autor

Alberto Cantú, Vice President of Sales, NUTEC Bickley

Alberto Cantú es vicepresidente de Ventas de NUTEC Bickley. Cantú tiene más de veinte años de experiencia profesional y ha escrito prolífi camente para una gran variedad de revistas y publicaciones. Cantú es uno de los galardonados por Heat Treat Today’s 40 Under 40 Class del 2020.

Para mayor información: Contactar a Alberto escribiendo a albertocantu@nutec.com.

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Anatomy of Induction Coils

/ FEATURED NEWS, INDUCTION HEATING EQUIPMENT TECHNICAL CONTENT, MANUFACTURING HEAT TREAT
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Consider the numerous systems in your heat treat operations. What makes up the anatomy of each furnace or system? In this “Anatomy of a . . .” series, industry experts indicate the main features of a specific heat treat system. In this feature, the full-page spread identifies main features of induction coils.

The mark-ups for these reference images are provided by John Gadus, design and sales specialist, Induction Tooling, Inc.

View the full graphics by clicking the image below.

This Technical Tuesday article is drawn from Heat Treat Today’s April/May 2024 Sustainable Heat Treat Technologies print edition, that had a special focus on green heat treat technologies.

Search www.heattreatbuyersguide.com for a list of induction equipment providers to the North American market. If you are an induction equipment supplier and are not listed here, please let us know at editor@heattreattoday.com.

This series will continue in subsequent editions of Heat Treat Today’s print publications. Stay tuned!

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Vacuum Furnace for Nitriding Service Provider

/ MANUFACTURING HEAT TREAT, NITRIDING NEWS, VACUUM FURNACES NEWS

A nitriding service provider in Brazil will increase their production line with a single-chamber vacuum furnace from a manufacturer with North American locations.

Peter Lutz, president of Nitrion do Brasil says, “We were looking for a solution that would help not only increase our metal processing capabilities, but also efficiency and effectiveness.”

The SECO/WARWICK Vector vacuum furnace will operate in a new production hall and will handle Nitrion do Brasil’s increasing order volume. This order is a result of cooperation between SECO/WARWICK and their strategic partner in Brazil, Combustol.

Maciej Korecki
Vice President of Business of the Vacuum Furnace Segment
SECO/WARWICK

“Combustol supports SECO/WARWICK not only in sales but also in service activities and the supply of spare parts. Such a partner in such a remote location is a huge advantage,” commented Maciej Korecki, VP of the Vacuum Furnaces Segment in the SECO/WARWICK Group. He added, “[Nitrion do Brasil] bought a furnace that we could deliver quickly.”

The furnace on order will solve the commercial heat treater’s problem of hardening larger elements, because the furnace is equipped with a large working space. This will affect the process economics (energy savings and the graphite chamber’s increased efficiency) as well as the process cleanliness and speed. The furnace is equipped with convection heating – a system that improves the heat transfer efficiency when heating at lower temperatures, as well as directional cooling, which allows the system to efficiently cool parts with problematic shapes in various ways.

The original press release is available here.

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