10TH EDITION, APRIL 2020 NUTEC BICKLEY

CERAMICS SPECIALPROBLEMS THAT OUR SANITARYWARE SHUTTLE KILNS WILL HELP YOU SOLVE10TH EDITION, APRIL 2020

10TH EDITION, APRIL 2020 NUTEC BICKLEY

RODRIGO GONZÁLEZVP - Ceramics

Editorial

It feels strange to send out our e-bulletin while Covid-19 is raging but

it’s important for us to keep in touch with everyone, and by the same

token we encourage all of you to stay connected with us as well. I and

all Nutec Bickley employees salute the amazing work being undertaken

by all health professionals, emergency services, and essential service

workers. Life would be so much worse without their unstinting and

selfless efforts. We sincerely hope that our suppliers, our customers,

and their families, friends and colleagues remain safe and well at this

most difficult time.

The Ceramics Business Unit has continued to work hard in its efforts

to build the best possible units, with extraordinary efficiencies and

maximum use of the latest available technology, both in-house and

third-party supplied. Let me demonstrate this with a couple of quick

examples.

In the area of special refractories, we have successfully completed a project for a world-leading manufacturer that involved

supplying 17 separate pieces of equipment – 15 new units and two retrofits (relocated by our expert team from another

factory). We already enjoyed a very good relationship with this customer, which contributed greatly towards the project’s

success, and all facets of the operation have ended up much stronger as a result.

The kilns involved here are expected to operate in a demanding environment and to perform at the highest level. The kilns we

have installed fire at temperatures from as low as 150°C (300°F) right up to 1,760°C (3,200°F) – and everything in between

– with close control and great accuracy.

In a completely different area, we have designed and constructed a superb shuttle kiln for one of the internationally renowned

names in sanitaryware manufacture. Apart from an extremely high spec fabrication in all sections, we have introduced more

burners and fantastic control architecture.

The advanced shuttle kiln has an operational temperature of around 1,250°C (2,280°F). It is a nine-car, three-deck model

with a setting height of 2.2m. The total weight of kiln furniture is reduced by 20% as compared with more traditional set-

ups and the fuel usage is significantly reduced. We sincerely believe that this kiln can outperform anything offered by our

competitors and brings with it unmatched fuel efficiency and excellent first-quality product output.

From an ethos perspective, the Ceramics BU lines up with the rest of Nutec Bickley in its aim ‘to delight our customers

with equipment performance, quality, execution and service’. As you know, we strongly encourage maximum customer

engagement in each and every project, and we are implementing agile transformation procedures to empower all our project

teams.

As always, I am here to address all your individual questions, so please contact me at any time. Enjoy reading all the articles

and features in this e-bulletin. Stay well.

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10TH EDITION, APRIL 2020 NUTEC BICKLEY

At Nutec Bickley we are renowned across the world for constantly innovating with our

combustion and control systems.

Over the years, we have developed new technologies that offer significant advantages for

all kinds of industrial kilns. Below, we would like to talk to you about the advantages of our

shuttle (intermittent) kilns, for your business operation.

4 PROBLEMS THAT OUR SANITARYWARE SHUTTLE KILNS WILL HELP YOU SOLVEBy: Rodrigo González

1. Addressing the need for a different kiln for each process

A common problem faced by sanitaryware

manufacturers is the lack of flexibility that

their kilns offer. Typically, the plants are

configured to process simple, high-volume

parts in tunnel kilns and more complicated

pieces in shuttle kilns (in addition to

reprocessing or second fire pieces).

In the visits we make to our clients’ plants,

we often find that the kiln being used to run

first fire cycles can’t be used for second

firing (refiring).

The IMPS® combustion and control system allows us to deliver a very flexible kiln to the customer, one which

is capable of running cycles for both first and second firing, with fully controlled slow and fast heating curves

as required, depending on the type of piece, body or glaze to be processed.

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10TH EDITION, APRIL 2020 NUTEC BICKLEY

2. Where the customer’s process must be adapted to the size of the kiln offered by the kiln manufacturer

The product mix, area available for manufacturing,

and the loading and unloading equipment, varies

depending on the geographical location and

operating philosophies of the different sanitaryware

manufacturing companies.

Generally, the onus is on the customer to adapt

and choose between the available models offered

by the kiln supplier. This precludes the opportunity

for process optimization obtained when actually

having a kiln designed specifically for the customer’s

application.

Our design philosophy aims to address the specific

requirements of each company and we propose

solutions that allow the highest possible efficiency

to be achieved for each process. For us, it is very

important to deliver a kiln that helps our clients

achieve their goals and that’s why we design all such

equipment based on what the client and the process

require. All our customers have specific needs and

challenges, so clearly the solutions we offer may not

be the same for different manufacturers.

3. High fuel consumption

Energy consumption in the sanitaryware firing process

has a significant effect on the competitiveness of all

manufacturers.

Our sanitaryware shuttle kilns are very efficient and

we guarantee fuel consumption below 1,400 Kcal/kg

for these units.

This is possible thanks to our IMPS® combustion and

control system, which allows you to configure what

the kiln does in each segment of the firing curve. The

air:gas ratio in the burners can vary during the cycle,

keeping excess air to a minimum, depending on the

process requirements.

Other elements that affect fuel consumption are the

kiln insulation and the design of the refractory load,

which must be considered when designing the kiln.

Our engineers have extensive experience in the design

of sanitaryware kilns and can offer different designs

that allow each client to achieve their objectives,

minimizing energy consumption.

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4. Metal contamination and the use of cordierite cover tiles

Metal contamination is a problem that sanitaryware manufacturers face all the time.

If they are not well designed, shuttle kiln roofs and gas outlet ports are a common source of such

contamination.

Our proprietary Jointless® insulation system eliminates the problem of metal contamination in shuttle

kilns.

Some of our customers eliminate the problem of contamination by using cordierite cover tiles to cover roof

insulation and gas outlets. Although these batts do help reduce the contamination in the kiln, they bring

with them the additional expense of increased fuel consumption and maintenance requirements.

We have kilns fitted with our Jointless® system that have operated continuously for more than 20 years.

Great benefits for your operation

In addition to helping you with these problems, our secondary cooling systems allow large volumes of air to

enter the kiln’s cooling section, thus allowing up to 21 more cycles per year to be completed – equivalent

to almost one month of additional production.

At Nutec Bickley we are specialists in the provision of customised systems. Contact our expert advice team

to learn more about all the solutions we have available for you.

WATCH VIDEO

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10TH EDITION, APRIL 2020 NUTEC BICKLEY

About the company

Our client is dedicated to the manufacture of

specialty technical ceramic items. The company

began production of these ceramic pieces in order to

guarantee the supply of a very complex component

made of high alumina.

We have been working with this client for 12 years

and this is the fifth kiln that Nutec Bickley has

supplied for this process.

Our client’s challenge to us

The client wanted to make a very large piece in

alumina with a complicated geometry. This called

for extremely precise temperature control in the kiln

starting from very low temperatures, in this case

from just 90ºC–100ºC up to 1,700ºC (around 210ºF

up to 3,090ºF).

Equipment and technologies used

• High speed burner with levels of up to 6,000%

excess air

• Heat recovery equipment to reduce fue consumption

by 25%

• SCADA (Supervisory Control and Data Acquisition

System), helping the client to have all necessary

process information in order to maintain quality

levels over time

• PFPS (Power Failure Protection System), which

allows the kiln to continue operating in its entirety

in the event of a power failure

Benefits obtained

• The quality levels obtained in the ceramic pieces

produced reached a value greater than 99%

• Low fuel consumption

• High level of asset utilization

Our Nutec Bickley solution

The customer was supplied with a high temperature

kiln featuring a combustion and control system

capable of working in two modes:

Excess air mode:

Controls very low temperatures, maintaining

temperature uniformity

Stoichiometric mode:

It can reach very high temperatures, delivering

efficient fuel consumption

The flexibility of working in these two modes of

operation results in both an appropriate and productive

kiln atmosphere, bringing the best of both worlds.

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RECENT PROJECT

Nuteck Bickley receives order for high temperature elevator kiln

10TH EDITION, APRIL 2020 NUTEC BICKLEY

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CERAMIC INDUSTRIES SERVEDAt Nutec Bickley, we design and manufacture kilns for the ceramic

industry using leading technology and best practice.

Products for Sanitaryware

We have extensive experience designing and manufacturing tunnel and shuttle kilns for the sanitaryware industry, having installed and commissioned over 100 units to the leading brands over the globe.

Products for Electro-PorcelainNutec Bickley supplies tunnel kilns and shuttle kilns for the electro-porcelain industry with the latest technology in combustion and controls to fire electrical insulators under both oxidizing and reducing atmosphere conditions.

Products for Refractories

We have a vast know-how in designing tunnel kilns, shuttle kilns and Carbell® kilns to fire all types of refractories shapes. Our kilns for refractories can be designed to fire refractory materials to up to 1,800°C (3,200°F).

Products for Technical Ceramics

Nutec Bickley offers a vast array of different kiln designs to fire technical Ceramics. Our elevator, Carbell®, tunnel and shuttle kilns can be used to achieve optimal efficiency while firing technical ceramics.

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10TH EDITION, APRIL 2020 NUTEC BICKLEY

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Products for Vitrified Clay Pipe

Nutec Bickley supplies tunnel kilns and shuttle kilns with the latest technology in combustion and controls to fire vitrified clay pipe and fittings from small to large diameters.

Products for Tableware

Nutec Bickley has experience designing and manufacturing tunnel, roller and shuttle kilns for the tableware industry.

Products for Ceramic Colors

Nutec Bickley has extensive experience designing and manufacturing roller, tunnel and shuttle kilns for the pigment and color producing industry.

Products for AbrasivesNutec Bickley has many years of experience designing kilns to fire abrasive wheels, segments and special shapes. Tunnel kilns, shuttle kilns and Carbell® kilns can be used for this purpose offering improved product quality and the lowest energy usage.

CERAMIC INDUSTRIES SERVEDAt Nutec Bickley, we design and manufacture kilns for the ceramic

industry using leading technology and best practice.

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10TH EDITION, APRIL 2020 NUTEC BICKLEY01

Sept 22 - 23, 2020Cleveland, OH

Ceramics Expo USA

Booth 438

Here’s the question: How many squares can be

formed with the points shown above?

CHALLENGEInstructions:Answer the question that appears below

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Furnaces North America

Forging Congress

Sept 30 - Oct 2, 2020Louisville Booth 803

Sept 19 - 21, 2020Chicago

Table Top 17

Oct 22 - 23, 2020Chicago

WE HOPE YOU’LL JOIN US THIS FALL 2020.

EVENTS POSTPONED.

(RESCHEDULED DUE TO COVID-19)

Booth 211Orlando, FL

International Aluminium,Extrusion TechnologySeminar & Exposition

Oct 18 - 21, 2020Anaheim, CA

15th World Conference onInvestment Casting &Equipment Expo 2020

Booth 423

New dates to be confirmed

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10TH EDITION, APRIL 2020 NUTEC BICKLEY45TH ANNIVERSARYNUTEC GROUP

February the 18th 1975 marked the first day in the life of Nutec Group, a family-owned

company that over time has become a recognized leader in the world of industrial heating

and high-temperature insulation. Throughout the intervening period, the company

has experienced several different transformations, some of them prompted by tough

times, but mostly in its drive to grow and keep positioning itself as a key player in the

international markets.

And so here we are in 2020, with Nutec Group celebrating its first 45 years – and this

is a celebration that includes all our associates, whom we are proud to call the ‘Nutec

family’.

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10TH EDITION, APRIL 2020 NUTEC BICKLEY09

Across all our facilities, the teams came together to mark this milestone, in the

process sharing anecdotes, memories and talking about their long-term vision

for the company.

Nutec Procal in Spain, Nutec Inc in the USA and all the Mexican operations took

a pause in their daily activities and toasted everyone in a relaxed and friendly

environment, one which has been carefully created by our culture of mutual

trust and respect.

Companies and society are transforming more rapidly all the time, and our

challenge is to set the pace in the coming years to ensure we remain as leaders

in innovation, quality and customer service.

Congratulations to all in this great ‘Nutec family’.

WATCH VIDEO

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10TH EDITION, APRIL 2020 NUTEC BICKLEY

DO YOU NEED A QUOTE FOR ANY OF THESE SOLUTIONS?

Contact us at bulletin@nutec.com and let us know about your project requirements so that we can respond effectively and as soon as possible. We look forward to hearing from you.